Manufacturing Problems Research Articles

Sustainability of battery-operated products

The analysis of battery-powered products from different industries shows how sustainable they are. The focus is not only on the batteries, but also on the charging infrastructure and the devices themselves. In addition to the customer’s point of view, in particular user behavior, the problem of manufacturers and government intervention options are discussed. Solutions from individual industries are examined for transferability. The modular product architecture and the advantages and disadvantages of standardization are highlighted.

ПРОБЛЕМЫ РОССИЙСКОГО ПОТРЕБИТЕЛЬСКОГО РЫНКА КРУП И ЗЕРНОВЫХ В УСЛОВИЯХ НЕСТАБИЛЬНОСТИ ВНЕШНЕЙ СРЕДЫ

The article describes the changes in the economic situation that occurred in the consumer market of cereals and cereal flakes in the first half of 2022. The main events and problems of manufacturers are considered. The stages of changes in the economic situation are highlighted. On the basis of the data by the Federal State Statistics Service of the Russian Federation and internal data by AO MAKFA, a comparative analysis has been carried out for the dynamics of exchange rates, producer price lists, the volume of trade and retail prices of retail chains, raw material prices as the main indicators characterizing the market situation. The instability of the political and economic situation has had a negative impact on the situation in the cereals and cereal flakes market. The cost price increase, which the manufacturers faced in February March 2022, has been put on the consumer by raising shipping prices. The market is currently showing signs of stabilization, most supply issues have been resolved by manufacturers, exchange rates have been favorable, but reliable long-term forecasts of the market situation are not yet possible.

The product-mold-machine manufacturing problem

This paper introduces the product-mold-machine manufacturing problem, which is related to the manufacturing process of tires, plastics, ceramics, and glass. Each product has its own shape and mechanical properties obtained from processing a specific mold on a machine. Each machine can process a set of molds at the same time and, hence, the processing time on a machine depends on the longest processing time among the set of molds on the machine. The objective is to find a production plan that minimizes the total number of periods needed to meet the demand of each product, considering a limited number of machines, molds, changeover times, and incompatibilities constraints. We provide a mixed integer linear programming model for the problem and propose two constructive heuristics of polynomial-time, which provide upper bounds on the optimal value and easy-to-implement feasible solutions. Numerical experiments carried out over instances based on real data show the effectiveness of the proposed approaches.

Two-Stage Meta-Heuristic for Part-Packing and Build-Scheduling Problem in Parallel Additive Manufacturing

Two-Stage Meta-Heuristic for Part-Packing and Build-Scheduling Problem in Parallel Additive Manufacturing

Mitigation of liquation cracking in selective laser melted Inconel 718 through optimization of layer thickness and laser energy density

Conventionally, the main goal of process optimization in selective laser melting is to achieve the highest relative density. However, for Inconel 718, this study has demonstrated that the highest relative density does not correspond to the best mechanical properties. Moreover, similar relative densities can result in significant differences in mechanical properties. This phenomenon arises from the presence of cracks in the microstructures. The research was carried out to study the problem systematically using combinations of 2 layer thicknesses (40 and 50 μm) and 2 laser energy densities (3.17 and 3.47 J/mm 2 ). Microcracks were observed near the melt pool boundaries and within the heat-affected zones of the newly deposited layer, occurring along the grain boundaries and interdendritic regions. Evidence was obtained to show that the cracking was associated with remelting of Laves phase; therefore, it was identified as liquation cracking. It is interesting to observe that layer thickness has a much greater influence on crack formation than laser energy density, owing to the significant change in the melt pool shape and grain boundary morphology when the layer thickness was changed. The influence of laser energy density was only observed at the larger layer thickness as the severity of cracking was amplified when laser energy density was increased due to microstructural coarsening. Thus, this presents a unique problem in additive manufacturing (AM) regarding liquation cracking in Inconel 718 as one of the key differences from conventional manufacturing is the successive heating and reheating of multiple layers of material in AM.

