Showing papers on "Production engineering published in 2000"

Research challenges in process systems engineering

Abstract: Introduction Companies must design and operate chemical processes effectively and efficiently so they may survive in today’s highly competitive world. Providing the methods, tools and people that allow industry to meet its needs by tying science to engineering is a compelling aspect of Process Systems Engineering (PSE). Despite the importance of the PSE, the scope and research of this area are often not well understood. One of the major reasons is that chemical engineering has evolved over the past five decades from being an engineering discipline rooted in the concept of unit operations to one based on engineering science and mathematics, and most recently to one with increasing ties to the natural sciences. This very significant change in emphasis has created a gap between the science-based and the systems-based research in chemical engineering. We argue here that this gap might be closed in two ways: first, by broadening the definition of Process Systems Engineering through the introduction of the concept of the “chemical supply chain,” and second, by gaining a better appreciation of the intellectual research challenges in this area. We address this last issue by discussing the nature and major accomplishments of the PSE area and outlining emerging research directions.

The application of axiomatic design and lean management principles in the scope of production system segmentation

Abstract: Systematic design and evaluation of segmented production system structures is the subject of this paper. Recently emerged paradigms of Lean Management and Business Process Re-engineering call for a...

Introduction to manufacturing simulation

Abstract: The article presents an overview of simulation in manufacturing design and scheduling. A review of the modeling considerations in both application areas is provided. Finally, a number of example applications are presented to illustrate the concepts.

Modified method time measurements for ergonomic planning of production systems in the manufacturing industry

Abstract: The paper reports on an evaluation of a method called ErgoSAM. This method is based on SAM, a higher-level method-time-measurement (MTM) system, and is for use by production planners, e.g. production engineers. In addition to the SAM information, the ErgoSAM method considers information on weight handled or forces applied, and work zone. The method is designed to predict the physical demands of work postures, force and repetitivity, according to a scientific model, the Cube model. In co-operation with the Volvo Car Corporation, six workstations of an assembly line, were analysed by a production engineer using ErgoSAM. The total assembly time analysed was about 17 minutes. The results were compared to results from ergonomic analyses made by an ergonomist using the Volvo Car Corporation’s standards. The results showed that ErgoSAM predicts work situations of high physical stress for the workers. However, the method does not consider stressful positions for the hand, wrist and neck or mental stress. The production engineer judged the ErgoSAM analyses to require about 5% more time than SAM analyses alone. It is concluded that the method shows considerable promise for predicting physically stressful work situations, but needs to be further evaluated and refined.

Distributed constraint processing for production logistics

Abstract: The Fakos production planning system developed for Mercedes-Benz relies on a combination of multiagent and constraint technologies that intuitively represents production flow knowledge at automobile manufacturing plants. The prototype presented compares favorably with centralized constraint and operations research approaches.

A descriptive multi‐attribute model for reconfigurable machining system selection examining buyer‐supplier relationships

Abstract: Presents a model of the machining system selection process that is focused on capital intensive, complex machining systems that are intended to provide service over a long time horizon. This model was developed based on interviews with both machine tool suppliers and buyers. The systems considered here increasingly face potentially conflicting demands such as: the ability to be quickly and inexpensively upgraded and reconfigured in order to have quick new product change‐over and ramp‐up time; and high product variety at close to mass production costs. This new “reconfigurability” capability increases the importance of the supplier‐buyer relationship after the machining system has been selected. We also remark that the selection process can serve as the basis for internal consensus and team building within the buyer firm and for enhancing supplier base quality.

Analyzing requirements engineering processes: a case study

Abstract: Thorough process improvement starts with an analysis of the current situation. This is also true for requirements engineering processes. The goal of cooperation between DaimlerChrysler and the department of Software Systems Engineering at the University of Essen is to establish a framework for such RE process analysis in the area of car manufacturing. In this paper, we report on our first analysis using a traditional interview technique and the results obtained. We compare the major findings with existing research and other experiences, identify a set of challenges and provide an outlook of our future investigations.

