Showing papers on "Production engineering published in 2008"

Model-based integration and testing of high-tech multi-disciplinary systems

Abstract: • A submitted manuscript is the author's version of the article upon submission and before peer-review. There can be important differences between the submitted version and the official published version of record. People interested in the research are advised to contact the author for the final version of the publication, or visit the DOI to the publisher's website. • The final author version and the galley proof are versions of the publication after peer review. • The final published version features the final layout of the paper including the volume, issue and page numbers.

A model for integrating process planning and production planning and control in machining processes

Abstract: The goal of process planning is to propose the routing of a previously designed part and results in a sequence of operations and their parameters. It concerns and requires detailed information about the process. The goal of production planning, on the other hand, is to schedule, sequence and launch the orders introduced on the routing sheet into the job-shop according to the enterprise's strategic goal and the actual conditions of the production plant. The goals, information and decisions taken in process planning and production planning and control are often very different and, because of that, it is very difficult to integrate them. The objective of this work is to develop a model that can be applied in the future to the development of an integrated process planning and scheduling tool using an integrated definition (IDEF) methodology to design an activity model, which integrates process and production planning in metal removal processes. An activity model will be used to develop a system that allows the user to plan the process and the production at the same time in collaborative engineering work. To design the activity model, a wide range of parts were evaluated and processed in an actual job-shop factory. Several activities were developed in detail to be tested in real cases, and an example of one of them is introduced in this article.

Design of dynamic multi sensor systems

Abstract: Recent increase in machine automation, machine capability, and the performance of machining processes lead to high demands on process monitoring systems. In the Center of Production Engineering in Hannover Gentelligent® manufacturing systems are researched, which will be able to meet those requirements. One enabling factor for these systems is the “feeling” capability, achieved by multi sensor systems. This paper copes with the design of these systems. This includes on the one hand the development of sensor configurations and on the other hand a concept for sensor fusion. For the search of optimum sensor configurations a previously developed algorithm is extended to consider the dynamic behavior of the sensor systems.

Production engineering for self-organizing complex systems

Abstract: Today’s models in production engineering are mainly based on quasi-stationary design assumptions. With increasing dynamics, models reflecting the nonlinear characteristics of production are becoming increasingly relevant. Several approaches have been formulated to design self-organizing systems, leading to good results with regards to the efficiency in which dynamics are mastered by local interaction of a system’s entities. While in self-organization a system’s characteristics emerge bottom-up, effectiveness is designed into a system by an analytical, top-down design approach. The paper discusses how a target oriented analytical design approach can be combined with the concept of self-organization and shows its application and impact on practical examples.

Valuation of changeable production systems

Abstract: The introduction of changeable production systems increases the adaptability of factories in an uncertain environment. This paper analyzes the valuation of the economic efficiency of such systems using the real options theory. The developed approach proposes a structured valuation process for selecting options related to production engineering and factory planning. Based on a classification of possible modifications of a production system, options profiles are derived. Considering the existing uncertainty of a company’s environment these profiles may be utilized to identify real options which ought to be included when valuating a technical production system design.

Application of a knowledge engineering process to support engineering design application development

Abstract: The design, analysis and optimization process of complex products can be supported by automation of repetitive and non-creative engineering tasks The Design and Engineering Engine (DEE) is a useful concept to structure this automation Within the DEE, a product is parametrically defined using Knowledge Based Engineering (KBE) techniques To develop and successfully implement the concept of the DEE in industry, a Knowledge Engineering (KE) process is developed, integrating KBE techniques with Knowledge Management (KM) The KE process is applied to develop an application supporting the design and manufacturing of aircraft wiring harnesses, focussing on the assignment of electrical signals to connectors The resulting engineering design application reduces the recurring time of the assignment process by 80%

The Management of Engineering

Abstract: Managing engineering is more difficult, more demanding and more important than managing any other human activity in modern society. The article explains how, by adhering to the principles taught by Peter F. Drucker in his landmark book The Practice of Management, managers can exploit the full potentials of their peoples’ talents and of changing technologies, methods and markets. The chapter is extracted from parts of the book [1] by the author.

