Manufacturing Software Research Articles

Can the Manufacturing Process Be Improved by FMEA? A Study on X Company in Plastic Packaging Industry in Vietnam

This study based on the FMEA method, provides a systematic approach, which include identifying potential errors in the production process, tracking priority issues, proposing improvement solutions, and putting those solutions into practice in order to improve the flexible plastic packaging manufacturing process at a typical X company in the plastic packaging industry in Vietnam. It is found that four large errors – GP8, SM4, LM4, and BF4 – stand out as having an RPN index higher than 250. The aforementioned issues are also analyzed, and their root causes are tracked down using techniques like brainstorming, cause-effect diagram, and 5 Whys. Then, appropriate actions are taken to deal with these causes. Overall, the findings can serve as an insightful reference for Vietnamese manufacturing companies using the FMEA method to identify any potential errors in their production processes. After that, the company is able to organize proper inquiries and make recommendations for potential failure prevention strategies as well.

Liposome/chitosan coating film bioplastic packaging for Litchi fruit preservation

Chitosan is an ideal coating film for food preservation, but the performance of a single chitosan coating film is not good. Herein, the liposome was prepared by embedding copper nanoparticles (CuNPs) and thyme essential oil (TEO) in the hydrophilic and hydrophobic double-domain structure formed by phospholipids, and combining with chitosan to obtain a chitosan-based coating film for litchi preservation. The liposome was well-dispersed and stable with an average particle size of about 190 nm. The liposome showed excellent controllable release properties, and the cumulative release rate of TEO was 65.17 % and that of CuNPs was 15.17 % after 7 days. Furthermore, the oxygen and water vapor barrier properties of the coating film were greatly improved. Importantly, the film possessed effective antioxidant, antibacterial activity and excellent safety, which presents a better fresh-keeping effect on litchi. This study provides insights into the design and manufacture of food packaging for controllable and long-lasting preservation.

Scientific and Regulatory Lessons Learnt on Building a Chemistry, Manufacturing, and Controls (CMC) Package for COVID-19 Variant Vaccine Updates in the EU—A Regulator’s Perspective

During the COVID-19 pandemic, eight COVID-19 vaccines were authorised in the European Union (EU); as a result of emerging SARS-CoV-2 variants and waning immunity, some of these have been adapted to broaden the immunity against circulating variants. The pace at which variants emerge challenges the technical feasibility to make adapted vaccines available in a suitable timeframe and in sufficient quantities. Despite the current absence of a clear-cut seasonal spread for COVID-19, the EU regulatory approach thus far is a pragmatic approach following a pathway similar to that of seasonal influenza. This approach currently requires chemistry, manufacturing, and controls (CMC—the design, development and consistent manufacture of a specified medicinal product of good quality) and non-clinical data (from product laboratory and animal studies), as well as demonstrating that updated vaccines induce an immune response that can predict clinical efficacy and safety in humans. For CMC data, COVID-19 mRNA vaccine adaptations generally made use of the same formulation, control strategy, manufacturing process, and inclusion of registered manufacturing sites for the drug product; therefore assessment was generally streamlined. The experience gained from the vaccine adaptations, combined with a continuous early regulator-developer scientific discussion, permits increasingly greater predictability for timing and positive regulatory outcomes. Here, we review key aspects of the quality control and manufacture of updating COVID-19 vaccines to protect against new variants. Although most experience has been gained with mRNA vaccines, we note that investment in the streamlining of manufacturing processes for recombinant protein vaccines would facilitate future strain updates/adaptations thereby safeguarding availability of different COVID-19 vaccine types, which is considered of value for public health. We also reflect on the challenges and opportunities in establishing more predictable regulatory mechanisms for future COVID-19 vaccine adaptions and more widely for future vaccines containing rapidly evolving pathogens with the potential to cause health threats.

