Small Quantity Batch Research Articles

Tool Wear Monitoring System Using Seq2Seq

The advancement of smart factories has brought about small quantity batch production. In multi-variety production, both materials and processing methods change constantly, resulting in irregular changes in the progression of tool wear, which is often affected by processing methods. This leads to changes in the timing of tool replacement, and failure to correctly determine this timing may result in substantial damage and financial loss. In this study, we sought to address the issue of incorrect timing for tool replacement by using a Seq2Seq model to predict tool wear. We also trained LSTM and GRU models to compare performance by using R2, mean absolute error (MAE), and mean squared error (MSE). The Seq2Seq model outperformed LSTM and GRU with an R2 of approximately 0.03~0.037 in step drill data, 0.540.57 in top metal data, and 0.16~0.45 in low metal data. Confirming that Seq2Seq exhibited the best performance, we established a real-time monitoring system to verify the prediction results obtained using the Seq2Seq model. It is anticipated that this monitoring system will help prevent accidents in advance.

A Cluster-Based Optimal Computation Offloading Decision Mechanism Using RL in the IIoT Field

In the Industrial Internet of Things (IIoT), various tasks are created dynamically because of the small quantity batch production. Hence, it is difficult to execute tasks only with devices that have limited battery lives and computation capabilities. To solve this problem, we adopted the mobile edge computing (MEC) paradigm. However, if there are numerous tasks to be processed on the MEC server (MECS), it may not be suitable to deal with all tasks in the server within a delay constraint owing to the limited computational capability and high network overhead. Therefore, among cooperative computing techniques, we focus on task offloading to nearby devices using device-to-device (D2D) communication. Consequently, we propose a method that determines the optimal offloading strategy in an MEC environment with D2D communication. We aim to minimize the energy consumption of the devices and task execution delay under certain delay constraints. To solve this problem, we adopt a Q-learning algorithm that is part of reinforcement learning (RL). However, if one learning agent determines whether to offload tasks from all devices, the computing complexity of that agent increases tremendously. Thus, we cluster the nearby devices that comprise the job shop, where each cluster’s head determines the optimal offloading strategy for the tasks that occur within its cluster. Simulation results show that the proposed algorithm outperforms the compared methods in terms of device energy consumption, task completion rate, task blocking rate, and throughput.

Investigation for Developing 3D Concrete Printing Apparatus for Underwater Application

Recently, the demand for atypical structures with functions and sculptural beauty is increasing in the construction industry. Existing mold-based structure production methods have many advantages, but building complex atypical structures represents limitations due to the cost and technical characteristics. Production methods using molding are suitable for mass production systems, but production cost, construction period, construction cost, and environmental pollution can occur in small quantity batch production. The recent trend in the construction industry calls for new construction methods of customized small quantity batch production methods that can produce various types of sophisticated structures. In addition to the economic effects of developing related technologies of 3D Concrete Printers (3DCP), it can enhance national image through the image of future technology, the international status of the construction civil engineering industry, self-reliance, and technology export. Until now, 3DCP technology has been carried out in producing and utilizing residential houses, structures, etc., on land or manufacturing on land and installing them underwater. The final purpose of this research project is to produce marine structures by directly printing various marine structures underwater with 3DCP equipment. Compared to current underwater structure construction techniques, constructing structures directly underwater using 3DCP equipment has the following advantages: 1) cost reduction effects: 2) reduction of construct time, 3) ease of manufacturing amorphous underwater structures, 4) disaster prevention effects. The core element technology of the 3DCP equipment is to extrude the transferred composite materials at a constant quantitative speed and control the printing flow of the materials smoothly while printing the output. In this study, the extruding module of the 3DCP equipment operates underwater while developing an extruding module that can control the printing flow of the material while extruding it at a constant quantitative speed and minimizing the external force that can occur during underwater printing. The research on the development of 3DCP equipment for printing concrete structures underwater and the preliminary experiment of printing concrete structures using high viscosity low-flow concrete composite materials is explained.

