Design Of Manufacturing Systems Research Articles

A software platform for supporting the design and reconfiguration of versatile assembly systems

This paper presents a System Engineering Platform which supports the design and reconfiguration of versatile manufacturing systems that are based on reconfigurable mechatronic objects (MO). The platform assists system designers, to generate, evaluate and optimize system designs that can efficiently adapt to dynamic demand and product evolutions scenarios, along the system life cycle. To this end, the platform includes analysis software tools and provides the design outputs based on Pareto frontiers, showing various key performance indicators. This platform has been applied to study use cases in the ReCaM project, and the initial results motivate its potential for industrial applications.

Design of leagile manufacturing system in a traditional pump manufacturing company

During the recent years, a section of researchers have been addressing the implementation of leagile manufacturing paradigm in traditional companies for facing the intensified competition. As the title implies, leagile manufacturing paradigm is incorporated with lean and agile manufacturing principles. Although leagile manufacturing paradigm was evolved about three decades back, it is yet to find application in many traditional industries. One among them is pump industry. In order to fill this gap, the research reported in this paper was carried out. While pursuing this research, the sales trend of pumps over the past five years were gathered by visiting a traditional pump manufacturing company. By referring to this trend, leagile manufacturing system was designed. Subsequently, the steps to be followed to implement this leagile manufacturing system was evolved. After presenting these details, the challenges and benefits of implementing this leagile manufacturing system are described in this paper. While concluding, it is claimed that this research has opened an avenue for exploring the steps for successfully implementing leagile manufacturing paradigm in traditional industries.

Integration of Energy Consumption and CO2 Emissions into the DES Tool with Lean Thinking

Products are often made by accomplishing a number of manufacturing processes on a sequential flow line which is also known as manufacturing systems. In a traditional way, design or evaluation of a manufacturing system involves a determination or an analysis of the system performance by adjusting system parameters relating to such as system capacity, material processing time, material-handling and transportation and shop-floor layout. Environment related parameters, however, are not considered or considered as separate issues. In the past decade, there has been a growing concern about the environmental protection and governments almost in all over the world enforced certain rules and regulation to promote energy saving and reduce carbon dioxide (CO2) emissions in manufacturing industry. To date, development of a sustainable manufacturing system requires designers who need not merely to apply traditional methods of improving system efficiency and productivity but also examine the environmental issues in production of the developed manufacturing system. Most researchers, however, focused on operational systems, which do not incorporate the effect of environmental factors that may also affect the system performance. This paper presents a research work aiming to addresses these issues in design and evaluation of sustainable manufacturing systems incorporating parameters of energy consumption and CO2 emissions into a DES (discrete event simulation) tool.

Self-similar architectures for smart manufacturing and logistics systems

Self-similar architectures simplify design and interoperability for smart manufacturing and logistics systems. Self-similar architectures for these domains extend existing models of self-similar controller architectures to include unified models, or abstractions, of plant behavior and planning and operational control functions. This paper proposes modeling system units as discrete event logistics systems (DELS), an abstraction that unifies heterogeneous system models for the manufacturing and logistics domain. Similar DELS then can be composed into self-similar architectures for larger, more complex DELS.

2017 the 2nd International Conference on Functional Materials and Metallurgy (ICFMM 2017)

PREFACEIt is our great pleasure to welcome you to 2017 2nd International Conference on Functional Materials and Metallurgy which has been held in Kuala Lumpur, Malaysia during November 28-30, 2017. ICFMM 2017 is dedicated to issues related to functional materials and metallurgy.The major goal and feature of the conference is to bring academic scientists, engineers, industry researchers together to exchange and share their experiences and research results, and discuss the practical challenges encountered and the solutions adopted. Professors from Singapore, Australia and China are invited to deliver keynote speeches regarding latest information in their respective expertise areas. It is a golden opportunity for the students, researchers and engineers to interact with the experts and specialists to get their advice or consultation on technical matters, teaching methods and strategies.These proceedings present a selection from papers submitted to the conference from universities, research institutes and industries. All of the papers were subjected to peer-review by conference committee members and international reviewers. The papers selected depended on their quality and their relevancy to the conference. The volume tends to present to the readers the recent advances in the field of new material design and performance analysis as well as mechanical design and digital manufacturing systems etc.We would like to thank all the authors who have contributed to this volume and also to the organizing committee, reviewers, speakers, chairpersons, and all the conference participants for their support to ICFMM 2017.ICFMM 2017Organizing CommitteeDec 20th, 2017