Optimal Dual-channel Distribution Configuration of a Manufacturer Under Showrooming

We study the channel configuration problem of a monopolistic manufacturer under three dual-channel supply-chain configurations (DCSC). The first DCSC configuration corresponds to the manufacturer, the retailer (brick-and-mortar store) and the e-tailer (online store) who are all independent entities. In the second DCSC configuration, the manufacturer sells through its own brick and mortar stores (company stores) and competes with an independent e-tailer. In the third DCSC configuration, the manufacturer sells through an e-marketplace it owns and competes with an independent retailer. We find the equilibrium profit, price, and demand of each entity. Using numerical analysis, we find the effect of showrooming (examining product at the brick-and-mortar store and then buying from the online store).

Mathematical Models for Minimizing Total Tardiness on Parallel Additive Manufacturing Machines

In this research we tackle the scheduling problem in additive manufacturing for unrelated parallel machines. Both the nesting and scheduling aspects are considered. Parts have several alternative build orientations. The goal is to minimize the total tardiness of parts. We propose a mixed-integer linear programming model which considers the nesting subproblem as a 2D bin-packing problem, as well as a model which simplifies the nesting subproblem to a 1D bin-packing problem. The computational efficiency and properties of the proposed models are investigated by numerical experiments. Results show that the total tardiness optimization significantly increases the complexity of the problem, only the simple instances are solved optimally, whereas the makespan variant is able to solve all testing instances. Using the 1D bin-packing simplification allows for solving more instances to optimality, but with a risk of obtaining nesting-infeasibility. We also observed the compromise between the total tardiness and makespan objectives, which originates from the dilemma of “packing more parts to benefit from the common machine setup/recoating time” or “packing less parts to maintain the flexibility for handling distributed duedates”.

Industrial Revolution and Deindustrialization of Indian History – An Overview

The idea that India suffered deindustrialization during the 19th century has a long pedigree. The image of skilled weavers thrown back on the soil was a powerful metaphor for the economic stagnation Indian nationalists believed was brought on by British rule. However, whether and why deindustrialization actually happened in India remains open to debate. Quantitative evidence on the overall level of economic activity in 18th and 19th century India is scant, let alone evidence on its breakdown between agriculture, industry, and services. Most of the existing assessments of deindustrialization rely on very sparse data on employment and output shares. Data on prices are much more plentiful, and this paper offers a new (price dual) assessment of deindustrialization in 18th and 19th century India supported by newly compiled evidence on relative prices. A simple model of deindustrialization links relative prices to employment shares. We think the paper sheds new light on whether and when deindustrialization happened, whether it was more or less dramatic in India than elsewhere, and what its likely causes were. The existing literature primarily attributes India’s deindustrialization to Britain’s productivity gains in textile manufacture and to the world transport revolution. Improved British productivity, first in cottage production and then in factory goods, led to declining world textile prices, making production in India increasingly uneconomic (Roy 2002). These forces were reinforced by declining sea freight rates which served to foster trade and specialization for both Britain and India. As a result, Britain first won over India’s export market and eventually took over its domestic market as well. This explanation for deindustrialization was a potent weapon in the Indian nationalists’ critique of colonial rule (see e.g. Dutt 1906/1960, Nehru 1947). The historical literature suggests a second explanation for deindustrialization in the economic malaise India suffered following the dissolution of Mughal hegemony in the 18th century. We believe the turmoil associated with this political realignment ultimately led to aggregate supply-side problems for Indian manufacturing, even if producers in some regions benefited from the new order. While deindustrialization is easy enough to define, an assessment of its short and long run impact on living standards and GDP growth is more contentious and hinges on the root causes of deindustrialization.

Optimizing the wiring sequence based on a Constraint Satisfaction Problem for robot-based manufacturing of solderless wrapped connections

The manufacturing of solderless wrapped connections in traceable and reproducible high quality requires an automated manufacturing process. However, one key challenge for robot-based wiring is the definition of wiring sequence, as the proximity of the array-oriented wrapposts exacerbates tool accessibility. In this research, we optimize the wiring sequence by treating it as a constraint satisfaction problem, whereby a solution is indispensable, even if the constraints are not fulfilled. Experiments on a pilot plant for robot-based manufacturing of wrapped connections show that the percentage of automatically wired connections can be significantly increased with the developed approach.