Technological complexity: A support to management decisions for product engineering and manufacturing

Abstract: Complexity is a topical interdisciplinary subject debated in different scientific circles. Complexity is difficult to univocally define as it isn't a physical quantity simple to measure but an abstract concept for which different definitions can be given. This paper deepens technological complexity applied to engineering and industrial manufacturing, focusing the related aspects that can affect a product and a production system and investigating the different measurement approaches proposed in literature, classifying them into five categories. Technological complexity is significant in product engineering development, where designers have to consider this aspect to create a functional and reliable product. Technological complexity measures are important in order to support manufacturing enterprises management in decisions concerning selection of new products to be manufactured and their production. Once a technological complexity level is defined for each product, it is possible to develop feasibility studies in order to check the plant capability to produce it.

Manufacturing systems and technologies for the new frontier : the 41st CIRP Conference on Manufacturing Systems, May 26-28, 2008, Tokyo, Japan

Abstract: Plenary and Keynote Papers: Driving Innovation, An Industry Case to Enhance Manufacturing Competitiveness Architecture-based Comparative Advantage in Japan and Asia Manufuture and Sustainable Manufacturing Challenges for the Manufacturing Enterprise to Achieve Sustainable Development Complex Adaptive Systems (CAS) Approach to Production Systems and Organisations Scientific Approach to Services: What is the Design of Services?.- Manufacturing System Evaluation: A General Economic Model for Manufacturing Cost Simulation Implementation of an Economic Model to Simulate Manufacturing Costs A Dynamic Cost Model for the Effect of Improved Process Flexibility in Steel Plants Manufacturing Characteristics of Subcontractor SMME:s - an Empirical Study Integrated Information as an Enabler for Change Impact Evaluation in Manufacturing Life-cycle Management Total Performance Analysis of a Downsized Manufacturing System Environmental Burden Analysis for Machining Operation Using LCA Method Efficient Maintenance of Machine Tools --Adapted Maintenance Activities and Assembly-Specific Maintenance Intervals.- Manufacturing System Organization: Strategy-oriented Qualification Framework as a Supporting Function of Lean Production System Implementation in Small and Medium-sized Enterprises An Environmental Perspective on Lean Production Quantified Interdependencies between Lean Methods and Production Figures in the Small Series Production Further Potentials of Smart Logistics Production Management in SME Networks - Evaluation of Potentials and Achievements Digital Virtual Holons -- An Approach to Digital Manufacturing Systems Complex Manufacturing Space: An Integrated Description Model of Real and Virtual System Concepts for Information Enhanced Manufacturing Grid Engineering for Networked and Multi-scale Manufacturing Smart Factory - A Step towards the Next Generation of Manufacturing Sustainable Manufacturing - Challenges and Possibilities for Research and Industry from a Swedish Perspective Characteristic of a Proactive Assembly System Virtual Manufacturing Work Systems Virtual Enterprise Model for Integrated Planning in Manufacturing Supply Network Manufacturing System to Support Design Concept and Reuse of Manufacturing Experience.- Implementation and Design System: Globalization-Compatible Product Structure Based on Technological Core Competences Reducing Design Complexity of Multidisciplinary Domain Integrated Products: a Case Study PLIB Ontology for Great Group Technology Geometrical Properties of Paper Spring Application of Axiomatic Design to Develop a Lean Logistics Design Methodology Measuring and Analysing Levels of Automation in an Assembly System Sustainable Design of Machine Tools through Load-Dependent Interventions and Adapted Services Modeling and Implementation of Digital Semantic Machining Models for 5-axis Machining Application Compensation of Thermal Deformations at Machine Tools Using Adaptronic CRP-Structures Image Noise Reduction Using Wide Range Tuned Mass Damper for Scanning Electron Microscope.- Planning: A Model for Adaptively Generating Assembly Instructions Using State-based Graphs Evaluating Assembly Instruction Methods in Cell Production System by Physiological Parameters and Subjective Indices Assembly Work Settings Enabling Proactivity - Information Requirements Assembly Information System for Operational Support in Cell Production Multimedia Based Assembly Supporting System for Cell Production Development of a Computer Aided Procedure to Control Division of Labour Based Disassembly Systems A New Method to Control Work-in-Process Inventory for High Manufacturing Productivity An Evolutionary Algorithm for Vehicle Routing Problem with Real Life Constraints Integrated Data Management in Factory Planning and Factory Operation. An Information Model and its Implementation Future Challenges in Process/Resource Planning Due to Increasing (Product) Variants.