Computer-aided design and computer-aided manufacturing ceramic biomaterials in dentistry: Past to present

Esthetic dentistry, driven by a high demand for esthetically appealing and naturally looking restorations, especially, all-ceramic restorations, has become a segment of dentistry which has experienced tremendous improvements in the recent years. The increasing use of polycrystalline alumina and zirconia as framework materials and the increasing popularity and variety of computer-aided design and computer-aided manufacturing (CAD-CAM) systems seem to be mutually accelerating trends. In fact, CAD-CAM technology opens up a new opportunity for dental biomaterials scientists in the research field. Newer and improved materials are available at every moment. The present review gives an overview on the different materials available in ceramics used in dental CAD/CAM technology. A search of English language peer-reviewed literature was undertaken using MEDLINE and PubMed with a focus on CAD-CAM ceramic articles published between 1996 and 2014. A hand search of nonindexed literature was, also, completed. Search terms included: CAD/CAM; All Ceramics; Zirconia. The literature demonstrates that multiple all-ceramic materials and systems are currently available for clinical use and there is not a single universal material or, system for all clinical situations.

Comparison of the marginal fit of milled yttrium stabilized zirconium dioxide crowns obtained by scanning silicone impressions and by scanning stone replicas.

PURPOSETo determine the discrepancy in monolithic zirconium dioxide crowns made with computer-aided design and computer-aided manufacturing (CAD/CAM) systems by comparing scans of silicone impressions and of master casts.MATERIALS AND METHODSFrom a Cr-Co master die of a first upper left molar, 30 silicone impressions were taken. The 30 silicone impressions were scanned with the laboratory scanner, thus obtaining 30 milled monolithic yttrium stabilized zirconium dioxide (YSZD) crowns (the silicone group). They were poured and the working models were scanned, obtaining 30 milled monolithic yttrium stabilized zirconium dioxide (YSZD) crowns (the plaster group). Three predetermined points were analyzed in each side of the crown (Mesial, Distal ,Vestibular and Palatal), and the marginal fit was evaluated with SEM (×600). The response variable is the discrepancy from the master model. A repeated measures ANOVA with two within subject factors was performed to study significance of main factors and interaction.RESULTSMean marginal discrepancy was 22.42±35.65 µm in the silicone group and 8.94±14.69 µm in the plaster group. The statistical analysis showed significant differences between the two groups and also among the four aspects. Interaction was also significant (P=.02).CONCLUSIONThe mean marginal fit values of the two groups were within the clinically acceptable values. Significant differences were found between the groups according to the aspects studied. Various factors influenced the accuracy of digitizing, such as the design, the geometry, and the preparation guidance, as well as the texture, roughness and the color of the scanned material.

Exhaustive Search Based Heuristic for Solving Machine Layout Problem in Reconfigurable Manufacturing System Design

Reconfigurable manufacturing systems (RMS) are designed to overcome the shortcomings of conventional manufacturing systems in terms of effectiveness and responsiveness facing the increasingly influencing factors imposed on the manufacturing environment by unpredictable market condition and global competition. RMS is required to be more robust, flexible and reconfigurable, which makesmachine layout problem a key step to fulfill such design. Thus, any proposed layout needs to be changeable and easily redesigned. In this paper, we consider the machine layout problem in reconfigurable context. We develop an exhaustive search based heuristic to solve it. To propose the best respective machine layout, the heuristic considers various constraints from the manufacturing environment, and the initial generated process plan for the designed RMS under performance metrics. The proposed layout must at its best, respects both the constraints imposed by the generated process plan and those depicting the available location in the shop floor where machines are going to be placed. An illustrative numerical example is proposed to demonstrate the applicability of our approach.

