Showing papers on "Production engineering published in 1999"

Current practices of engineering change management in UK manufacturing industries

Abstract: The management of engineering changes (ECs) entails serious resource implications in all manufacturing companies, because nearly all the functions of the organisations will be involved. Indeed, these functions may be the sources and also the victims of ECs. Manufacturing companies have to cater for these ECs by adjusting their activities constantly. The robustness of manufacturing can be crippled by ineffective and inefficient management of ECs, irrespective of the advances in manufacturing technologies. This paper studies the current industrial practices in managing ECs in the UK manufacturing industries. The study draws reference from a comprehensive investigation carried out in 1996 within 100 UK manufacturing companies. Numerous aspects have been examined, including the systems, organisations, activities, influential factors, strategies, techniques, and computer aids. One major concern is the balance between the effectiveness and efficiency of the engineering change management (ECM) system. The findings reveal that guidelines for good ECM practices are required for the majority of the companies involved in the study. The study has also shown clearly that ECM has not attracted sufficient attention in research despite its industrial relevance.

CADCAM: Principles, Practice and Manufacturing Management

Abstract: From the Publisher: The application of computers to the product design and manufacturing process (known as CADCAM) is a successful and important technology which integrates the traditionally separate disciplines of Design and Manufacture. Chris McMahon and Jimmie Browne's text will guide you carefully through the processes of defining a product design with the aid of computers, developing manufacturing plans and instructions for the product, and managing the manufacturing system itself. Their accessible writing style is supplemented by examples throughout and end-of-chapter problems are included to test your knowledge. This text is ideal for students of Industrial, Mechanical, Manufacturing and Production Engineering. The mix of theory, practice and analysis makes the book suitable for both analytical and overview courses.

Process and Product Engineering: Achievements, Present and Future Challenges

Abstract: In this paper, present and future challenges faced by chemical engineers are discussed. To place the development of this discipline in its industrial and social context, a short history of chemical engineering in one of the major global chemical companies (BASF) is given. The ‘scientific part’ of chemical engineering consists in breaking down real complex systems into subsystems, which are then described using our understanding of fundamental chemical and physical processes. The ‘engineering part’ of chemical engineering consists in using this new-found knowledge in the design and construction of a working plant which is capable of producing the desired product, even if our understanding of the single subsystems is today incomplete. From the components that make up our discipline, process engineering has in the last several decades attained a high degree of scientific maturity. Further developments are needed and expected in the improved description of fundamental chemical and physical processes necessary particularly to model reaction systems. The other field, product engineering, is a younger, less mature area where the scientific elucidation of the structure/property relationship at molecular and microscopic levels first needs to be tackled. This knowledge is required to model disperse systems so as to design products and develop appropriate production facilities. Improving the design and evaluation of complex systems for the production of real products will require further research into methodologies, tools and strategies. Firstly, these improvements will enable us to combine various unit operations so as to obtain an optimal overall process within an optimally designed production plant. And secondly, this individual production plant should in turn be optimally integrated into the entire production site. Such procedures must take into account both the requirements of customers as well as environmental concerns. The challenges faced by the chemical engineering community can only be met if two preconditions are fulfilled: both organizations carrying out basic research and R&D departments focused on applied research within companies must be at the cutting edge of technology. And furthermore, they must work even more closely together if we are to meet the challenges described in this paper. It is also essential that young engineers and scientists as part of their education should be integrated into this research effort and become fully committed to it.

Can pull techniques be used in design management

Abstract: Concurrent engineering has a longer history in manufacturing than it does in construction. In manufacturing, it is closely associated with the advent of new production management concepts and techniques, known variously as lean production, agile manufacturing, etc. Concurrent engineering is the name used to signify the structuring and management of product development processes within the new management philosophy. Consequently, production control techniques such as pulling information forward through the engineering process belong to the realm of concurrent engineering. Pull techniques for managing work flow were developed in manufacturing and have recently been applied to construction. Can pull techniques be used in the management of design as well? Pull techniques are explained and obstacles to their application in design are reviewed. Benefits and preconditions of pulling are also presented. Concepts and techniques are proposed to overcome obstacles and satisfy preconditions for pulling. Future research is suggested in the application and testing of these concepts and techniques.

Production/manufacturing planning system

Abstract: A production/manufacturing planning system is provided with a production planning planner 10 and a manufacturing planning scheduler 12. The production planning planner 10 makes the production planning for the whole factory, and the manufacturing planing sheduler 12 makes the manufacturing planning schedule for each of manufacturing lines on the basis of the production planning for the whole factory. Thus, it is possible to more precisely make the production planning and manufacturing planning than that in conventional systems.