Full-scale wind turbine performance assessment using the turbine performance integral (TPI) method: a study of aerodynamic degradation and operational influences

Abstract. This study investigates how blade aerodynamic modifications, including leading edge roughness (LER), influence wind turbine performance over their operational lifespan. It introduces a methodology developed to examine the intricate relationship between blade erosion, blade enhancements, operations and maintenance (O&M) events, control programmable logic controller (PLC) parameter updates, and their cumulative impact on turbine efficiency. Analysing data from 12 multi-megawatt offshore turbines over a 12-year period, the investigation hinges on the integration of supervisory control and data acquisition (SCADA) data, O&M records, and air density corrections. A key contribution is the development of the turbine performance integral (TPI) method, which, for the investigated turbines, leverages generator speed and power output data to track performance trajectories. Seasonal trend decomposition using locally estimated scatterplot smoothing (STL) further isolates long-term trends and seasonal variations in performance. Despite data availability and quality limitations, the study reveals significant findings concerning the impact of manufacturer software updates on turbine control strategies, resulting in improved performance; the variable effects of blade repairs and enhancements; and the complex interaction between O&M events and performance. This work applies a methodical approach and statistical rigour, offering a path forward for effectively monitoring wind turbine efficiency and advancing renewable energy.

Optimizing Compressed Air Operations for Electrical Energy Savings: A Case Study in Pharmaceutical Packaging Manufacturing

This study in pharmaceutical packaging manufacturing focuses on improving compressed air efficiency through targeted strategies at both the source and user levels by establishing a baseline to analyze energy consumption patterns. Key measures, including minimizing air leaks, adjusting pressure, and optimizing compressor performance, aim to achieve a 20-50% increase in efficiency, thereby supporting environmental sustainability. The User Point and Source Point approaches are expected to lower Specific Power Consumption (SPC), with data collected from December 2020 to May 2022 providing insights into potential energy savings. Establishing this baseline, based on machine runtime and productivity, offers a solid foundation for evaluation. Results show a 23% reduction in compressor electricity usage and a 7-8% decrease in compressed air consumption. A structured improvement process and strong collaboration between engineering and management are essential for enhancing productivity and achieving sustainable energy efficiency in the industrial sector.

Design of the recruitment and selection process for interns in a packaging manufacturing company

Currently, personnel selection is a necessary process that allows for analyzing individuals who wish to be part of any institution; this is the case in a packaging manufacturing company that recruits professional residents or interns with the aim of carrying out projects that contribute to the company’s growth, while allowing the interns to apply the knowledge acquired during their professional studies. However, there was no formal recruitment and selection process for professional residents, resulting in time inefficiencies, as candidates took an average of 5.41 hours to go through all the filters before being hired. Additionally, there was no designated person responsible for overseeing the interns, leading to projects not being completed satisfactorily. Consequently, there arose the need to apply the 8D methodology to organize, document, control, and evaluate the intern selection process within the company.

Pioneering high barrier packaging for pressure assisted thermal sterilization of low-acid food products

Pressure-assisted thermal sterilization (PATS) utilizes flexible packaging with low oxygen and water vapor transmission rates (OTRs, WVTRs). In this study, pouches made from metal oxide (MO)-coated (A–D) and ethylene vinyl alcohol (EVOH)-containing (E, F) multilayer films were filled with water and mashed potatoes (MP), preheated at 98 ± 0.5 °C for 10 min, and processed using a pilot-scale high-pressure processing machine (HPP) at 600 ± 5 MPa for 300 s. The initial vessel temperature and the fluid medium were 90 °C, and during processing, the temperature of the fluid medium increased to approximately 120 °C. After processing, the water-filled pouches were emptied, refilled with a novel oxygen indicator, and stored at 40 ± 0.2 °C for 80 days. The MP-filled pouches were stored at 49 ± 1 °C for 60 days. MO-coated film D contained fewer defects, had ultra-low OTRs and WVTRs, showed insignificant (p > 0.05) moisture absorption and changes in crystallinity after PATS processing, and exhibited minimal color change in both the oxygen indicator and the packaged MP during the 60 days of storage. The ultra-high barrier of film D could be attributed to the presence of multiple AlOx-coated PET layers that successfully prevented oxygen ingress, even after exposure to high temperature and pressure conditions during PATS processing. Among the EVOH-based structures, the Film F showed a 22.3 % lower OTR than Film E (p < 0.05), due to a 16.7 % greater EVOH-layer thickness, despite having a lower overall thickness than Film E. Overall, this study can assist packaging manufacturers in designing and developing high-barrier flexible packaging suitable for in-package, shelf-stable food products.