샌드 3D 프린팅 기술 융합을 통한 생산성 혁신 사례 연구

Recently, competition in the manufacturing industry related to the preoccupation of new markets has drastically changed due to the increase in small quantity batch production products. Besides, business models utilizing 3D printing technology suitable for flexible manufacturing are gaining interest. As 3D printing technology is becoming more common, Design for Additive Manufacturing is also in the spotlight. However, the productivity of 3D printing technology is still insufficient in terms of mass production. In this study, the possibility of innovation in mass production process that combines 3D printing technology is presented through the case of innovation in manufacturing productivity of medium-speed engine cylinder head through the integration of sand 3D printing technology. It outlines how sand 3D printing technology is applied to cylinder head mass production processes, how the quality of cylinder head products can be improved compared to conventional pattern-based molding methods, and how productivity can be maximized by reducing process time and human error through hybrid production method with sand 3D printed integrated design cores. In conclusion, this paper presents the effectiveness of sand 3D printing technology which can secure product competitiveness by increasing the production capacity of mass production process, reducing production costs, improving quality, and reducing loss.

3차원 프린팅을 활용한 부분적 빈 공간 기판 집적 도파관과 1:2 진행파 전력합성기

In this paper, we propose a partially hollow microstrip line(PHMLIN), partially hollow substrate integrated waveguide(PHSIW) and their transition that are implemented using the 3D printing techniques of light induced planar solidification(LIPS) and metal line printing. A partially hollow structure uses a resin substrate whose most part is removed and filled with air. Although they are implemented on a relatively lossy substrate, the PHMLIN and PHSIW show better transmission performance, compared with other conventional microstrip line and substrate integrated waveguide(SIW). The PHMLIN-PHSIW transition has an insertion loss of about 0.2 dB at 7 GHz. Using the proposed 3D printed structures, a 1:2 traveling-wave power combiner is demonstrated, and shows an insertion loss of less than 0.87 dB and a power combining efficiency of 82.1~87.9% in 6.5~7.5 GHz. The proposed structures using 3D printing are very useful for small quantity batch production of microwave components.

Development of a modular garment assembly line simulator

PurposeThe purpose of this study is to develop a modular garment assembly line simulator that can be used for various production methods such as traditional mass production or modern small quantity batch production.Design/methodology/approachFor realistic simulation, the actual shape and sewing information of the garment patterns were used. The assembly line consists of process units including the cutter, preprocessor, module assembly, final assembly, finish, and stack units. Any number of units can be arranged and connected to form various layouts. The simulation can be run at an arbitrary speed.FindingsThis system can be used to estimate the time required to process the given order for a specific layout. Therefore, it can be utilized as the basis for optimum production line design.Originality/valueThis system is expected to be utilized by garment manufacturers for obtaining the productivity improvement, production cost reduction, and increased competitiveness.

A Case Study of the Construction of Smart Factory in a Small Quantity Batch Production System: Focused on IDIS Company

A Case Study of the Construction of Smart Factory in a Small Quantity Batch Production System: Focused on IDIS Company

Analysis of EU Safety Control Regulations for Cosmetics: Market Strategies for the Korean Cosmetic Industry

Recently, risks in the export and local industry have been increasing due to the rapid change of the domestic and global environment. The cosmetics industry which creates high value addition in small quantity batch production and is eco-friendly is no exception. So the cosmetic industry as cutting-edge technology and brain intensive industry could lead to the future oriented fourth industry revolution suitable to our state that run short of natural resources. Meanwhile, the EU is on an upward trend of common policy application scope with its own legal system and policy discretion unlike other international organizations. Thus, this paper would like to analyze their safety control regulations for cosmetics, a sector which has been consistently growing in Korea. EU cosmetics regulations could be classified largely into EU certification and procedure, RP nomination, CPNP registration, labelling, PIF documentation. Also this study suggests the advancement strategy for the use of overseas market expansion after the analysis of various factors and purchasing pattern of consumers and market characteristics in order to enter into diverse market of cosmetic industry.

물류창고 불출자 로드밸런스율 증대 휴리스틱 알고리즘 개발

Companies are pursuing the management of small quantity batch production or JIT(Just-in-time) system for improving the delivery response and LOB(Line Balancing) in order to satisfy consumers' increasing demands in the current global economic recession. And in order to improve the growth of production for reducing manufacturing cost, improvements of the Load Balancing have become an important reformation factor. Thus this paper is aimed at warehouse which procures materials on the assembly line in procurement logistics of automotive logistics and proceed with research on heuristic algorithm development which can increase the Load Balancing of workers. As a result of this study, when applied the primary target value, it was verified that the whole workers decreased from 28 to 24. Furthermore, when specified the secondary target value and applied algorithm once more, it was verified that the Load Balance Ratio was improved from 44.96% to 91.7%.

