Simulated Production Environment Research Articles

Simulated Production Environment Today – Evaluation of the numerical process simulation of selective laser melting

Simulated Production Environment Today – Evaluation of the numerical process simulation of selective laser melting

Electrochemical Study of Corrosion Inhibition of Carbon Steel During Oil/Water Intermittent Wetting

Application of corrosion inhibitors in production systems containing oil and water is an economic method to protect carbon steel against internal corrosion. This study investigates how intermittent oil/water wetting of such a steel surface, simulating multiphase flow phenomena, impacts corrosion inhibition in exploration-production (high salinity with CO2) and refinery (low salinity without CO2) environments. The employed corrosion inhibitor was a pyrimidinium-type model compound, its effectiveness against corrosion being characterized using linear polarization resistance measurements and electrochemical impedance spectroscopy. Experimental results demonstrated that the presence of an aliphatic oil promotes corrosion inhibition in the exploration production condition, but failed to do so in the refinery condition. Electrochemical impedance spectroscopy revealed two different protection mechanisms in the presence of oil between the two environments. The inhibitor layer in refinery condition with oil was different from in the simulated exploration production environment after oil wetting. Results also demonstrated that the inhibitor in this study was physically adsorbed on the surface steel via electrostatic attraction. Anions, identified as chloride ions, played a critical role in inhibitor adsorption.

Distributed real-time production control for resilient manufacturing systems

To enable resilient manufacturing, production control systems must be able to adapt quickly and flexibly to unexpected changes. Motivated by Industrie 4.0, multi-agent systems offer a promising approach to meet these requirements. This paper presents a method for distributed production control that enables production entities to make optimal decisions regarding capacity utilization and the compliance of delivery dates in real-time despite disruptive events. Based on a multi-agent Markov Decision Process, production entities are modeled as autonomous software agents that can solve Flexible Job-Shop Problems through message passing. The performance of the proposed method is evaluated in a simulated production environment.

Automated Testing of Session Border Controller in Simulated Production Environment

Abstract: A Session Border Controller plays a crucial role in Unified Communications, Contact Centre Modernization and Cloud communication Services. Therefore, testing the functionality of SBC is extremely critical to the modern communication infrastructure. Testing various call scenarios through the SBC by manually making call through devices is cumbersome, timeconsuming and error-prone. Session Border Controller (SBC) devices sit in between a lot of traffic in a service provider or VoIP infrastructure and thus testing the SBC to see if all most relevant call scenarios are tested is a must in today’s production SBC environment. To enable an automated tested approach, we have simulated the setup of a real production environment SBC and tested the calls using SIPp scripts to test all the relevant VoIP call scenarios. This paper covers a methodology on how to test Session Border Controllers to be robust and reliable to be deployed in enterprise and service provider customers. This paper demonstrates how to make these simulated calls using automated scripts using an XML (eXtensibke Markup Language) based scripting tool called SIPp. To verify these tests, an opensource and free packet sniffer like Wireshark is used to follow through and check if all the intended calls have taken place. In this paper, we perform thirteen of the most relevant SIP (Session Initiation Protocol) calls by running scripts at the endpoints of our setup. The proposed approach of testing SBC makes the overall process of testing easier through automating via scripts and also allows a novice with basic understanding of the Session Initiation Protocol to test and debug issues related to the SBC faster

Dynamic group formation in an online social network

• Recommendations for forming small online groups must balance the needs of the host and potential members. • We present a framework of algorithms for making group recommendations in constantly changing problem sets. • We evaluate the framework using a simulated production environment. • We compare our framework’s approximations to an absolute optimal using network flow optimization. For those seeking to recruit teammates for a specific purpose, like a project or study group, challenges quickly arise once they have exhausted their social circle. In the wake of the current pandemic, meeting new people that are right for a specific team is even more difficult than before due to the lack of in-person events. On social media platforms, users often have large networks of connections but have very few close personal relationships within them. This makes it difficult to find compatible people that share the same goal, and are interested in niche groups on those platforms. We present a scalable framework for establishing small online groups that balance two objectives, making the best group recommendations to users and guiding group hosts to the best users for their group. We illustrate this framework using three use cases. Lastly, we evaluate a serverless implementation using a large social media dataset to simulate a production environment and compare our framework to a network flow approach to solving the problem.