- Human Aspects in Manufacturing Systems: Modernisation of Industrial Engineering: Enhanced Participation of Employees Towards Optimal Worker Assistance: Investigating Cognitive Processes in Manual Assembly Social Aspects of Plant Monitoring and Visualization Cluster Manufacturing Management to Improve Equipment Efficiency and Productivity.- Scheduling: Penalty Distribution Method for Scheduling Based Supply Chain Management Social Contract Based Manufacturing Scheduling with Combinatorial Auction Mechanism Agent-based Dynamic Process Planning and Scheduling in Flexible Manufacturing System GA Based Reactive Scheduling for Aggregate Production Scheduling Development of a Multi-Agent Model for Production Scheduling in Innovative Flexible Manufacturing System A Real-time Scheduling Method Considering Human Operators in Autonomous Distributed Manufacturing Systems Production Scheduling System with Dynamic Lot Size in Case of Considering Set-up Time The Impact of Lot Splitting in a Single Machine Scheduling Problem with Earliness - Tardiness Penalties Integration of Process Planning and Scheduling Using Multi-Agent Learning.- Manufacturing System Design: Module Structured Production System Lean Production System Design from the Perspective of the Viable System Model Implementation Strategy for a Flexibility Oriented Production System A Study of Design Factors for Information Supporting System in Cell Production On Reconfigurable Robotic Working Cells - a Case Study Linking Modules for Reconfigurable Manufacturing Systems Global Footprint Design TSUNAMI Effect Prediction Methodology for Critical Resource Analysis Factory-in-a-box -- Demonstrating the Next Generation Manufacturing Provider.- Electro-Physical and Chemical Processes: Planning the Use of High-Power Excimer Laser for Psoriasis Treatment Optimization Strategies of Laser Hardening of Hypo-eutectoid Steel Fabrication of Wire Saw with Patterned Hard Bumps by Electrical Discharge Machining with Powder Suspended in Working Oil Creation of Cross-Section Changing Hole with a Hemisphere by Means of Electrical Discharge Machining.- Cutting: Study of Cutting Temperature in Cold-Air Milling of Ti6Al4V Alloy Environmentally Friendly Machining of Aluminum Using Minimal Quantity Lubrication System An Evolutionary Strategy for Optimizing Multi-pass Turning Operation under Dry Machining Conditions.- Machines and Forming: Proposal of Real-Time Balancing Mechanism Using Magnetic Fluid for Machine Tool Spindle Prototyping of Autonomous CNC Machine Tool Based on Digital Copy Milling Concept Intricate Shaped Manufacturing by 6-Axis Non-rotational Cutting with the Application of Ultrasonic Vibrations Expanding the Possibilities of Position Error Compensation in CAM for PKM Milling Machines Optimization of Toolpath Generation in Medical CAM for a Machine Tool for Orthopedic Surgery Development of CAM System to Estimate Tool Wear of Ball-end-milling Model Based Control of a Piezo-actuated Axis Register Control of Sectional Drive Rotogravure Printing Press Incremental Sheet Forming with a Robot System for an Industrial Application Multi-Technology Platform for Hybrid Metal Processing Super-Resolution Imaging for Automatic Visual Inspection Systems Instrumented Fixtures for On-line Correction of Welding Paths.- Micro-Nano Technology and Surfaces: Surface Roughness and Microstructure in Ultrasonically Assisted Turning of W-Fe-Ni Alloy Finishing Complex Surfaces with Zonal Polishing Tools Sub-wavelength Pitched Cubic Mosaic Multi-layer Precisely Pressed by Nano-features Mold for Multi-functional Optical Elements.- Grinding: Simulation of Workpiece Kinematics in Centreless Throughfeed Grinding Development of an Electroplated Polishing Tape Applying Electrodeposited Nickel Foil Method Development of Ultrafine-Crystalline cBN Abrasive Grains for Innovative Grinding Technology.- Service Engineering: System for Planning of Resources in IPSA -Delivery Product Diffusion in a Market with Network Externalities: An Approach from the Viewpoint of Value-creation among Consumers Cost Evaluation Method for Service Design Based on Activity Based Costing Definition of Design Operation for Service Industrial Product-Service-Systems - Typology of Service Supply Chain for IPS2 Providing A Method of Supporting Conflict-Solving for Service Design Learning Networks: a Method for Integrated Product and Service Engineering -- Experience from the IPSE Project Proposal of Idea Generation Support Methodology for Eco-Business Multi-Agent Market Modeling Based on Analysis of Consumer Lifestyles Strategic Servicification - A Quality Based Approach beyond Service-Engineering From Product to Service Orientation in the Maritime Equipment Industry - a Case Study Knowledge Generation as a Means to Improve Development Processes of Industrial Product-Service Systems Modelling Approach for the Integrated Development of Industrial Product-Service Systems Integrating Function Model and Activity Model for Design of Service Remanufacturing of Products Used in Product Service System Offerings Integrated Design of Industrial Product-Service Systems Evaluation of Product-Service Systems during Early Design Phase.

