Reconfigurable Production Research Articles

A Function Based Approach for Product Integration

Reconfigurable and multifunctional products are breeds of products that cater to the increased diversification of customer needs. Unlike single-state static products which can perform only one primary function, these products cater to different customer needs by performing more than one function with or without changing their configuration. However, there is a lack of systematic methods to support the conceptual task of combining two existing single-state products into an integrated product that provides multiple functions. In this work, a function based approach is proposed which provides more rigorous support to assess the feasibility of integrating two products. The function structures of the existing products are combined to obtain the overall function structure of the reconfigurable product. Function sharing, based on quantified functional similarity, is proposed and applied to identify functions that can be shared by the same component. The information obtained from the function structure is then mapped to the components of two existing products to analyze their roles in the final reconfigurable product architecture. A case study illustrates the proposed approach by analyzing the integration of a power drill and a dust buster.

Prediction of machine reconfigurability using artificial neural network for a reconfigurable serial product flow line

Reconfigurable machines (RMs) are considered to be one of the vital elements of modern manufacturing systems like reconfigurable manufacturing systems (RMSs). These machines offered customised flexibility in terms of capacity and functionality. Reconfigurable machines are assembled using some basic/essential modules and auxiliary modules. The RMTs can be reconfigured into several other configurations for variable functionality and capacity by keeping its base modules and just adding/removing or adjusting the auxiliary modules. Measuring machine reconfigurability may be considered as one of the important challenge in assessing the performance of these manufacturing systems. In the present paper, an artificial neural network model has been proposed for quantitative assessment of reconfigurability values of RMs on the product flow line. The data is generated using a developed mathematical model based on multi attribute utility theory. The ANN predictive model could thus provide a flexible and objective framework for manufacturers to evaluate reconfigurability of machines for a given product flow line. The developed approach has been demonstrated using a multi stage serial reconfigurable product flow line.

Methodology for the Evaluation of Forecast Reliability of Production Planning Systems

The high dynamics of markets are only one reason for the increasing complexity of production planning and control. To handle this complexity manufacturing companies have implemented IT systems to support decision-making in detailed scheduling processes. However, applied IT systems often do not provide a reliable forecast of delivery dates, because the planning models are implemented uniquely and have never been adapted due to changes in the production system. This paper presents an approach to verify the forecast reliability of detailed planning systems by identifying deviations between the predicted production schedule, determined by the IT system, and the observed production processes in reality. The paper introduces the reasons for deviations and explains how they can be determined. The approach represents how categorical and continuous verification methods can be applied to identify the described deviations. Depending on the determined deviations the forecast quality index of detailed planning systems is developed. Besides the assessment of the forecast quality the reasons for deviations are of interest to production planners. Identified reasons are the starting point for adaptions in planning models to enable a reliable forecast of re-configurable production planning systems in the future.

Reconfigurable Integrated Production Control System of industrial processes on QNX Neutrino platform

This paper presents the structure and implementation of the Integrated Reconfigurable Production Control System. The solution offers monitoring, control and supervision of manufacturing systems equipped with Enterprise Resource Planning (ERP) and Supervisory Control and Data Acquisition (SCADA) systems. The article proposes the architecture and the main principles of such a system, as well as its substantive tasks. QNX Neutrino system was chosen for a development platform as it provides real-time operations for control loops. The proposed project is intended for continuous industrial production systems.

Machine Reconfigurability Models Using Multi-Attribute Utility Theory and Power Function Approximation

Reconfigurable Machines (RMs) are considered to be one the key elements of modern manufacturing systems like Reconfigurable Manufacturing Systems (RMSs). These machines offered customized flexibility in terms of capacity and functionality. These machines are modular machines assembled using basic/essential modules and auxiliary modules. These RMs can be reconfigured into several other configurations offering variable functionality and capacity by keeping its base modules and just adding/removing or adjusting the auxiliary modules. Measuring machine reconfigurability may be considered as one of the important parameter in assessing the performance of these manufacturing systems. In the present paper, reconfigurability models were developed using Multi Attribute Utility Theory (MAUT) and Power Function Approximation. The developed models are explained and demonstrated using multi stage serial reconfigurable product flow line.

An approach towards scalability for reconfigurable product flow line through unbalancing

A timely and cost effective response to dynamic market scenario is becoming one of the key factors for the success of manufacturing enterprises. Reconfigurable manufacturing systems are recognised as the next generation manufacturing systems, which are responsive to these market changes. One of the major challenges which need to be addressed for designing and operating such systems include implementing scalability within these systems. In the past, some strategies have been proposed for scalability aspect based on routing flexibility and stage paralleling. In this paper, an approach based on ‘unbalancing’ is proposed as a potential technique for scalability of reconfigurable product flow lines. The proposed approach is based on the fact that productivity variations may be achieved from a flow line by varying the degree of imbalance in mean operation time values at stations on the product line. The proposed approach is demonstrated using a coupled reconfigurable product flow line.