Enabling a Multi-Agent System for Resilient Production Flow in Modular Production Systems

Volatile markets with strongly fluctuating customer demand and uncertainties in the global supply chain challenge manufacturing companies with increasing complexity. A flexible, reconfigurable production system like the concept of Modular Production by Kern is one way to meet these challenges and at the same time to produce more efficiently. Such plants can quickly adapt to new production demands, but also come with challenging requirements on the planning and control of production programs. To fulfil these requirements, new information structures are needed. Previous approaches, as traditionally prevalent in the automotive industry, are structured rigidly hierarchical leading to monolithic systems. These are designed for static production cycles and therefore offer only limited flexibility. To reach a higher flexibility, new information structures are needed which enable centralized as well as decentralized decision making. One approach to meet these requirements are Multi-Agent Systems (MAS). In this paper a design approach for deploying a semi-heterarchical system structure is presented that puts special emphasis on a resilient production planning and execution with the help of Asset Administration Shells (AAS). The potential of AAS for the self-description of Industrie 4.0 Components and agents in Holonic Manufacturing Systems as well as their usefulness as interoperable interfaces are described and discussed in this work. This is elaborated and discussed in a simulated production environment using an example from the automotive industry.

Microservices Data Mining for Analytics Feedback and Optimization

When microservices-based architectures are adopted for an enterprise application, a basic requirement would be an evaluation of the performance with the objective of continuous monitoring and improved efficiency. This evaluation helps businesses obtain a quantitative measure of the benefits of a shift from monolith to microservices. Additionally, the metrics obtained could be used as a mechanism for continuous improvement of production application. This research proposes a model based on the principles of data mining called stream analytics feedback and optimization (SAFAO), which can be used to achieve a continuous optimization of microservices. Stream analytics is due to the fact that the analysis is performed on online application with continuously generated lived data. This approach has been tested in a simulated production environment based on Docker containers. The authors were able to establish empirical measures which were continuously extracted via a data mining methodology and then fed back into the running application through configuration management. The results show a continuous improvement in the performance of the microservices as indicated in the results presented in this research.

Lesser mealworm (Alphitobius diaperinus) powder as a novel baking ingredient for manufacturing high-protein, mineral-dense snacks

Increasing interest in consuming foods that are high in protein, vitamin, amino acid, and mineral contents is steering growth in the market for fortified snacks. The aim of the present study was to evaluate the use of lesser mealworm (Alphitobius diaperinus) powder (LP) (at 10 or 30% substitution for wheat flour) for the protein and mineral fortification of crunchy snacks (rusks). Hence, the technological, microbiological, nutritional, and sensory characteristics of the fortified rusks were evaluated. The protein content was enriched up to 99.3% in rusks with 30% substitution; moreover, a notable increase in the essential amino acids content was observed, with histidine fortification reaching up to 129.1% in rusks with 30% substitution. The incorporation of LP has led to an enrichment of almost all the minerals considered here, and especially Fe, P and Zn, with Zn showing fortification percentages of up to 300% in rusks with 30% substitution for LP. The experimental rusks showed pleasant sensory traits and low aw values. In view of the potential industrial manufacturing of insect-based rusks, the proposed product can be assigned to level 4 (validation in a laboratory environment) of the Technology Readiness Level (TRL) scale, and it is thus ready to be tested in a simulated production environment.