A Methodology to Support Manufacturing System Design Using Digital Models and Simulations: An Automotive Supplier Case Study

Emerging tools for digital manufacturing support the decision making during the design of production systems. Simulations have proved to enhance the plant design process by generating accurate predictions allowing the evaluation of different alternatives. However, the use of these tools needs to be guided to achieve an efficient decision-making process. Therefore, this paper proposes a methodology to guide the engineering efforts towards plant design and operation using discrete event simulation tools. The methodology integrates all essential activities to develop, optimize, and validate the plant. The presented methodology aims at specifying the approach taken to generate the technology viewpoint from the Sensing, Smart and Sustainable Enterprise Reference Model (S3E-RM) which allows the integrated manufacturing enterprise design. A case study is presented to demonstrate the results obtained when using the methodology. The case study is a plant from a Tier One Automotive Supplier that produces plastic and metal parts. The advantages and limitations of the proposed methodology are visualized in the case study implementation and then discussed in the conclusions.

Voids Based Approach for Solving Cell Formation Problems

Cellular Manufacturing Systems is finding wide application in industries now-a-days. Cell Formation is the vital aspect of Cellular Manufacturing Systems design. Various Approaches are proposed by different authors to the Cell Formation problems using traditional and heuristic approaches. However some of those approaches have deficiencies and do not always produce proper machine cells and part families from the initial machine-component incidence matrix. In this paper, a new approach is proposed based upon voids. This approach is simple, will take less time and overcomes many limitations of some traditional based approaches. This new proposed method is tested against well known approach Rank Order Clustering (ROC) in solving Cell Formation Problems and test results will conclude that the approach is efficient

Guiding Manufacturing Enterprises to Achieve Long-Term Business Sustainability Using the Collective System Design Approach

This paper addresses several issues discovered by working with different industries attempting to sustain their business enterprise and to become “Lean.” The three key points addressed by the paper are: 1) Designing a new system or re-designing an existing system should focus on collecting a complete set of customer needs and deriving functional requirements from those needs. 2) Illustrating the path-dependency or sequence of implementation of Physical Solutions (PSs) to achieve Functional Requirements (FRs) of partially coupled designs. 3) Lean is not what we implement as a system, rather lean is what we become as a result of meeting customer needs with the utilization of the least amount of resources possible in a sustained manner. When lean is viewed as a set of tools to implement, the people in an enterprise will face ever-increasing diffculty in long-term business sustainability. The primary problems arise early in the design/re-design phase due to the lack of a clear set of system functional requirements. Without clearly defined system FRs, driven by recognizing customer needs/concerns, an enterprise will implement point solutions in an attempt to improve part(s) of a system. The Manufacturing System Design Decomposition (MSDD), a product of Axiomatic Design (AD), illustrates the path-dependency among the solutions of the associated requirements of any manufacturing facility. The MSDD provides a system-wide view and a clear sequence for system design implementation. The Collective System Design approach is discussed to provide the steps for senior leadership to re-design an existing system or to design a new system that results in long-term sustainability and become “lean.”

Design and control of manufacturing systems: a discrete event optimisation methodology

Simulation optimisation has gained a great attention due to its success in the design of complex manufacturing systems. In this paper, we look at manufacturing as a special class of queueing systems and propose the Discrete Event Optimisation (DEO) methodology, which provides a formal way to develop integrated mathematical models for the simultaneous simulation and optimisation. In the case, the obtained model is a mixed integer linear programming model; the methodology provides a formal way to generate approximations of them. The analytical properties of DEO models are analysed for the first time in the framework of sample path optimisation and mathematical programming. The methodology represents a reference for the use of mathematical programming as a way to model simulation optimisation for queueing systems. The applicability of the DEO methodology to complex problems is showed using the task and buffer allocation problem in a production line.