Introduction to FACTOR/AIM

Abstract: FACTOWAIM (AIM) is a simulation system designed specifically for use in manufacturing decision support. AIM has been successfully applied to engineering design, scheduling, and planning problems within numerous manufacturing organizations. AIM operates on the Windows platform and all model data is stored in a Microsoft Access@ database. This open database structure provides many opportunities. Models can be built faster by importing data from existing sources into AIM. Custom reports are easily created with Access@ report wizards. In addition, simulation based decision support applications complete with menus and dialog boxes can be developed with Access@ application wizards. Unlike language-based simulation products which require modelers to learn specific syntax and then abstract your system to fit this syntax, AIM uses the language of manufacturing. Example AIM components include machines, operators, materials, parts, jobsteps, process plans (routings), and conveyors. In addition, a comprehensive set of pre-defined manufacturing rules is available to you. Using AIM you can quickly and accurately build a model of any manufacturing process on your PC. Spending less time on modeling means more time to use the model to help you make decisions to improve your manufacturing operations. This paper provides an introduction to AIM including AIM modeling constructs, the use of AIM for capacity engineering, planning and scheduling, and costing with AIM. 1 USING AIM TO MAKE MANUFACTURING DECISIONS AIM is designed to help you make decisions regarding your manufacturing organization’s productive capacity. When you build an AIM model, you develop a more thorough understanding of how your system operates and its capacity. You can use the model to investigate a variety of issues, for example to determine the impact of a proposed change, without affecting production. This enhances your ability to manage the system, control its capacity, and make better decisions regarding its operation. Which in turn improves profitably and your ability to predictably deliver quality product to your customers. These issues of predictability, profitability, and quality face every manufacturing organization today. Figure 1 shows the functional breakdown of the capacity management decision areas. Figure 1 : Capacity Management Decision Areas Engineering problems focus on long-term questions regarding system design and continuous improvement. Planning problems address capacity issues including evaluating the impact of changing product mix or demand. Scheduling problems seek solutions to daily issues including on-time order completion, priority changes, and unplanned changes in resource availability. Most products focus on one capacity management decision area. With AIM you build a single model and use it to support engineering, planning and scheduling

Process Monitoring in Grinding Using Micromagnetic Techniques

Abstract: In production engineering, the demands on monitoring systems are steadily increasing owing to the automation of machining processes. In the past, the detection of defects was sufficient. Today, the avoidance of any defect is necessary. Therefore, monitoring systems have to be fast and reliable to guarantee zero-defect manufacturing. Most systems monitor acoustic emission (AE), power consumption or forces while machining. Thus, the quality of the workpiece is only indirectly described and the determination of workpiece quality characteristics must be made by metallographical inspections of random samples. These investigations are time-consuming and often destructive. Micromagnetic techniques make fast and non-destructive quality control of ground workpieces possible. For post-process measurements, the magnetic quantities of Barkhausen noise and field strength are used. The sensor systems have been adapted to different applications such as grinding of gears on bearing rings. In this paper the basic principle of this technique and the results of industrial implementation will be presented. A new micromagnetic analysing system will be introduced which can be used for the direct measurement of workpiece quality characteristics while machining. This system uses twelve different magnetic parameters and is a combination of the above mentioned system and an eddy current analysing system. Residual stresses, surface hardness and case hardening depth are measured in-process and can be used for process control. Furthermore, the 100% quality documentation is possible with out any additional post-process measurement. In addition to the measuring principle, first results and examples of automotive applications will be shown.

Techniques and Applications of Production Planning in Electronics Manufacturing Systems

Abstract: Electronics industry is a major part of modern manufacturing, and electronic systems play an increasingly important role in a majority of today''s products. Electronic systems are usually implemented with printed circuit boards (PCBs), and, consequently, PCB assembly has become an important sector of the electronics manufacturing industry overall. However, operating effectively in this industry is becoming more diffcult as the companies must compete with high quality standards, rapidly changing technologies, short production cycles, and increasing product variety and complexity. In addition, the capital equipment cost of electronics assembly industry facilities are high in comparison to the usual turnover of a company. As a result, production planning decisions need to made more and more frequently due to continuous changes in the production conditions. In this work we discuss production planning in electronics assembly--and, in particular, in PCB assembly. Our intention is to identify the typical problems arising from production planning and to give a survey of the solution methods suggested in the literature. In addition to this theoretical perspective, we will briefly review applications designed for production planning in PCB assembly. This work is organized as follows: We begin with an introduction to flexible manufacturing systems in general and present a framework for production planning systems in Section 1. Next, we study the fundamentals of PCB assembly process in Section 2 and survey the relevant literature in Section 3. In Section 4 we review existing commercial applications for production planning, and in Section 5 study more closely one of these systems. Finally, in Section 6 we sum up the discussion and outline few important topics for the future research.