The impact of safety audit timing and framing of the production outcomes on safety-related rule violations in a simulated production environment

In an experimental study, participants (n=79) assumed the role of control room operator of a simulated plant. For a total of 36 times, they had to decide whether to violate a safety-related rule to maximise their own salary, or to comply with it at the cost of a lower income. The experimental variation was the timing of audits in the simulated production year (“early”=audits accomplished within weeks 13–30 versus “late”=audits accomplished within weeks 31–48) and framing of production outcomes and salary (gain versus loss). Results show that early-audited participants committed significantly fewer rule violations in the early period than those who had not yet been audited. Later on, the early-audited participants began to violate the rule, whereas the late-audited participants continued violating even though they had now been audited. Participants who experienced a loss-framed production outcome committed significantly more violations than participants in the gain-framed condition.

Onshore Petroleum Centre of Excellence—collaboration by industry partners, government and TAFE to deliver trained staff for an expanding onshore petroleum industry

Santos, Beach Energy and Senex Energy are collaborating with the SA Government and TAFE SA to set up a hub for onshore oil and gas training in Adelaide. The training facility provides a fully immersive simulated oil and gas production environment, as well as static equipment displays for demonstration and educational purposes. It is used for technical training, including safety, environmental and sustainable operational principles and key maintenance activities. The simulated production environment includes different pump types, gas compressors, a pig launcher and receiver, gas metering skid, field separator and small tanks, as well as associated pressure safety valves, flow valves and other instruments. Water is used to simulate oil and air is used to simulate gas flow. The static equipment display includes various valve types, flanges and a wellhead. Santos, as operator of the SA Cooper Basin joint venture (of which Beach Energy is a member), has committed significant oil and gas production and mechanical equipment, engineering design, transportation and installation of the training facility’s equipment. The SA Government, Senex Energy and Beach Energy have committed funding for fit-out, capital works and the running of the facility for the first two years. Industry partners GPA Engineering, Fyfe Engineering, Logicamms, Veolia Environmental Services, Toll Energy, Transfield Services, Ottoway Engineering, Bureau Veritas, MRC Group, Max Cranes, Whitham Media Australia, Inductabend, Toyota Australia, James Walker Australia, Coventry Fasteners, Centralian Controls and Central Diesel are providing expertise and services. The training facility officially opened on 16 February 2015

Development of a Platform for Lean Manufacturing Simulation Games

More than ever, the economic globalization is creating the need to increase business competitiveness. Lean manufacturing is a management philosophy oriented to the elimination of activities that do not create any type of value and are thus considered a waste. One of the main differences from other management philosophies is the shop-floor focus and the operators' involvement. Therefore, the training of all organization levels is crucial for the success of lean manufacturing. Universities should also participate actively in this process by developing students' lean management skills and promoting a better and faster integration of students into their future organizations. This paper proposes a single realistic manufacturing platform, involving production and assembly operations, to learn by playing many of the lean tools such as VSM, 5S, SMED, poke-yoke, line balance, TPM, Mizusumashi, plant layout, and JIT/kanban. This simulation game was built in tight cooperation with experienced lean companies under the international program “Lean Learning Academy,”http://www.leanlearningacademy.eu/ and its main aim is to make bachelor and master courses in applied sciences more attractive by integrating classic lectures with a simulated production environment that could result in more motivated students and higher study yields. The simulation game results show that our approach is efficient in providing a realistic platform for the effective learning of lean principles, tools, and mindset, which can be easily included in course classes of less than two hours.

Corrosion Behavior under Black Deposit on Low Cr Bearing Steels in NaCl Completion Fluid