Effect of Different Porous Size of Porous Inorganic Fillers on the Encapsulation of Rosemary Essential Oil for PLA-Based Active Packaging.

Essential oils are interesting active additives for packaging manufacturing as they can provide the final material with active functionalities. However, they are frequently volatile compounds and can be degraded during plastic processing. In this work Rosmarinus officinalis (RO) essential oil was encapsulated into Diatomaceous earth (DE) microparticles and into Halloysite nanotubes (HNTs) and further used to produce eco-friendly active packaging based on polylactic acid (PLA). PLA-based composites and nanocoposites films based on PLA reinforced with DE + RO and HNTs + RO, respectively, were developed by melt extrusion followed by cast-film, simulating the industrial processing conditions. As these materials are intended as active food packaging films, the obtained materials were fully characterized in terms of their mechanical, thermal and structural properties, while migration of antioxidant RO was also assessed as well as the compostability at laboratory scale level. Both DE and HNTs were able to protect the Rosmarinus officinalis (RO) from thermal degradation during processing, allowing to obtain films with antioxidant properties as demonstrated by the antioxidant assays after the materials were exposed for 10 days to a fatty food simulant. The results showed that incorporating Rosmarinus officinalis encapsulated in either DE or HNTs and the good dispersion of such particles into the PLA matrix strengthened its mechanical performance and sped up the disintegration under composting conditions of PLA, while allowing to obtain films with antioxidant properties of interest as antioxidant active food packaging materials.

Analisis Produktivitas pada Mesin BM 206 D-2 Menggunakan Metode Total Productive Maintenanace (TPM) dengan Pendekatan Overall Equipment Efectiveness (OEE) di PT. Berlina Tbk

Productivity is key to success in the manufacturing industry, particularly at PT.BERLINA Tbk, which specializes in plastic packaging manufacturing. This study focuses on enhancing the operational effectiveness of the BM 206 D-2 machine trough the implementation of Total Productive Maintenance (TPM) and measurement of Overall Equipment Effectiveness (OEE) as well as the identification and mitigation of Six Big Losses. The research involves two sampling periods, each spanning two quarters. During the first period, the average OEE value of 66% indicated that the greatest losses were due to machine breakdown or Breakwon Losses, related to deficiencies in operator and technician skills, inadequate planes maintenance, and machine cleanliness. Following the implementation of improvements based on these findings, the average OEE incrased to 71% in the second period. These results underscore the importance of enhancing technical skills, effective maintenance, and strict cleanliness to improve productivity and reduce production losses.

Bisfenol A na indústria alimentícia. Análise comparativa entre carnes e produtos cárneos enlatados e não enlatados

Bisphenol A is a chemical substance capable of producing harmful effects on human and animal health, among which reproductive, neurological, metabolic and digestive alterations and developmental disorders stand out. Despite these contraindications, its use is widespread worldwide and is in high demand in the industry due to the resistance properties it offers. In the food sector, it is used in the manufacturing of packaging, specifically in cans coated with epoxy resins and in polycarbonate packaging. Various scientific studies have been able to confirm that meat products contain significant amounts of it, both in their canned and fresh forms. This bibliographic review aims to understand the legal context in which Bisphenol A is found and its tolerable daily intake levels, as well as to analyze its impact on human and animal health, investigate the main routes of exposure to this substance and the possible migrations of bisphenol A towards canned and fresh meat products. In addition, alternatives to its use are explored, including the use of its analogues. This review highlights the large presence of Bisphenol A in meat products and the need for stricter legal regulation to preserve the health of the population. Likewise, the urgency of greater scientific research to find safer and more sustainable alternatives to its use is concluded.