Engineering design change management

Abstract: Outlines the economic consequences of changes that are made during the design process and manufacture. Computer and paper based systems are considered, and the advantages of a computer based system are discussed. Experience in the use of a computer based system in a company is reviewed with respect to the sources of design changes, the control of design changes and the benefits gained. The use of bespoke and proprietary software is briefly discussed. Notes that engineering design change management plays an essential role in successful manufacturing organisations. Also notes that the bespoke system described has led to a considerable improvement in the company’s change control process.

Digital factory - planning and running enterprises of the future

Abstract: This paper describes an innovative approach to factory automation - the digital factory. The first part gives a short overview of current CIM (computer integrated manufacturing) and CAPE (computer-aided production engineering) tools. The second part specifies the concepts "virtual engineering", "digital mock-up" and "digital factory" and introduces a method which links several CIM/CAPE tools together using a shared product/process data management system. Finally, we present a new distributed, scalable, Internet-based tele-diagnosis and monitoring system for robots and robot cells.

Innovative and Economical Bench-scale Process Engineering Experiments*

Abstract: Through funding of the National Science Foundation (NSF), some novel experiments have beendeveloped that present process science principles suitable for a variety of chemical engineering andprocess-related core courses. These experiments are cost effective and represent some of theemerging areas: polymer processing, food processing, environmental reactor design, fluidization,and membrane separation. These experiments have been utilized by chemical engineering faculty ata unique hands-on industrially integrated NSF workshop on Novel Process Science and Engineer-ing conducted at Rowan University. We have integrated these experiments into our curriculum sothat students can see chemical engineering process principles in action and therefore improve thequality of education.

Lead-free solder implementation for automotive electronics

Abstract: Lead-free solders for electronics have been actively pursued since the early 1990's here and abroad for environmental, legislative, and competitive reasons. The National Center for Manufacturing Sciences (NCMS-US), the International Tin Research Institute (ITRI-UK), Swedish Institute of Production Engineering Research (IVF-Sweden), Japan Institute of Electronics Packaging (JIEP-Japan), Improved Design Life and Environmentally Aware Manufacture of Electronics Assemblies by Lead-free Soldering (IDEALS-Europe), and, more recently, the National Electronics Manufacturing Initiative (NEMI-US) have been aggressively seeking lead-free solutions. The automotive environment is one of the toughest since it includes chemicals both solvents and salt spray, wide temperature ranges, vibration, and humidity. A change in alloy requires extensive testing and durable materials. Tests of PWB surface finishes, Tg, and thickness will be described as they relate to lead-free solder implementation. Requirements for boards and components will also be discussed.

The implementation and integration of information systems for production management in manufacturing: An empirical study)

Abstract: Information technology support for manufacturing systems embodies complex and systematic activities in modern industrial enterprises. In order to successfully and profitably operate in rapidly changing markets, highly flexible production, computer-integrated manufacturing (CIM), supplychain management (SCM) and customer relationship management (CRM) need to be developed. The aim of the paper is to describe the results of a comparative study of the implementation and integration of computer aided production management (CAPM) in Taiwan and the UK, one of the emerging 'little dragons' of Far East Asia and manufacturers in the developed Western economy of the UK. The research design used both qualitative and quantitative data analysis techniques to introduce and examine a model of best practice in the CAPM for manufacturing systems, by drawing on the practical experience of senior managers of production and MIS in Taiwan and the UK. Two phases of fieldwork were undertaken. In the first phase, 20 case studies ...