Escape from the unnecessary : some guidelines for production management

Abstract: This paper emphasizes the importance to a manufacturing company of decreasing the product structures, both in width and depth, thereby shortening the throughput times, standardizing and reducing complexity, and identifying bottlenecks in order to increase efficiency and profitability. Having once been a production control and plant manager at Ericsson and Benzlers, the author has drawn upon his experience in researching this paper. Other influences include knowledge of well-known trends in production management, e.g. WorldClass Manufacturing, Lean Production, Time-Based Management, OPT, etc. The paper also stresses that it is difficult to present real new ideas concerning production management, but nevertheless discussions and publications of ideas and incentives to achieve an efficient production of products and services must continue.

Challenges of integration in semiconductor manufacturing firms

Abstract: Manufacturing efforts to reduce time to market often adopt a concurrent engineering approach that focuses on coordination and integration among engineering, production and marketing functions. Technological complexity in the semiconductor industry requires an extension of this paradigm to include multiple engineering groups and a strong production maintenance department. Through interviews with employees drawn from engineering, production, maintenance, marketing and other departments at three semiconductor plants, organizational problems are uncovered that inhibit successful integration within firms in this industry. Ideas for overcoming these problems are given with suggestions for future research.

Concurrent Engineering in Real and Virtual Tool Production

Abstract: Tool production is a widespread and indispensable part of every serial and mass production job. International competition and globalization require ever shorter time frames from idea to placement of the products on the market, and the time needed to produce the tools plays an important part in this process. A proper information system plays a crucial part in concurrent engineering, because it en ables greater reviewability of the production process and thus, greater overlapping of individual phases (Prasad, 1996).The first step in the re-engineering of a company's information system is gaining a thorough knowledge of the work process. This paper presents the methodology of analysis of information creation and information flow. The most important requirements are identified, and con crete solutions are presented for the creation of an appropriate information system. We have connected tool production and the develop ment of serial products and managed to reduce the time to product fabrication. In individual...

Digital Library Support for Engineering Design and Manufacturing

Abstract: This paper describes our initial efforts to deploy a digital library to support engineering design and manufacturing. This experimental testbed, The Engineeting Design Repository, is an effort to collect and archive public domain engineering data for use by researchers and engineering professionals. CAD knowledge-bases are vital to engineers, who search through vast amounts of corporate legacy data and navigate online catalogs to retrieve precisely the right components for assembly into new products. This research attempts to begin addressing the critical need for improved computational methods for reasoning about complex geometric and engineering information. In particular, we focus on archival and reuse of design and manufacturing data for mechatronic systems. This paper presents a description of the research problem and an overview of the initial architecture of testbed.

Information control in manufacturing 1998 : (INCOM '98) : advances in industrial engineering : a proceedings volume from the 9th IFAC Symposium, Nancy-Metz, France, 24-26 June 1998

Abstract: Volume and chapter headings: Volume 1. Inaugural Session. Plenary I: Advanced Automation Engineering. Industrial Applications of Petri Nets. Worldwide Grafcet. Control of Hybrid Systems. Formal Verification for Automation Engineering. Theories for Advanced Control Systems. Control System Engineering. Plenary II: Emerging Technology for Advanced Manufacturing. Microrobotics and Microsystems. C.A.P.P.: Computer Aided Process Planning. Mechatronics: Co-Design of Software and Hardware. Flexible Manufacturing Systems. Advanced Technologies. Product and Manufacturing Cell Engineering. Plenary III: Information Technology for Integration in Manufacturing. Industrial Communication Systems. Petri Nets for Scheduling Manufacturing Systems. Scheduling. Production Planning. Concurrent Engineering. Plenary IV: Intelligent Manufacturing and Process System Engineering. Volume 2. Design of Distributed Architectures by the Interconnection of Intelligent Components. Multi-Agent Manufacturing Systems. Fuzzy Information Engineering I. Fuzzy Information Engineering II. Intelligent Manufacturing System Engineering. Plenary V: Management of Advanced Industrial Systems. Joint Design of Technology and Organisation. Integrated Design: From Theory to Practice. Educational Engineering for Engineers Training. Towards Virtual Reality for Advanced Technology Management. Enterprise Engineering I. Enterprise Engineering II. Manufacturing System Management: Models and Methods. Plenary VI: Industrial Safety, Dependability and Quality. Control Reconfiguration. Process Fault Diagnosis. Economical and Technical Aspects in Industrial Maintenance. Design of Automated Production Systems: Principles of Safety Integration. Integration of Dependability in the Design Process of Production Automated Systems. Quality Dependability and Fault Tolerance. Author index.