고장력강 파이버 레이저 용접부의 HAZ 연화 특성에 관한 연구

Laser welding sector in the automotive industry has been widely recognized as one of the most important bonding processes, such as parts welding. Efforts to improve productivity and weld quality have been progressing steadily. In addition, laser welding is suitable for welding process that can produce high-quality welds suitable for flexible production and small quantity batch productions. In order to ensure the rigidity of the material, high strength material are applied to more than 1 GPa class body parts and automotive bumper beams. However, not only the situation is that the trend of domestic research, but also development is based on product molding considering freedom of shape where reinforcement is applied to meet the safety regulations and high-speed crash performance, despite the use of high strength materials. The tendency for heat-affected zone (HAZ) softening phenomenon common in areas of laser welded high tensile steel welding confirmed the occurrence of weld softening effect according to the process parameters. Based on this, range of process parameters could be selected for ensuring weld quality.

The Current Condition and Improvement Plan of Native Herbaceous Plants in Selling Online

This study was performed to determine the status of native herbaceous plants in selling online that the public can easily access to purchase the plants, as a basis research for popularizing the garden culture. Results in June 2015, companies that sell native plants online were 130points (built its own blog or homepage were 50points, and 80 points were companies registered in two places aggregator). The public was able to purchase 75families 468genera and 248species of native herbaceous plants online including 31families 66genera 87species of endangered species of rare plants (CR), endangered species (EN), and Vulnerable species (VU), and 10families 13genera 14species of naturalized plants. This study surveyed the extent and accuracy of the information that plant’s dealers provide to purchasers since the online distribution of plants is based on the information given to purchasers who have not seen the actual dealers. As a Result, 74% plant’s dealers were selling cultivar and foreign species in wildflower category, and 60% plant’s dealers recognized herbaceous plants with wildflowers. Also, it is expected that the detailed classification categories of wildflowers listed without a rank will give buyers confusion and inconvenience. More than 50% of the plant ’s dealers were providing only literature information of plants such as visual characteristics and use properties, but it is also required for dealers to give practical information such as how to plant and manage plants. Furthermore dealers need to provide accurate information in fact that 74% of companies showed an error in naming of plants in their information sections. In order to activate distribution of native plants online based on this study which investigating the current situation of native herbaceous plants in selling online, there are things to consider as follow. First, the construction of portal site specialized in the Native Plants is needed for small quantity batch production of small companies. Second, it is required for relevant authorities to improve existing law or legislate for conservation and distribution of rare plants sold indiscriminately. Third, precise definitions, names and a detailed classification for native plants should be systematically placed so that the public can easily get useful information. Keywords: Indigenous herbaceous plant, Native plant aggregator, Online selling plants, Rare plants, Wildflower

Success Factors of the Local Food Movement and their Implications: The Case of Wanju-gun, Republic of Korea

In Korea, a policy of encouraging the production and distribution of local food has been implemented in order to resolve the problems rural societies are facing. The policy has focused not only on ensuring profits for farmers, but also on recovering the communal character of rural areas and restoring their living foundations. Wanju-gun (similar in size to a US county) in Jeollabuk-do Province is today regarded as one of the most successful examples in terms of policy implementation and achievement. Wanju has been supporting local food as a core business, and is launching various activities such as reforming local farming toward a small quantity batch production system, revitalizing farmers’ education, and opening up direct local food markets. Against this background, this study aims to identify the success factors of the local food movement in Wanju-gun, and to discuss measures for spreading this movement further. Data on the area of Wanju, homepage websites and news reports were employed to analyze the success factors of Wanju's local food movement.