Rule-Based Genetic Algorithms for Integrated Scheduling of Parallel Batch Additive Manufacturing and Batch Delivery Problem

Rule-Based Genetic Algorithms for Integrated Scheduling of Parallel Batch Additive Manufacturing and Batch Delivery Problem

Manufacture and installation problems in modular heat generators

This report deals with some practical cases of application of chapter R.3.F of the “Raccolta R”, 2009 edition, and the technical information drawn up by INAIL, attached to the note INAIL no. 60202 20/05/2015.0003445. The cases examined relate to both the approval of modular heat generator prototypes and their commissioning tests. In particular, some represented errors in the design and installation of the systems could nullify the safety indications provided by Raccolta R and by the aforementioned note.

Flexibilization 4.0 for production manufacturing optimization

The continuous variations of requirements and the versatility of customers have a real impact on the company performance. Digital transformation corresponds to one lever for making the company more competitive. New technologies and tools are required as recommended in Industry 4.0 concepts for making this transformation a success. This paper focuses on production manufacturing problems such as human-machine collaboration, to achieve a high level of performance while maintaining a wide range of operational complexity, guaranteeing the flexibility of the workstations and thus the company’s ability to respond to varied demands. A sustainable digital transformation methodology has been elaborated for solving problems related to human-robot collaboration during the production process, to reduce lead time and decreasing series changing time. After a literature review on artificial intelligence (AI), collaborative robotics and production performance optimization methods, this article describes the developed sustainable digital transformation methodology and focuses on operational problems that could be solved in this frame. Then, the results obtained on an electronic card Industry 4.0 demonstration platform will be presented.

領域分割法と簡略化熱源モデルを用いた金属積層造形問題の熱弾塑性解析とバリデーション

The metal additive manufacturing problems can be modeled by the one way coupling problem from a heat conduction to a thermal elastic plastic analysis. It costs a lot of time and temperature steps to analyze the problems. To reduce the numbers of these steps, our previous studies used the balancing domain decomposition method as a parallel strategy, and a simplified heat source model. The model allows to sequentially heat an entire layer one by one, and this process continues until all layers are simulated. However, it was only applied to a simulation of depositing a plate. Thus, this study focuses on applying the model to a shape other than a plate with the balancing domain decomposition method. Especially, a half pipe model was considered. The paper presents how to find parameters of the simplified heat source model on the half pipe model. One of numerical results showed a speedup of more than one hundred times. They were also verified and validated.

Study and implementation of lean manufacturing strategies: A literature review

Lean manufacturing, organizations are utilizing maximum resource and minimization to waste and do the Non-Value-Added Activity. In the period Industries are paces to changing business environment, every manufacturing sector is fought to challenges so they are required for agile elevation. In this paper, a critical review was attempted which focuses on lean manufacturing and reverse engineering for joint propeller shaft. It systematically categories by definitions, design bases, organizations base, material bases and tool use bases. It also provided quality of work processes in every manufacturing organization. In this paper’s analysis about lean manufacturing concepts, lean wastes plus strategies, obstacles to lean as well as implementation of lean. Emphasize to tool & techniques of lean manufacturing organization of find out to numerous outcomes than the organization is sustained to their good repo in the market. Uses of this tool performance measurement and find out greatest improvement.Industry 4.0 is relatively anewer concept that is among the most promising methods to dealing with thefuture manufacturing problems such as the high demand for customised products. Many sorts of study focus on combining the two principles to sustain an efficient as well as flexible manufacturing process. The notion of Industry 4.0 (I4.0) is formed by the widespread use of Information and Communication Technologies(ICT) in production, which connects physical to thedigital systems as well as integrates value chains. LM as well as I4.0 have the same aims of enhancing flexibility as well as productivity, but via distinct methodologies. By merging both theories & carefully identifying the unification, this study overcomes the difficulty.