Production planning and control in flexibly automated manufacturing systems: current status and future requirements

Abstract: Starting from the observation that currently we lack the control policies to effectively establish and manage the operational flexibilities required by contemporary flexibly automated manufacturing systems, the paper articulates a proposition towards the development of a formal production planning and control framework for these environments. This framework essentially attempts to integrate emerging results on the representation and control of these environments through a bottom-up hierarchical modeling and analysis approach. Open research problems that will underlie such an integration effort are identified, and potential solution approaches are briefly outlined.

Simulation-based planning and control of production fractals

Abstract: In order to increase their competitiveness, companies optimize their manufacturing processes by adapting structures to the requirements of technology and market. Appropriate organization forms, such as the fractal company, are distinguished by high flexibility, rapid adaptability and exploitation of human potentials. However, these manufacturing companies also require appropriate production planning and control (PPC) systems. The most important elements of such a PPC-system are long-range analysis of the production structure, medium- and long-range planning for the entire production area, short- and medium-range coordination among production fractals and short-range shop-control inside the fractals. At the Fraunhofer Institute for Manufacturing Engineering and Automation, simulation-based systems are being developed to support the planning and control of such organization forms within production. The user is put into the position of planning job orders reliably and optimizing production by making use of the advantages of decentralized structures.

A framework for automating cost estimates in assembly processes

Abstract: When a product concept emerges, the manufacturing engineer is asked to sketch out a production strategy and estimate its cost. The engineer is given an initial product design, along with a schedule of expected production volumes. The engineer then determines the best approach to manufacturing the product comparing a variety of alternative production strategies. The engineer must consider the capital cost, operating cost, lead-time and other issues in an attempt to maximize profits. After making these basic choices and sketching the design of overall production, the engineer produces estimates of the required capital, operating costs, and production capacity. This paper describes the development of computer tools to aid manufacturing engineers in their decision-making processes. This computer software tool provides a framework in which accurate cost estimates can be derived from design requirements at the start of any engineering project.

Construction of recycle system of toner cartridges

Abstract: A recycling system for the toner cartridges used in office equipment such as copiers and printers is constructed, whereby the used toner cartridges are collected and the priority is put on the reuse in the level of subunits/parts. The design is changed so as to facilitate recovery of the toner cartridges and production engineering for recovery is developed. Thus, an inverse manufacturing plant, clean and friendly to both the environment and to people, is built. The toner cartridges recovered are of the same quality level as newly made products and are broadly accepted and used with ease by customers.

CIGR Handbook of Agricultural Engineering, Volume III Plant Production Engineering, Chapter 2 Mechanization Systems, Part 2.1 Systems Engineering, Operations Research, and Management Science

Abstract: First paragraph: The Engineering Council for Professional Development defined engineering (Whinnery, 1965) as the profession in which the knowledge of science (biology, chemistry, physics, and mathematics) gained by study, experience, and practice is applied with judgment to develop ways to utilize, economically, the materials and forces of nature. Systems engineering incorporates a holistic view of the problem with mathematical tools to assist the engineer with decision-support information. These same tools are utilized in operations research and management science by consultants and managers. The Operations Research Society of America defined operations research as scientifically deciding how to best design and operate man–machine systems (Ravindran et al., 1987), usually under conditions requiring the allocation of scarce resources. The terms systems engineering, operations research, and management science refer to the same process, which is the application of systems analysis to gain a better understanding of the problem and make decisions that increase profit. Agricultural managers and engineers are required to make many decisions that impact the economic viability of agribusinesses during the course of their careers. It is assumed that the quality of management and engineering decisions will be improved by the appropriate and proper application and understanding of results of systems analysis. The goal of the application of mathematical tools is to improve the quality of management and engineering decisions. The knowledge of systems tools is not a replacement for experience and judgment but can be used to augment the basis for the decision making process.

A model for assessing the effect of new technologies on production

Abstract: The model presented in this study has been adopted from the control engineering field. Its purpose is to allow system designers or engineers to view a complex production process in an abstract and a compact form so that they can easily assess the effect of introducing new technologies and organizational forms into production.

CT-Assisted Engineering and Manufacturing

Abstract: X-ray computed tomography (CT) is an important and powerful tool in industrial imaging for obtaining shape and dimensional information of industrial parts. It also serves to provide digital models of parts for inputs to new and emerging technologies in the manufacturing industry that have begun to embrace CT-assisted engineering and design. Since a large number of objects encountered in industrial CT are made either of a single homogenous material or a few homogenous materials, algorithms for discrete tomography should, in principle, yield CT images whose resolution and dimensional accuracy are superior to CT images obtained by conventional algorithms. This in turn should result in significant improvements in the accuracy of boundaries extracted from CT images for the creation of digital models of a large class of parts of interest in CT-assisted manufacturing. This chapter looks at some important applications in CT-assisted engineering and manufacturing that can benefit from the techniques of discrete tomography, and discuss some of the technical challenges faced in extracting boundaries with the degree of accuracy demanded for engineering and manufacturing applications.