Spare Parts Production Planning Model Based on Fuzzy Programming

In the field of civil aviation, MRO market has a strong seasonal characteristic. Combined with research on continuous airworthiness of the aircraft, the spare parts order procedure and flight planning process, and analysis on fuzzy demand and fuzzy production capacity, the model of spare parts order with fuzzy reliability constraints is established. Under the background of actual civil aviation enterprises, spare parts quantitative order model and algorithm in spare parts planning decision system in non-deterministic environment are put forward. It applies the theories and methods of fuzzy mathematics and probability and statistics, building the target programming model for reconfigurable spare parts, to formulate optimal reconfigurable spare parts production plan. Overall steps to solve the model are proposed, which make decision process in fuzzy environment more flexible, and reduce the number of emergency orders.

Throughput-driven condition-based maintenance for frequently reconfigured mass production equipment

Heavily utilised reconfigurable production equipment has uneven deterioration rate caused by frequently changing configurations and complex subsystem interaction. Thus, traditional maintenance approaches that rely on reliability modelling are ineffective when applied on this class of equipment. This paper introduces a throughput-driven condition-based maintenance framework intended to perform predictive maintenance for heavily utilised reconfigurable production equipments. The effectiveness of the proposed method is experimentally validated using actual production records of the semiconductor test handlers. The primary benefit of the proposed framework is its prediction efficacy while accounting for the complex subsystem interaction through Bayesian statistics. It is low cost to implement because it only uses existing resources already available in most manufacturing plants.

Column Generation Approach for Planning the Operation of Reconfigurable Production Line Segments with Bideractional Conveyance System

The advent of reconfigurable assembly lines brought about increased manufacturing flexibility that enables an extremely efficient production. The machines in reconfigurable systems are characterized by ultra-fast orientation changes as well as fast tool changes. The lines often enable non sequential flow and large degree of automation (including routing). In this paper we suggest a simple column generation technique to efficiently utilize the various machines. We discuss the suitability of the suggested method to various reconfigurable systems. We also discuss other possible formulations that may be pursued in the future.

Enhancing changeability of automotive Hybrid Reconfigurable Systems in digital environments

Changeability accomplishes the engineering design of competitive sustainable manufacturing systems, considered as industrial products characterized by inherent life cycle. Main drivers for changeability are manufacturing system reconfigurability and hybridization. A Hybrid Reconfigurable System (H-RS) is characterized by the coexistence and cooperation of industrial robots and skilled human workers to perform complex tasks within a common reconfigurable production environment. H-RSs rise use-productivity along their total system life cycle, fostering the evaluation and implementation of feasible and innovative technologies, and increasing the utilization ratio and the multiple use—or re-use—of resources. The paper proposes an engineering method which aims at enhancing changeability in H-RSs through the application of a multi level reconfigurability approach within a digital environment. The method includes the advanced design and modeling of digital devices which embed mechanics, electronics, control logic and software code. Advanced models are exploited to analyze the system performance in the system domain of changes and to realize an effective human training. An industrial case study describes the application of the method to the design of a hybrid reconfigurable workcell for manufacturing and assembly of top class car chassis.

A methodology for static and dynamic scheduling of automation tasks in reconfigurable production systems

The development of distributed architectures for logic control systems has a number of advantages related to the system capability of being reconfigurable and responsive toward changes of production requirements. However, the execution of various portions of the control system on multiple physical resources represents a challenge as for the control task scheduling and synchronization perspectives. The proposed work outlines a scheduling approach – named ISA (Integrated Scheduling Architecture) – supporting the dynamic execution of control tasks in distributed control systems while enriching the control nominal behavior with data gathered from the shop-floor. The benefits of the approach have been validated with reference to a flexible transportation system operating in a pilot assembly line.

Reconfigurable production system design – theoretical and practical challenges

Purpose – The purpose of this paper is to explore theoretical and practical challenges to achieve reconfigurable production system designs. Design/methodology/approach – The empirical material of this paper includes a multiple-case study with an embedded design (Yin) including four cases, where each case represents a production system design project. The consideration of reconfigurability and its characteristics in the production system design projects was studied. To enhance validity, two real-time studies were combined with two retrospective studies (Leonard-Barton). Findings – For more than a decade foresight reports have pointed out the need for responsiveness to change through reconfigurability in production system design. In order to achieve reconfigurable production systems, three challenges were identified: to use a structured design methodology, to gain knowledge in reconfigurability and its characteristics, and to include the reconfigurability knowledge in a structured design methodology. Still there is no comprehensive support available for reconfigurability in the production system design process. Research limitations/implications – Limitations are mostly related to the chosen methodology approach, and additional empirical studies to establish generic results are required. Practical implications – By combining knowledge from the production system design field with the reconfigurable manufacturing system field a potential of meeting identified challenges is pointed out. Originality/value – This paper adds to current knowledge by pointing out three main challenges to achieving reconfigurable production systems. The paper also contributes with ideas on how to respond to these challenges.