Research directions for an open unit manufacturing process repository: A collaborative vision

The design of manufacturing systems can see dramatic improvements through the use of digital technologies for modeling and simulation prior to deployment. At the 2017 ASME International Manufacturing Science and Engineering Conference held jointly with the 45th SME North American Manufacturing Research Conference, researchers met within a workshop to discuss structuring and presenting research for modeling manufacturing processes to support life cycle assessment. Workshop participants explored a vision for using standard formats to represent manufacturing processes in a community-based repository and identified research opportunities and challenges. This paper places these resulting research directions into a plan for implementing the vision.

Plant layout design and assessment consideration of cellular manufacturing system via G.A

Cellular manufacturing is a wide world and many study and researches discussed are concerning with it because of the large demand in market and wheel technology push the scientist to find tools that can stand with this fast change in demand according specific market , so that they invent the best way to deal with optimization purpose. In this research the dealing with cellular optimization in such a way that can be manageable by AI and using type of AI that named natural optimization . The applying of genetic algorithms was carried out on factory of electrical motor also all data was taken from the factory which is depend on the position and sequence of operations took place in the factory . The theory in this field were also taking in consideration and the applications was carried out . the research deals with problem in two way theoretically that can take in consideration the positions of machines inside the plant and its equations that covers with some constraints and the secondly the routing of part during product life cycle and execute results and applying it on factory configuration . There are multi solutions (results ) in the research for the problem that can achieve the flexibility , simplicity and also desired distance

Manufacturing of modular buildings: a literature review

The recent decade has seen a growing interest in applying modular construction in high-rise buildings. However, the manufacturing of modular buildings remains slow in making technical progress and the productivity in the factory is low. The production of modules is unique and complicated as it incorporates both manufacturing features and construction trades. Whereas previous studies have proposed technologies and tools associated with design, operation and optimisation of module manufacturing systems, this field of research is currently fragmented. This paper aims to provide a systematic review of existing academic perspectives and suggest future research directions to improve module manufacturing systems. The review explores critical research issues from five aspects: process and activities, organisation and people, factory configuration, technology, and information and control system. Outlined suggestions for research opportunities include (1) increased utilisation of digital manufacturing, (2) more exploration of strategies for the adoption of automated technologies, (3) development of holistic and practical approaches to supporting DfMA methodology, (4) well-defined information management systems through BIM. The findings should contribute to a more comprehensive understanding of the practices, challenges and the state-of-the-art research in the manufacturing of modular buildings.

Influencing factors of synchronization in manufacturing systems

Manufacturing systems exhibit two types of synchronisation phenomena: logistics and physics. Previous research has established synchronisation measures for both types and has shown that they are related to the due date performance. However, there is a lack of knowledge about the factors triggering synchronisation emergence as well as a holistic understanding of synchronisation effects on logistics performance. Thus, this research aims to further explore the relation between synchronisation, its influencing factors and its effect on logistics performance. Based on a profound literature review, we derive first hypotheses on the cause-and-effect-relationships between structural and dynamic properties of a manufacturing system and the emergence of logistics and physics synchronisation as well as logistics performance. By conducting a discrete-event simulation study on diverse manufacturing system types (line, flow shop and job shop production), we are able to test these hypotheses. We conclude that manufacturing network architecture as a structural property as well as processing time variability and system workload as dynamic properties may be exploited for an advanced and synchronisation-oriented manufacturing system design.

A Generalized and Efficient Approach for Accurate Five-Axis Flute Grinding of Cylindrical End-Mills

Wheel position (including wheel location and orientation) in the flute grinding process of an end-mill determines the ground flute's geometric parameters, i.e., rake angle, core radius, and flute width. Current technologies for calculating the wheel position to guarantee the three parameters' accuracy are either time-consuming or only applicable to the grinding wheels with singular points. In order to cope with this problem, this paper presents a generalized and efficient approach for determining the wheel position accurately in five-axis flute grinding of cylindrical end-mills. A new analytic expression of the wheel location is derived and an original algorithm is developed to search for the required wheel position. This approach can apply not only to the wheels with fillets but also to the wheels with singular points. Simulation examples are provided to validate the new approach and compared with the results from other literature. Besides the ability to determine the wheel position, the new approach can evaluate extrema of the core radius and flute width that a specified wheel can generate. Owing to the evaluated extrema, automatic 1V1 wheel customization according to the designed flute is realized in this paper. This work can improve the efficiency and automation degree of the flute grinding process and lay a good foundation for the development of a comprehensive computer-aided design and computer-aided manufacturing system for end-mill manufacturing.