3% Cr steel has been developed as a tubing material for CO2 oil well considering CO2 corrosion resistance. However, an oil leakage problem occurred 6 months after the start of oil production in a CO2 oil well which was completed by tubing of 3% Cr steel. 3% Cr steel was exposed to an alkaline NaCl completion fluid environment before exposed to the oil production environment. Corrosion under the black deposit, which developed locally on 3% Cr steel in the NaCl completion fluid, was identified to be a cause of oil leakage. The conditions of the black deposit formation on 1% Cr and 3% Cr steels were investigated by immersion test in a simulated NaCl completion fluid varying dissolved oxygen (DO) concentration, pH and temperature. 1% Cr steel is a representative Cr bearing steel and used as a comparable material. If the fluid was alkaline and DO concentration was above 77 ppb, the black deposit formed locally on 1% Cr and 3% Cr steels. Localized corrosion was observed just under the black deposit. If the DO concentration was equal to or less than 33 ppb, the black deposit did not form. Corrosion behavior of the specimens with the black deposit was also investigated in a simulated oil production environment. It is concluded that corrosion progress under the black deposit on 3% Cr steel in the production environment resulted in the oil leakage 6 months after the start of production. The black deposit was identified as Fe3O4 mainly by X-ray diffraction analysis. In order to prevent oil leakage on 3% Cr steels in the oil production environment, it is necessary to control the DO concentration in the alkaline NaCl completion fluid to or below 33 ppb that prevents formation of the black deposit.

Effects of Warning Validity and Proximity on Responses to Warnings

The effects of a warning's validity and display characteristics on the responses to binary warnings were studied in a categorization task that resembled the control of a simulated production environment. Students performed a visual signal detection task and were aided by a binary warning indicator. Experimental conditions differed in the validity of the warning and its proximity to the judged stimulus. Participants' performance improved over the course of the experiment, and they partly adjusted their responses to the validity of the warnings but continued to respond to nonvalid warnings throughout the experiment. It was particularly difficult to ignore the nonvalid information when it was integrated with the continuous information. There was evidence for nonoptimal use of the information from the warning system, whether it was valid or not valid. The results indicate a possible distinction between two dimensions of users' trust in warning systems: compliance and reliance. Actual or potential implications of this research include improved warning design based on analysis of system and operator characteristics.

The economic justification of machine changeover time reduction in a manufacturing cell

In this paper, an analysis model is formulated to resolve the economic justification of machine changeover time reduction in a manufacturing cell. This model examines the effects of changeover time reduction for each machine and minimizes the total relative cost in the manufacturing cell while demand is variable. Adding the concept of a product's life cycle, we develop a mathematical model to deal with variable demand in the planning horizon. The budget constraint is also added to meet the conditions of different invested amounts. Finally, an example, which is derived from different set-up time reduction projects, and simulated production environment is used to demonstrate the details of the model. The optimum investment amount on changeover reduction operation for each machine can be found via the proposed model and the maximum benefits are then obtained.

Bottleneck allocation methodology (BAM): an algorithm

Takes the development of a new optimization process for production scheduling and develops it into a systematic‐mathematical algorithm. Tests this algorithm against a simulated production environment and compares the generated schedules against those generated by EOQ, MRP, JIT, and OPT. The result is that bottleneck allocation methodology (BAM), with its critical resource based capacity scheduling out‐performs these other models in an intermittent demand discrete manufacturing environment.

The activity of (S)-hydroprene space spray against three stored products pests in a simulated food production environment

The synthetic juvenile hormone analogue (JHA) hydroprene was applied as a space spray against three species of stored products insect. Food media in glass crystallising dishes was placed in open and in enclosed situations under simulated food production conditions. The area was treated with hydroprene on three occasions: three months before the introduction of insect eggs into the food media, two days before infestation of the media, and three months after infestation. Space spray applications of the commercial formulation of hydroprene (Protrol®) were conducted using a cold fogger at a rate of 18 mg/m 2 floor area. Hydroprene, which appeared to accumulate in the food media, disrupted the normal development of the three species tested leading to lengthened larval development time and increased sterility in adults. With food media in the open, non-deformed adult emergence was reduced by 100% for Tribolium castaneum and Ephestia cautella and by 94% for Tribolium confusum. With the food media enclosed, to simulate the situations found in food processing machinery, the effect of hydroprene was somewhat reduced but was still considered promising.