인더스트리4.0 기반 사이버물리시스템과 생산관리시스템간의 미들웨어 구축을 통한 수평적 통합

Recently, Industry 4.0 (next generation industrial revolution) designed by Germany to retain initiative in manufacturing business is actively studied. Goal of Industry 4.0 is 'Smart factory' which manages progress of production, supply logistics and services. To achieve the goal, we can construct value creation and new business model by integrating organically with production management systems which is existing and cyber-physical systems, Internet of Things, Services Internet and sensor, etc. However, if integration with production management systems does not work effectively by adding and developing new technologies, It does not have performance. Hence, in this research, we will analysis Industry 4.0 which is possible for small quantity batch production and one of the light and flexible manufacturing systems, and based on this, we will suggest methodology to horizontally integrate with production management systems.

성인 여성복의 KS 치수 표준 개정을 위한 제안 연구

KS K 0051(2009) was established in 1990 and revised in 1994, 1999, 2004 and 2009. Recently the structure of apparel production and distribution are changing like as small quantity batch production, increase of importing abroad apparel and increase of on-line shopping mall. Based on Social and economic conditions, examine the potential for use of KS K 0051(2009) standard sizing system for female adult's garments are needed. Through which, it was intended to suggestion for the revision of standard sizing system for female adult's garments which can facilitate communication among consumer, producer and sellers. The improvement point was discussed through review of the current KS K 0051 (2009) and abroad standard sizing system for female adult's garments, ISO 3637(1977), ISO 4416(1981), BS EN 13402-2(2002), BS EN 13402-3(2004), JIS L 4005(2001) and GB/T 1335.2(2008). Also, the revision of standard sizing system for female adult's garments was suggested using data of 6th Size Korea. As a result of this study, in the revision, formal wear, casual wear, training wear and under wear were separated to simplify the classification and the classification of body type were excluded. Also, it is possible that size designation was simplified through optional notation and letter code based on bust girth could be marked together in casual wear.

주물 산업의 수익력 극대화를 위한 생산부문의 TPI 최적화 연구

The production type of foundry industry is a small quantity batch production methods that require the highly skilled technology in the global competition in the variety of customer needs and directly under the influence of fluctuations characteristic. Therefore suitability for small quantity batch production and flexible production capacity and price competitiveness is needed more than anything. To do this, we need transcription and comprehensive innovation activities to maximize the revenue structure of the organization and field survival foundation should be developed the TPI(Total Profit Innovation) process in all aspects of the organization and all employees are involved in order to create a cost, quality, time, and service part of the overall aim how to achieve those effects within a short period of time. We applied the TPI process for S company in the foundry business innovation and productivity through cost reduction. We will expect the productivity improvement and financial performance improvement and then continually accumulate and review the results.

패스트 패션의 비즈니스 전략 -자라의 사례 연구-

This study analyzes the business strategy of fast fashion through Zara, a successful fashion brand from Inditex Spain. An in-depth case approach is adopted based on extensive secondary research that includes literature and press releases published in Korean as well as English. The findings of this research demonstrate a speedy and flexible process occurring in the supply chain of its fast fashion business and the cooperation between the company`s headquarters and international subsidiaries. Zara`s headquarters executes four representative strategies: competitive market research, an integrated organizational structure, small quantity batch production, and a specialized distribution system. Zara`s international subsidiaries execute their own four representative strategies: differentiated international expansion, independent human resource management, small but fundamental IT, and maximization of store resources. These two core parts intimately work together to satisfy target customers all over the world by bringing competitive advantages to the fashion business and represent a key concept of Zara`s business strategy. The main drawbacks of case studies are limited validity and representativeness restraining the potential for making generalizations. However this case is considered sufficient to provide valuable insight and improve the understanding of operation strategy in fast fashion.

An Exploratory Study for Designing Business Services Based on Sensor Networks

As manufacturers tried to change into a small quantity batch production system, the enterprise resource planning system has been introduced. In production sites, however, there is discontinuity of information flow between an enterprise management system and a production system because data is still managed manually, so that models have been developed to enable gathering of on-the-spot context information in real time and exchanging information and collaboration for the whole lifecycle of products by exploiting sensor network technologies. However, because sensor network technologies have not reached a commercialization and diffusion stage yet due to various specialties and are primarily limited to creation of new application models, it is time to induce companies to participate in active utilization of sensor networks through user-oriented support.Accordingly, in this study, to enhance companies' understanding of sensor networks and increase their utilization, an exploratory study was carried out to design business services based on sensor networks. In detail, it investigated and analyzed companies' awareness levels for sensor networks market, technologies and their advantages and disadvantages, correlations between sensor networks and business, and requirements for introduction of sensor network technologies. Also, The problems of applying the sensor network based business services and the improvement methods were classified into the technological levels, security, marketability and standardization to carry out.