Reduced warpage in semiconductor packages: Optimizing post-cure temperature profile considering cure shrinkage and viscoelasticity of epoxy molding compound

Warpage in semiconductor packages is a critical issue that affects their reliability and performance. This study aims to minimize the warpage of a bi-material dummy package by optimizing the post-mold curing (PMC) temperature profile. A warpage simulation model was developed considering the viscoelastic properties and cure shrinkage behavior of the epoxy molding compound (EMC). A compression molding monitoring system was also developed to analyze the cure behavior of the EMC. The gelation point of the EMC during compression molding was determined using a dielectric sensor, while cure shrinkage behaviors were analyzed using a fiber Bragg grating sensor. Viscoelastic properties were characterized through stress relaxation tests, and thermal properties were measured using three-dimensional digital image correlation. The developed simulation model was used to optimize the PMC temperature profile using a genetic algorithm. Experimental validation showed that the optimized temperature profile reduced the warpage from ∼1519 μm to 486 μm compared to a linear profile. The findings of this study have broader implications for the design and manufacturing of semiconductor packages, as the proposed approach can be applied to minimize warpage and improve package reliability.

Stock Valuation of PT. Panca Budi Idaman, Tbk. (PBID) based on Free Cash Flow to the Firm and on Relative Valuation

The stock valuation of PT Panca Budi Idaman, Tbk. (PBID), an Indonesian plastic packaging manufacturer, is evaluated using the absolute and relative valuation. The absolute valuation is based on Discounted Cash Flow (DCF) method. In relative valuation, PBID is compared to its peers, which in this study are IPOL, PDPP, and TRST. Indonesia’s significant economic growth and the vital role of the plastic industry are noting strong demand for plastic packaging despite environmental challenges and regulatory pressures. Financial performance from 2017 to 2023 is assessed through profitability, liquidity, and solvency ratios, demonstrating PBID’s efficient operations and robust financial health. Future cash flows are projected, discounted using PBID’s Weighted Average Cost of Capital (WACC), and the terminal value is calculated. The intrinsic value is estimated at IDR 3,987 per share, indicating undervaluation compared to the current price of IDR 1,325 per share. Relative valuation compares PBID to industry peers using EV/EBITDA, P/E, and P/B ratios, reinforcing the undervaluation finding. Investment recommendations suggest PBID’s stock as a buying opportunity due to its strong market position and favourable valuation metrics.

Development of Performance Monitoring Dashboard for Product Packaging Manufacturer by using Waterfall Methodology

Implementation of a robust and advanced management information system can enhance the organizational efficiency by streamlining data management, improving decision-making processes, optimizing resource allocation, and facilitating seamless communication across all departments. PT. MPM wanted to increase organizational efficiency but discovered that the organization currently lacks an appropriate system for measuring and monitoring the performance of its core processes. In this research, a business intelligence (BI) solution was used to address the issue by developing a BI dashboard, i.e., sales performance dashboard and production performance dashboard. The waterfall approach was used as the development framework and Google Data Studio was utilized for developing the dashboard itself. The BI Dashboard offered clear and understandable information, pertinent and accurate data, as well as an interactive user interface, so the implemented system aided the business in making decisions or developing a business strategy. The BI Dashboard was evaluated through alpha and beta testing, and the users were satisfied with the BI Dashboard with an average score of 82%.

Performance of Structured Packing for the Deuterated Water Distillation Process at Above Atmospheric Pressure

The National Research and Development Institute for Cryogenics and Isotopic Technologies (ICSI) was established in 1970 for research focused the industrial pilot plant. ICSI was created with the purpose of developing the heavy water production technology needed mainly for the operation of the CANDU reactors that equip the Cernavoda Nuclear Power Plant in Romania. This technology has been demonstrated and has been successfully transferred to the heavy water production plant. The accumulated experience in the field of isotopic separation allowed for the development of a second pilot plant, also for the purpose of heavy water, but this time for the purpose of separating deuterium and tritium for the recovery of tritium, mainly from the tritiated heavy water of the CANDU reactors. This experimental pilot is based on a technology that combines two hydrogen isotope separation processes: liquid-phase water-hydrogen catalytic isotopic exchange and hydrogen isotope cryogenic distillation. The success of the separation process consists of the technical solution given to the exchange area, its geometry (distillation-isotopic exchange), and last but not least, the performance of the hydrophilic packing, respectively, of the catalyst. Thus, an extensive research program was initiated and carried out over many years for the development of mixed catalytic packages consisting of a hydrophobic Pt/carbon catalyst (with different concentrations of platinum up to 2%) and hydrophilic packing (stainless steel or phosphorous bronze) manufactured within ICSI and made in different configurations (successive layers, random or structured). This program for the improvement of catalytic packages continues by implementing new solutions regarding the improvement of materials that ensure a large contact surface between the liquid and vapors, respectively, vapor and gas, thus increasing the isotopic separation performance. This paper presents an experimental analysis of two types of hydrophilic stainless steel packings developed for the purpose of separating hydrogen isotopes by water distillation to be used in the manufacture of mixed catalytic packages for the catalytic isotopic exchange process. This paper refers to the experiments performed with deuterated water on the hydrophilic packing in conditions of total reflux. The experiments were performed on a column equipped with two types of hydrophilic packing.