A modified parametric index to estimate yield potentials for irrigated alfalfa on soils with gypsum in Quinto (Aragón, Spain)

A modelling approach is described to assess potential productivity of soils with gypsum in Quinto (northeastern Spain) for irrigated alfalfa, taking into account the environmental conditions, described during a detailed soil survey, and different management levels. The soils assessed in this article are: Xeric Torrifluvents, Xeric Torripsamments, Typic Haplogypsids, and Typic Haplocalcids. The methodology considers only two hierarchically ordered production situations. The simplest or highest situation is an alfalfa cropping system in which the production potential depends on radiation and temperature regime during the crop cycle. As these factors cannot normally be manipulated, the yield of alfalfa is only determined by its physiological characteristics, the prevailing level of irradiance and the temperature regime. Calculation of this climatic production potential (CPP) is based on the crop growth model of FAO AEZ-project. Water availability is considered optimal under irrigation, therefore yield potential in the second hierarchical production situation is determined by reducing the CPP for unfavourable soil conditions, including gypsum content, and by considering different management levels. The effect of unfavourable soil characteristics on the final land production potential (LPP), is expressed by a soil index, calculated using a parametric approach. The correlation between predicted yields and actual reported yields suggests a close resemblance between the simulated production environment and the situation in which alfalfa grows. The proposed model is useful in assessing comparative land productivity and allows an evaluation of the impact of the considered soil characteristics on the final crop production. Quantification of the major constraints allows estimation of the required inputs to increase productivity.

A regression model for matching parallel systems

Contends that parallel production sub‐systems may be cost effective and, in some cases, they are the only technically feasible way to improve output quality. Operating in either a standby‐redundancy or an ongoing capacity, parallel production sub‐systems are likely to be most cost effective when placed in upstream operations, where the leverage effect on output quality is considerably higher. Although typical research in parallel systems assumes a known distribution to estimate the output reliability of the parallel configuration, explains how this study used a simulated production environment to develop a regression model for assigning parallel system components by monitoring their actual past performance, and was therefore distribution free. Applying variables monitored during a previous production run in which quality is measured in a binary manner (i.e. either as acceptable or unacceptable), the model was used to determine optimal pairs of parallel subsystems. Claims that this matching model was about 2.5 times more accurate than Markov analysis in predicting the output quality of a given pair of parallel systems. The inclusion of an additional variable in the regression resulted in the model explaining about 75 per cent of the output variability of the parallel configurations and thus could potentially predict quality in lieu of direct inspection.

Computer-Aided Materials Management and Control for a Shipbuilding Yard

This paper deals with the development of a computerized information system for materials management and control for shipbuilding yards. It begins by critically examining the manual and semi-manual data processing methods used in medium and small-sized shipyards and highlighting their drawbacks. Based on this and with the knowledge of the ready availability of desktop computers in small/medium-sized shipyards, a computerized materials management and control system is proposed. The schema of the proposed database system is then presented by the help of block diagrams. A number of application programs have been developed to manage, control, and update the various database files under the "Network," "Purchase," "Inventory," and "Drawing" modules. The system has been tested in a simulated production environment by entering the production, planning, materials, and drawing information of two different vessels during construction. The range of information that can be obtained and the results from the proposed system are shown briefly. It is felt that a computerized information-based materials management system has a major role to play in the smooth and profitable running of a shipyard. It is very effective in a quick appraisal of complex queries relating to materials procurement, production and drawing status, and the cause of delays.

An approach to predict land production potential for irrigated and rainfed winter wheat in Pinan county, China

The methodology described in this paper provides land evaluators and land use planners with a tool to predict the land production potential for irrigated and rainfed winter wheat in Pinan County (China), taking into account environmental conditions and management practices of the local farmers. The correlation between predicted yields and actual reported yields by local farmers suggests a close resemblance between the simulated production environment and the situation in which the farmers operate. Incorporation in the model of quantified effects of limiting factors on crop performance allows estimation of inputs necessary to improve the actual yield level.