Optimising Automatic Tool Selection for 2½D Components

Abstract: An important step in planning the manufacture of a component by CNC machining is the selection of cutting tools. Although it has long been known that the choice of cutter sizes can have a dramatic effect on the overall machining time, few algorithms for optimisation have been available to the production engineer. This paper describes a method for determining a theoretical optimal combination of cutting tools for machining a given set of 3D volumes or 2D profiles. The algorithm considers residual material left behind by oversized cutters and the relative clearance rates of cutters that can access the selected machining features. The current implementation of the procedure described does not give exact results because several machining parameters are not included in the selection process such as tool path length, plunge rates, etc. However, the experimental results suggest that while these factors may make changes to the absolute values calculated, they typically make only a small difference to the relative ranking of the tools. The results presented here suggest that the correct combination of tools could reduce machining times by significant amounts. Consequently the paper concludes with a discussion of how the tool path generation routines used in commercial CAM systems could be modified to achieve this.

Center For Advanced Manufacturing And Production: Enhancing Engineering Education Through Team Based Multidisciplinary Projects

Abstract: The role of engineers has changed in recent years from solitary designers in the laboratory to members of teams that have to sell their ideas and work with customers. Engineering education is changing to meet the needs of the changing role of engineers. In response to these changes, the goal of the Center for Advanced Manufacturing and Production (CAMP) is to improve the education of undergraduate engineering students through team-based multidisciplinary projects. CAMP focuses on combining the individual student’s discipline expertise with the multidisciplinary team requirements in design and manufacture of a complex product. Realistic projects large enough to require teams provide the basis for experiential learning in communication skills, teamwork, and leadership abilities. Engineering students with at least a 3.0 GPA or special expertise are invited to join CAMP as juniors. In addition to taking required courses in manufacturing, multidisciplinary design, business, and networking, the CAMP students become leaders in multidisciplinary team projects as they progress through the program. CAMP contributes to the improvement of undergraduate education by involving students in challenging projects in competition with engineering students from across the country. "National norming" is an important part of CAMP -students compete in national engineering contests. The centerpiece CAMP projects are Sunrayce, SAE Mini-Baja, and Formula SAE Mini-Indy races. The teams are responsible for not only design and manufacturing, but also fund raising, publicity, and finding sponsors -skills that readily translate into their profession when they graduate. Industry sponsored projects are also part of CAMP. Projects appropriate to the academic calendar and student abilities provide experience for CAMP students and an aid to industry. The three faculty co-directors work with six graduate students and a dozen undergraduates who are managers and mentors for 33 CAMP student leaders who in turn lead multidisciplinary projects which involve approximately 100 students. Since many of these projects are connected with courses, approximately 400 students are indirectly affected.

A basic study on autonomous characterization of square array machining cells for agile manufacturing

Abstract: In this study, a manufacturing system locating machining cells in a square array is considered as an agile manufacturing system that can manufacture a variety of kinds of products with varying volumes. Each cell can process any work whose machining operations for each work are divided into some operation groups common to all works. An auction-based algorithm is proposed to select a cell to process a work after its processing of one operation group. Five types of bid are considered and their effects on the characterization of cells, i.e., concentration on the processing of specific work kinds and operation groups, are investigated.

Games in Operations Management.

Abstract: This paper deals with the role and actions of internal change agents as game facilitators. The paper describes a training programme called SIMNET for training new game facilitators to use a work process development method called the Work Flow Game. The Work Flow Game is an action-oriented, tailored simulation game where the participants simulate their own real work activities together. There were eleven internal change agents from nine different organisations participating in the training programme. The results of the training programme were evaluated by conducting a qualitative case study. All participants were able to carry out their simulation games and most of the projects gained results in terms of implementation of changes.

Process planning for sheet metal parts based on information management

Abstract: Design and manufacturing processes and their mutual interaction are reflected by the Manufacturing Engineering Reference Model. Information management, as the kernel of this reference model, encompasses structures that reflect the information. The three information structures that are discerned refer to products, resources and orders respectively. Originating from the demand for Concurrent Engineering, augmented effort is invested in the integration of the different processes applied in the manufacturing cycle of products. This paper discusses the integration of design and process planning-which is one of the main topics in Concurrent Engineering-along with the demand for Design for Manufacturing. Emphasis is on the application of production method knowledge and design support, especially for sheet metal parts.