The use of non-intrusive user logging to capture engineering rationale, knowledge and intent during the product life cycle

Abstract: Within the context of life cycle engineering it is important that structured engineering information and knowledge are captured at all phases of the product life cycle for future reference. This is especially the case for long life cycle projects which see a large number of engineering decisions made at the early to mid-stages of a productpsilas life cycle that are needed to inform engineering decisions later on in the process. A key aspect of technology management will be the capturing of knowledge throughout the product life cycle. Numerous attempts have been made to apply knowledge capture techniques to formalise engineering decision rationale and processes; however, these tend to be associated with substantial overheads on the engineer and the company through cognitive process interruptions and additional costs/time. Indeed, when life cycle deadlines come closer these capturing techniques are abandoned due the need to produce a final solution. This paper describes work carried out for non-intrusively capturing and formalising product life cycle knowledge by demonstrating the automated capture of engineering processes/rationale using user logging via an immersive virtual reality system for cable harness design and assembly planning. Associated post-experimental analyses are described which demonstrate the formalisation of structured design processes and decision representations in the form of IDEF diagrams and structured engineering change information. Potential future research directions involving more thorough logging of users are also outlined.

Changes and disturbances in manufacturing systems: A comparison of emerging concepts

Abstract: Changes and disturbances are of major concerns in manufacturing shopfloors as they would result in daily operation disruptions, and cause difficulties for companies to forecast and realise production plans. The capability of a company to rapidly respond to such issues is important to gain competitive advantage in the market. This review paper compares the response of emerging manufacturing systems to changes and disturbances. A review of various studies is presented on changes and disturbances in manufacturing, with particular attention to four known concepts namely holonic, biological, reconfigurable, and agile manufacturing systems. A number of criteria are then used to compare the performance of these manufacturing systems.