New type of UV cured low dielectric naphthalene resin: Structure-activity relationship of different substitution sites

UV-curing low dielectric materials exhibit wide applications in the field of additive manufacturing of electronic packaging, owing to their environmental protection, good thermal stability, low dielectric constant (Dk), and dielectric loss (Df). Wherein, one-step UV curing realizes process simplification of low dielectric materials gradually sparked widespread research. In this work, a series of novel naphthalene-based low dielectric materials were prepared for one-step UV curing. The double bond conversion rate of resins exceeds 90 % in a short time and the resins perform exceptional dielectric properties (Dk < 2.8, Df < 0.009, 110 MHz), high thermal stability (T5% > 270 °C), and hydrophobicity (water contact angle > 95°). Notably, 1,6-naphthalene dimethacrylate/Trihydroxymethylbutyl trimethylacrylate (1,6-NEA/TMPTA) suggests lowest dielectric performance (Dk = 2.19, Df = 0.005) with significant thermal stability (Tg = 190 °C, T5% = 367.4 °C) because the π-π conjugation of the asymmetric structure of 1,6-NEA, which allows for a greater variety of stacking patterns and increases the effective collisions between the reactive sites of the photosensitive monomer and the reactive diluent. This work has revealed the structure-activity relationship between the substituents on naphthalene derivatives and their photochemical properties, providing a novel methodology for the development of low dielectric electronic packaging materials through additive manufacturing techniques.

Integrating Small Team Project-Based Learning in Introductory Manufacturing Engineering Technology: Design, Manufacture, and Race Hot Wheels-Type Cars

We propose a compelling session for the ICONEST Conference 2023 that explores the innovative integration of small team project-based learning into introductory manufacturing engineering technology related courses. Our focus is on a hands-on project: designing, manufacturing, and racing Hot Wheels-type cars. This engaging project encompasses various facets of manufacturing engineering technology that includes simple design, manufacturing and assembly planning travelers, scheduling, budgeting, bill of materials, quality inspection, assembly and testing. Educators will gain insights into effective approaches, bridging the gap between theory and practice while equipping students with practical skills. We will explore the use of Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) software, fundamental tools in modern engineering, as well as explore simple machining, water jet cutting, and additive manufacturing. By incorporating project-based learning into our course curriculum, we not only foster a deep understanding of manufacturing principles but also cultivate problem-solving, teamwork, and creativity among students. The Hot Wheels-type car project is an ideal vehicle for teaching the entire manufacturing process, from conceptualization to execution and the students enjoy the competition. We believe that our proposal will make a valuable contribution to the conference's mission of advancing engineering technology education, and we look forward to engaging with colleagues and experts to further enhance the quality of manufacturing engineering technology and similar technology programs.

Optimising Warehouse Order Picking Through An Integrated Harmony Search and Simulated Annealing Algorithm: Application For A Food Packaging Manufacturer

Optimising Warehouse Order Picking Through An Integrated Harmony Search and Simulated Annealing Algorithm: Application For A Food Packaging Manufacturer

The Effects of Global Market Changes on Automotive Manufacturing and Embedded Software

The procedures used to create modern cars require extensive thought in various relevant scientific domains. Arguably, the most challenging obstacle facing the automobile sector is the management of production facilities by integrating software production lines, continuous integration, and continuous delivery/continuous deployment (CI/CD). All this is determined by market demands, the engine of a vehicle, and the complexity of assembling the entire car and installing its corresponding embedded software. As a result, concerns about various types of global change have grown, as has the lack of the ability to use fossil fuels, creating a substantial impact on the purchase and sale of modern automobiles. The research foundation is reflected in covering strategies for the deployment and administration of software, as well as opportunities for business improvement in particular production processes. This article strives to provide a summary of a scientific investigation of original equipment manufacturers, market segmentation, and the effects of global market changes on automotive manufacturing by examining the correlation between certain changes in the purchase of a specific brand and the powertrain of a vehicle. The research examines numerous datasets from the United States of America and Washington State, based on which we estimate possible future changes in the automotive industry’s sales.