Performance assessment of assembly systems

Abstract: The work detailed in this dissertation relates to earlyconceptual decisions in the development of assembly systems forlarge, high-volume products, such as cars, trucks and homeappliances. Historica ...

Moving forward: assessment of competitive strategies and business excellence in the Turkish manufacturing industry: a benchmarking study

Abstract: Moving Forward: Assessment of Competitive Strategies, Business Excellence and Technology Management in the Turkish Manufacturing Industry: A Benchmarking Study aims to explore the state of business excellence in the manufacturing industry in Turkey and to draw some conclusions concerning possible near future developments. It is based on several sectoral benchmarking studies conducted in the manufacturing industries in Turkey.

Towards an Integration of Engineering Knowledge Management And Knowledge Based Engineering

Abstract: Knowledge is one of the key issues in every business today. Computer based support is gaining increasing importance here. This has currently two main objectives: knowledge management and knowledge based systems. The complexity of engineering knowledge results in high requirements for the knowledge structuring and retrieval techniques to be used here. It is also valuable as a first phase in the life cycle of knowledge based engineering systems. An Informal Model is introduced here as a representation of knowledge suitable for engineering knowledge management as well as to support the development of knowledge based systems.

Breaking the Cost Barrier: A Proven Approach to Managing and Implementing Lean Manufacturing

Abstract: An Opportunity for Advancement. The Evolution of Manufacturing in the Aircraft Industry. A Study in Manufacturing Affordability. The Principle of Variation Management. Production and Inventory Control: The Cornerstone Enablers. The Impact of Production Flow and Quality Enhancements. Improved Supplier Responsiveness. The Role of Product Design. The Culture of Manufacturing. Changing the Paradigm. A Final Note... Appendix. Notes.

Developing construction logistics management: the French experience

Abstract: To recover from the construction crisis, major French construction firms started developing ‘;package building’ strategies at the beginning of the 1990s. Today, their desire to open up continues, but they have also shown renewed interest in the management of construction site activities and production engineering, as witnessed by the practices of ‘logistics management’. How can we justify this inward-looking attitude to construction? What place is there for innovation? Along what lines must this new approach to production management develop? These questions are addressed with reference to the analysis recently produced by a panel of experts led by the authors. The study of various experimental construction sites shows that although it may not yet be well established, this approach has resulted in significant changes in the way construction projects are organized. It places the emergence of new forms of coordination both within and between firms right at the heart of the quest for production efficiency.

Pollution prevention: a new paradigm for engineering education

Abstract: It is estimated that our materials-dominated society consumes about 10 metric tons of raw materials per person per year in the production of consumer goods. Within 6 months of extraction or production of these materials, 94% of them become waste. More efficient manufacturing practices are needed to lessen the demands for raw materials and to reduce the amounts and toxicity of waste materials. It is estimated that 70% of this waste material could be eliminated through better design decisions and reuse of materials. Engineering education has evolved into fairly segregated disciplines which focus on narrowly defined design and manufacturing functions, often without consideration of the environmental consequences of these functions. This is no longer the case in industry, however, where pollution prevention and waste minimization have become very important. Unfortunately, most of our engineering graduates are not prepared to step into a role where “green engineering” principles are espoused. We must quickly incorporate the “green engineering” principles into the engineering curriculum in all disciplines to ensure that all engineering graduates understand the environmental and economic consequences of engineering decisions. This paper describes methods that can be used to introduce the principles of pollution prevention, environmentally conscious products, processes and manufacturing systems. Students will learn the impacts of wastes from manufacturing and post-use product disposal, environmental cycles of materials, sustainability, and principles of environmental economics. Materials selection, process and product design, and packaging are also addressed.