Design of Manufacturing System Layout using Digital Technologies

Current modern technologies as well as classical disciplines of industrial engineering, among which also design of manufacturing and logistics systems can be ranked, have achieved a new dimension. Technologies and concepts as digital factory, reverse engineering, 3D modelling, simulation of manufacturing and logistics systems, transform design into a virtual environment. These progressive technologies enable time reduction, thus also reducing development costs. Digital representation of manufacturing system have a great importance in connection with the development of intelligent factories and application of digital twin concept. This paper presents approach to manufacturing systems design using progressive digital technologies.

Developing a cellular manufacturing model considering the alternative routes, tool assignment, and machine reliability

The cell formation (CF) is one of the most important steps in the design of a cellular manufacturing system (CMS), which it includes machines’ grouping in cells and part grouping as separate families, so that the costs are minimized. The various aspects of the problem should be considered in a CF. The machine reliability and the tool assigned to them are the most important problems which have to be modeled correctly. Another important aspect in CMS is material handling costs that they consist of inter-cell and intra-cell movement costs. Moreover, setup and tool replacement costs can be effective in CF decision making. It is obvious that CF cannot be completed without considering the number of demand. With considering of all of the above aspects, an extended linear integer programming is represented for solving the cell formation problem (CFP) in this study. The objective is to minimize the sum of inter-cell movement, intra-cell movement, tool replacement, machine breakdown, and setup costs. In the other terms, for states that cost of movement is higher than tool-changing cost, although a part can have the inter- and/or intra-cell movements, the model tries to find a solution which part is allocated to one cell and with changing the tools, processes of that part is completed. In addition, to validate the model and show its efficiency and performance, several examples are solved by branch and bound (B&B) method.

Inverse kinematics for a novel hybrid parallel–serial five-axis machine tool

A unique successful postprocessor for a hybrid parallel-serial machine tool is developed.Smart machining must be accomplished without forcing the tool to make sharp turns when HSM controls detect a turn approaching.NC codes are recalculated to form a new path for the pivot that can avoid the discretization near the singularity points in this study.The novelty of the paper is successfully to propose a new hybrid parallel-serial five-axis machining model.The manufacturers that are interested in integrating the inverse kinematics into the design process of their hybrid product. Instead of obsessively emphasizing to interpolate more points from the linearization algorithm, the NC codes are recalculated to form a new path for the pivot that can avoid the discretization near the singularity points in this study. In previous studies, orientable-spindle machines were directly used to generate smooth tool paths traversing singular positions through inverse kinematics. In many characteristics and practices, PKMs (parallel kinematic machines) and serial machines are the opposites of each other. Fully PKMs have relatively very limited working-space, especially in terms of orientation characteristics. Fully serial machines have a problem of error accumulation. This paper presents a modular method to construct a postprocessor system for a novel hybrid parallel-serial five-axis machine tool. A hybrid parallel-serial mathematical model is introduced to analyze a structural configuration. The configuration decomposition of machine tools is used to create the kernel of the postprocessor. The proposed modified DenavitHartenberg notation is used in the coordinate conversion procedure, and then an algorithm is used for developing the inverse kinematics of five-axis machines. The feasibility of solutions depends on the surface normal along the tool path satisfying certain orientation constraints. The proposed algorithm can be easily adapted to convert between cutter contact path and cutter location code and implemented on computer-aided design and computer-aided manufacturing systems. Examples with end-milling and side-milling tools are demonstrated and real cutting parts are implemented for verifying the algorithm.