직접 교시 작업을 위한 로봇 작업 정보 편집 및 재생산 기법

Study of human-robot Interaction gets more and more attention to expand the robot application for tasks difficult by robot alone. Developed countries are preparing for a new market by introducing the concept of ‘Co-Robot’ model of human-robot Interaction. Our research of direct teaching is a way to instruct robot’s trajectory by human’s handling of its end device. This method is more intuitive than other existing methods. The benefit of this approach includes easy and fast teaching even by non-professional workers. And it can enhance utilization of robots in small and medium-sized enterprises for small quantity batch production. In this study, we developed the algorithms for creating accurate trajectory from repeated inaccurate direct teaching and GUI for the direct teaching. We also propose the basic framework for direct teaching.

AGV 운행을 위한 비전기반 유도선 해석 기술

AGV는 최근 생산라인에서 활용이 증대되고 있으며, 저렴하고 속도가 빠른 자기 테이프 유도 방식의 AGV가 널리 사용되고 있다. 그러나 이러한 방식의 AGV 운행 시스템은 고가의 설치비와 운행경로 변경의 유연성 저하 등으로 인해 다품종 소량 생산 시스템이나 협업 기반 생산 시스템에 적용하기 어려운 단점이 있다. 본 논문에서는 설치 및 변경이 매우 용이한 색 테이프 또는 페인트 기반의 유도선을 카메라 비전을 이용하여 검출하고 해석하는 기술을 제시한다. AGV 운행경로의 자유로운 설정 및 변경이 가능하도록 분기 지점이나 합류 지점과 같은 복잡한 구조의 유도선 부분도 자동으로 분석하는 방법을 제시하며, 또한 안정적인 AGV 운행이 가능하도록 적합한 유도선 추적방향을 결정하는 방법도 제시한다. 제시한 기술을 구현 적용한 실제 산업용 AGV의 실시간 운행 실험을 통해, 제시한 기술이 산업현장에서 실제로 안정적으로 적용 가능함을 확인하였다. AGVs are more and more utilized nowadays and magnetic guided AGVs are most widely used because their system has low cost and high speed. But this type of AGVs requires high infrastructure building cost and has poor flexibility of navigation path layout changing. Thus it is hard to applying this type of AGVs to a small quantity batch production system or a cooperative production system with many AGVs. In this paper, we propose a vision based guideline interpretation technique that uses the cheap, easily installable and changeable color tapes (or paint) as a guideline. So a vision-based AGV with color tapes is effectively applicable to the production systems. For easy setting and changing of AGV navigation path, we suggest an automatic method for interpreting a complex guideline layout including multi-branches and joins of branches. We also suggest a trace direction decision method for stable navigation of AGVs. Through several real-time navigation tests with an industrial AGV installed with the suggested technique, we confirmed that the technique is practically and stably applicable to real industrial field.

An effective quality assurance for small quantity batch manufactured products with digital engineering

The set of activities intended to ensure their products which can be goods and/or services, is getting crucial to the successful business in almost competitive markets. Though the mass production fields like electronics and automotive industries have matured and versatile methodologies on quality issues, in the case of small quantity batch processes especially after various manufacturing processes, problems of quality assurance highly depends on determination by the intended users, clients or customers. This study suggests digital simulation processes to cover wide categories of products required expensive real experiments under specified hydro-pressures. To cope with the diverse changes after manufacturing from nominal thickness of raw pipes, all geometry modeling reflected measured thickness distributions over specified points and validation tests for numerical simulations were performed to minimize the number of product disposals as the process of design proof tests. Through this project, the manufacturer established a business process of numerical simulation and validations, which make it possible that they are very confident from early stage of bidding to service steps after deliveries in terms of not only technical power but overall quality assurance, because they successfully attained meaningful agreements with major clients by proposed digital simulation process in this paper.