Investigation and Implementation of Environmental Protection and Energy Saving

Abstract. Xinjin technology group company is to provide professional electronics manufacturing services ( EMS ) Company. The main business is the assembly of PCB and small electronic products and packaging They are the main problem facing the enterprise that global oversupplies in the market, which includes cost saving, protection of the environment and improve efficiency.There are three primary aspects in this paper. They are electric circuit capacitance compensation, tin slag recycling and type U reconfigurable production line. They were to take the new technology, new production process to replace outdated., Profits were improved through these reform measures.

Operator allocation planning for reconfigurable production line in one-of-a-kind production

In a one-of-a-kind production (OKP) company, the operation routing and processing time of an order are usually different from the others due to high customisation. As a result, an OKP company needs to dynamically adjust the production resources to keep the production lines reconfigurable. Through a proper assignment of operators in different sections of a production line, bottlenecks and operator re-allocation during production can be reduced effectively. In this paper, a mathematical model is introduced for optimal operator allocation planning on a reconfigurable production line in OKP. The optimisation objectives are to minimise the total number of the operators, total job earliness and tardiness, and the average work-in-process storage. A branch-and-bound algorithm with efficient pruning strategies is developed to solve this problem. The proposed model and the algorithm are empirically validated by using the data of a windows and doors manufacturing company. A software system based on the proposed approach has been implemented in the company.

Modeling economic efficiency of multi-technology platforms

It is believed that for complex workpieces and small lot sizes complete machining with multi-technology platforms reduces cycle times compared to multiple stand-alone machines and is economically more efficient. However, so far in literature no mathematical model has been applied to compare these alternatives with respect to cost and productivity. This paper introduces a mathematical model for part costs and productivity and examines conditions under which multi-technology platforms are economically efficient. It is concluded that depending on the reduction of reconfiguration and processing times efficient production with multi-technology platforms is not solely limited to small lot sizes.

Reconfigurable production systems

Reconfigurable production systems

Reconfigurable production systems

Reconfigurable production systems

Research and optimization of reconfigurable manufacturing system configuration based on system reliability

PurposeThe purpose of this paper is to research the impact of hybrid series‐parallel and parallel‐series system configurations on system performances based on system reliability and to develop a configuration model to meet the requirement of reconfigurable manufacturing system (RMS).Design/methodology/approachBased on the criterion of system reliability, a RMS configuration model is presented – the hybrid parallel‐series model with waiting system characteristics. The configuration model is evaluated from reliability, productivity, and cost by combining system engineering theory, Boolean algebra methodology with statistical analysis theory. The model reliability has been used to ameliorate by adopting the integrated algorithm based on Shrama and Misra optimization algorithm.FindingsThe need for application of this method and model – some constraints must be limited, the hybrid parallel‐series configuration is superior and the integrated algorithm is effective to RMS system configuration.Research limitations/implicationsCost constraints, equipment weight constraints, and function independency of equipment are main limitations.Practical implicationsThe model and method have been used to ameliorate the reconfigurable automobile parts product line in SH automobile motor company of Shanghai. The operation result illustrates the validity of this configuration model and algorithm.Originality/valueThe new RMSs configuration model has been proposed. The new algorithm is proposed to ameliorate and optimize a reconfigurable product line with the integrated algorithm based on Shrama and Misra algorithm. The actual running effect is significant.

Description and Verification of Dynamic Software Architectures for Distributed Systems

Continuing growth and increasing complexity of distributed software systems make them be more flexible, adaptive and easily extensible. Dynamic evolution or reconfiguration of distributed software systems is one possible solution to meet these demands. However, there are some challenges for building dynamically evolving distributed software systems at runtime, where dynamic software architectures for them is one of the most crucial problems. In this paper, we proposed a formal method of describing and verifying dynamic software architectures for distributed systems using hypergraph grammars. We firstly gave out reconfiguration production rules and operations for software architectures based on hypergraph grammars, and then described dynamic reconfiguration of software architectures for distributed systems according to those rules. At last we verified the invariant property of dynamic software architectures for those systems using model checking, and gave out corresponding verification algorithms.

Agent-based distributed scheduling for virtual job shops

Nowadays, market globalisation and stiff world-wide competition require flexible, demand-driven, and reconfigurable production systems that can adapt to the requirements of the increasing reduction in product life cycle and rapid changes in market demand. The advent and development of network technology (especially the Internet) and distributed computing technology make it possible for geographically dispersed manufacturing resources to be integrated and deployed effectively and efficiently. In addition, manufacturing enterprises can expand their throughput within a short time and rapidly reduce the production cycle via transferring certain jobs to other available manufacturing resources in the globalised manufacturing environment, viz., manufacturing enterprises can expand their throughput through the dynamic formation of virtual job shops according to the production requirements. Owing to more open manufacturing environments and rapid changes of market demands, the traditional centralised scheduling approaches are not suitable for this open distributed manufacturing environment. This paper proposes a distributed scheduling approach in which a multi-agent solution towards a ‘task-machine’ assignment is presented. The main points of discussion are the formation of a virtual job shop that is based on market mechanism and the distributed scheduling approach based on negotiation.