Efficient and safe coumarin-carbazole-based oxime esters for one/two-photon polymerization of LEDs/NIR light

Photocuring has developed rapidly in recent years owing to its unique “5E” characteristics, especially in the industrial and manufacturing fields, where photoinitiators (PIs) are essential components of the polymerization system. However, most PIs have limited applications in fields that directly contact the human body, such as food packaging or biomedicine, due to migration stability and toxicity. Here, four oxime esters were designed as PIs by using coumarin-carbazole as the conjugate structure, and their properties were optimized by multisite modification of the molecular structure. First, substituents with different electronic properties were introduced at the 4-position of coumarin. The introduction of electron-withdrawing trifluoromethyl redshifted the molecule and better matched the light-emitting diode (LED) emission spectra (i.e., 365–450 nm). In addition, the introduction of long and branched alkyl chains on carbazole increased the solubility of the four PIs. The initiation efficiency of the PIs was improved by inserting long or cyclized alkyl chains at the α-position of C = N double bond. The experimental results demonstrated that these four PIs are superior to the commercial oxime ester OXE 02 in terms of light absorption and initiation ability under LED irradiation. The migration stability and cytocompatibility of these PIs were validated, ensuring a green and safe application in photocuring applications. Furthermore, these PIs exhibited a considerable writing speed and remarkable nanopatterning capabilities under 780 nm laser in two-photon polymerization. These outstanding properties indicated their great potential for applications in diverse areas of photocuring, especially in food packaging, bio-3D printing, tissue engineering, and nano-additive manufacturing.

Ultra-short time-echo based ray tracing for transcranial focused ultrasound aberration correction in human calvaria.

Magnetic resonance guided transcranial focused ultrasound holds great promises for treating neurological disorders. This technique relies on skull aberration correction which requires computed tomography (CT) scans of the skull of the patients. Recently, ultra-short time-echo (UTE) magnetic resonance (MR) sequences have unleashed the MRI potential to reveal internal bone structures. In this study, we measure the efficacy of transcranial aberration correction using UTE images.&#xD;Approach. We compare the efficacy of transcranial aberration correction using UTE scans to CT based correction on four skulls and two targets using a clinical device (Exablate Neuro, Insightec, Israel). We also evaluate the performance of a custom ray tracing algorithm using both UTE and CT estimates of acoustic properties and compare these against the performance of the manufacturer's proprietary aberration correction software. &#xD;Main results. UTE estimated skull maps in Hounsfield units (HU) had a mean absolute error of 242 ± 20 HU (n=4). The UTE skull maps were sufficiently accurate to improve pressure at the target (no correction: 0.44 ± 0.10, UTE correction: 0.79 ± 0.05, manufacturer CT: 0.80 ± 0.05), pressure confinement ratios (no correction: 0.45 ± 0.10, UTE correction: 0.80 ± 0.05, manufacturer CT: 0.81 ± 0.05), and targeting error (no correction: 1.06 ± 0.42 mm, UTE correction 0.30 ± 0.23 mm, manufacturer CT: 0.32 ± 0.22) (n=8 for all values). When using CT, our ray tracing algorithm performed slightly better than UTE based correction with pressure at the target (UTE: 0.79 ± 0.05, CT: 0.84 ± 0.04), pressure confinement ratios (UTE: 0.80 ± 0.05, CT: 0.84 ± 0.04), and targeting error (UTE: 0.30 ± 0.23 mm, CT: 0.17 ± 0.15). &#xD;Significance. These 3D transcranial measurements suggest that UTE sequences could replace CT scans in the case of MR guided focused ultrasound with minimal reduction in performance which will avoid ionizing radiation exposure to the patients and reduce procedure time and cost.&#xD.