Vol4 num2-20 Manufacturing and testing of a new CFRP node bonded by adhesives for its use in bus structures

In recent years exponential increase in the use of adhesives in industrial processes is observed. Nowadays these materials are used in applications as diverse as aerospace industry, automotive industry, railway industry or even civil construction. In the same way, the use of composite materials has grown enormously, especially in the aerospace industry, thanks to the benefits that this type of materials are able to provide, even as reinforcement. Current bus structures present serious problems of fatigue due to their rigidity, resulting in unexpected failures in certain nodes where stresses are concentrated. This work is part of a project that it is trying to provide more elasticity to the structure through the use of a new CFRP node joined by adhesives to the bus structure using polyurethane. The complex design of the node has caused numerous manufacturing problems. PLA node was manufactured using 3D printing for being used as a core. PLA node was covered layer by layer with CFRP by hand lay-up. In order to know the behavior of the whole set (CFRP node, adhesive and steel beams), four prototypes were manufactured and tested. Four point flexural test was carried out on the prototypes to validate the assembly. Results show the suitability and capacity of this new node concept to be used in bus structures. In recent years exponential increase in the use of adhesives in industrial processes is observed. Nowadays these materials are used in applications as diverse as aerospace industry, automotive industry, railway industry or even civil construction. In the same way, the use of composite materials has grown enormously, especially in the aerospace industry, thanks to the benefits that this type of materials are able to provide, even as reinforcement. Current bus structures present serious problems of fatigue due to their rigidity, resulting in unexpected failures in certain nodes where stresses are concentrated. This work is part of a project that it is trying to provide more elasticity to the structure through the use of a new CFRP node joined by adhesives to the bus structure using polyurethane. The complex design of the node has caused numerous manufacturing problems. PLA node was manufactured using 3D printing for being used as a core. PLA node was covered layer by layer with CFRP by hand lay-up. In order to know the behavior of the whole set (CFRP node, adhesive and steel beams), four prototypes were manufactured and tested. Four point flexural test was carried out on the prototypes to validate the assembly. Results show the suitability and capacity of this new node concept to be used in bus structures.

Structure of VT6 – SiC composite material

To date, the methods of additive technologies for manufacturing goods are applying more and more widely in the real sector of production and are rapidly developing. The development of various composite materials by these methods is of increased interest, since it has become possible to obtain composite materials with a different number of initial components of the matrix and reinforcer. It became possible to integrate ceramics into a metal matrix and vice versa by growing products from raw powder materials variously composed. The resultant materials may be used as a replacement for existing ones, since they have a cumulative unique set of properties that are necessary for technological and scientific expansion. Combination of well-known technologies, such as classical hot isostatic pressing, selective laser melting and ceramic fiber reinforcement, will make it possible to obtain unique composite materials. Thin-walled products from titanium alloys, including thin sections, may be obtained by the use of selective laser melting. The main problems in manufacturing of fiber-reinforced materials are setting the fibers in a given position, minimizing their displacement during consolidation, as well as limiting the matrix and fiber interaction during consolidation to prevent a reaction with the formation of an interaction zone. In order to create a new material, a silicon carbide reinforcing fiber was loaded into the shaped manufactured article, followed by encapsulated hot isostatic pressing. As a result, effective diffusion connections of individual matrix elements took place, as well as complete enveloping the fibers with the matrix material. A low-porosity structure without large defects visible on X-ray tomography was obtained.The work was carried out with the financial support of the Ministry of Science and Higher Education of the Russian Federation under the Grant agreement No. 075-11-2019-058 dated 25.11.2019 “Organization of production of locally reinforced parts made of titanium alloys operating under conditions of increased loads and temperatures for advanced aviation gas turbine engines”, approved by the Decree No. 218 of the Government of the Russian Federation.

Review of the Problems of Additive Manufacturing of Nanostructured High-Energy Materials.

This article dwells upon the additive manufacturing of high-energy materials (HEM) with regards to the problems of this technology’s development. This work is aimed at identifying and describing the main problems currently arising in the use of AM for nanostructured high-energy materials and gives an idea of the valuable opportunities that it provides in the hope of promoting further development in this area. Original approaches are proposed for solving one of the main problems in the production of nanostructured HEM—safety and viscosity reduction of the polymer-nanopowder system. Studies have shown an almost complete degree of deagglomeration of microencapsulated aluminum powders. Such powders have the potential to create new systems for safe 3D printing using high-energy materials.

Smooth transition for collision avoidance of redundant robots: An on-line polynomial approach

• Smoothing of transientin collision avoidance trajectoryconsidering thecontinuity • Collision avoidance trajectory adjusted by polynomial functions • Systematic formulation of trajectories aiming to decrease the calculation effort • Improvement behavior of transitions as a function of the polynomial order • Using Adaptive Extended Jacobian when the robot is out of collision imminence The presence of cooperation between robots and machines in the industrial environment improved the solution for several manufacturing problems. With cooperation, new challenges emerged, and among these stands out the collision avoidance between such robots and machines. Collision avoidance can be dealt with in several ways, taking into account the computational effort to make a decision and the quality of the calculated trajectory for the robots, evaluated, for instance, by smooth profiles avoiding sudden variations in joints’ velocities or acceleration. In these circumstances, the involved robots need to be redundant since new movements are necessary for avoiding collisions. The strategies for collision avoidance are offline (i.e., based on pre-programming the task), or online (i.e., implemented while the robot performs the main task). In online collision avoidance strategies, numerical performance must ensure the time requirements of the main task performed by the robot; so, numerically efficient solutions are the most appropriate. This paper presents a proposal for the collision avoidance treatment from fixed obstacles for redundant robots, based on polynomial functions. The proposed solution allows achieving smooth trajectories according to criteria based on the continuity of derivatives in trajectory curve transitions. When the robot is out of the imminent collision, it is proposed to solve the inverse kinematics through the Adaptive Extended Jacobians. Throughout the text, the mathematical developments based on polynomials are presented, and in the end, a case study graphically shows comparative results.

A DFT study of the effect of stacking on the quantum capacitance of bilayer graphene materials

Graphene is acknowledged as one of the ideal active electrode materials for electric double-layer capacitors because of its extremely high specific surface area and outstanding electronic conductivity. By introducing defects or heteroatoms into the graphene sheet, the electronic structure around the defects can be altered, which could lead to an increased quantum capacitance (CQ) and therefore te capacitive performance. One of the unavoidable problems for manufacturing and using graphene materials is that the stacking of the layers affects their electronic structure, and eventually their capacitance. DFT calculations were used to investigate the effect of layer stacking in bilayer graphene materials on CQ and the surface charge density. A two layer, AB-stacked graphene model, in which the top layer is defective and the bottom one is perfect was assumed for the calculations. The defective graphenes investigated are those containing Stone-Thrower-Wales defects, single vacancies (SV), three with double vacancies (5-8-5, 555-777 and 5555-6-7777), pyrrole-N graphene and the pyridine-N graphene. Results indicate that both the values and waveform of CQ of the materials are changed by stacking. The CQ values of most of these graphenes are significantly increased after stacking. The CQ waveforms of the SV and N-doped graphene are relatively insensitive to stacking. The basal layer contributes a considerable amount of charge, which is most obvious for the pyrrolic-N double-layer graphene and 5-8-5 double-vacancy graphene. The surface charge density provided by the defective top layer is increased by interlayer interaction, especially for the N-doped graphene. The uniform distribution of charge on the bottom layer partially alleviates fluctuations in the CQ waveform. These findings provide theoretical guidance for the micro-structural design of graphene materials to optimize their performance as electrode active materials.

Innovative and Robust Application of Automation for Unit Level Traceability on Dual Die configuration of Micro Electromechanical System Products

Strip mapping for unit level traceability on die attach process of semiconductor companies provide quality driven impression for end users on the market. On processing of Micro electromechanical system packages, strip map generated by operators manually, certain errors and discrepancies are encountered and inevitably experienced by the production line. This causes misleading analysis on manufacturing problems and may lead to inappropriate and incorrect solutions hurting the process line. The application of modern technology and internet of things have been considered as an improvement. This is to eliminate human intervention errors caused by manual practice and promoted fool proof design of procedures. Having a user-friendly application with integration of modern technology drives significant improvement provide benefits to both supplier and customer of the manufacturing world.