Formulation of Automation Strategy in Manufacturing Systems - Developing a Methodology for Analysing and Choosing Levels of Automation

Abstract: In the global environment where industrial enterprises strive for competitiveness, the ability to adjust quickly to changing conditions is important. This global industrial context challenges the companies to develop new capabilities. Capacity flexibility is an important measure of competitiveness and one important capability for improving productivity and effectiveness. Available resources contribute to capacity (output) and influence capacity flexibility. Thus, the way resources are managed is important. One way to manage resources within the manufacturing system is to choose resources that are the most suitable for the task performed by adopting task allocation. Task allocation between human and technology therefore becomes central for design of workplaces with optimal performance. This becomes the challenge of automation. However, to make the right decisions on automation and the skills required for the handling of tools and technology is a complex process of decision making for managers. In the light of this, the objective of this thesis is to develop a methodology for analysing and choosing levels of automation with the purpose to formulate automation strategy in manufacturing systems. The analysis is based on measurement of levels of automation and alignment between levels of automation and the business and manufacturing strategies. The application area of the research is the manufacturing industry and in particular assembly lines or cells because of the mixture of human and technological resources. As indicated by the objective, the outcome of this thesis is a structured methodology that analyses possible alternatives of levels of automation weighted against competitive priorities. The methodology consists of five stages: (1) preparation, (2) business and manufacturing strategy, (3) estimation of levels of automation for critical subtasks, (4) analysis of levels of automation, and (5) completion. The methodology supports visibility of results. Depending on where the company has its greatest improvement potential, different starting points in the methodology can be applied. Validation of the methodology indicates that usefulness, use, and satisfaction with the methodology can be seen as good. The issue of considering both humans and technology is critical for the success of the system, as it builds the resources of the manufacturing function. Overcoming barriers in measuring LoA and in aligning resources with market needs is crucial for developing long term automation strategies. Certain criteria of the manufacturing system influence the choice of LoA. Those criteria are production volume and specific product characteristics. Proposed improvements for formulating manufacturing strategy involve a focus on communication and knowledge sharing, introducing measures for learning and knowledge, enhancing interactions between inside and outside partners, and closing knowledge gaps. Those improvements should be seen primarily as research opportunities in the area of manufacturing strategy processes.

Emergence of simulations for manufacturing line designs in Japanese automobile manufacturing plants

Abstract: The aim of this research is to introduce the reader to a new perspective on the framework for designing a manufacturing line project in Japanese automobile manufacturing plants. All manufacturing aspects, manual, automated and hybrid manufacturing lines are considered; however, which line should be used for the factory is always under investigation within the factory. Simulation studies that include resource utilization, line productivity and manufacturing costs help to identify the most suitable manufacturing line type within a factory. By utilizing simulation studies, designers can make reliable decisions upon suitable manufacturing lines faster than conventional methods based upon engineering experience. In order to understand the framework of manufacturing line design, a project to design a new automobile component manufacturing line was investigated in this study, and the chosen manufacturing line was also checked by the manufacturing activities in the factory.

Engineering the soul of management in the nano era

Abstract: A goal-driven engineering process-an engine of invention, innovation, and growth-is described to be the soul of management. As this synergy is implemented and lessons learned in the management training, the outcomes are expected to be higher than the individual aspirations of people comprising an organization. In the nano era, the integration of the artificial (human-initiated engineering) and natural (divine engineering) is shown to be of paramount importance in enhancing productivity and in improving the standard of life. Biomedical engineering, nanotechnology, megacomputing and nano-robots will dominate the future of human race and hence an anticipated need for effective management of emerging technologies and related human resources. In support of the synthesis of management and engineering, outcome-based education (OBE) in the Washington Accord criteria are shown to integrate development of management and entrepreneurial skills as part of the engineering training in desiging a product and marketing it. An algorithm of these deliverable attributes by considering the university as an organization dedicating to enhancing the industrial competitiveness is given.

A methodology for manufacturing system development

Abstract: In a model driven development scenario, the models of parts, processes and resources themselves are the carriers of information which is used and refined throughout the work processes. In this arti ...

Implementation of core manufacturing simulation data in aerospace industry

Abstract: This presentation will describe how Boeing implements the Core Manufacturing Simulation Data (CMSD) information model. The presentation will include visualization of manufacturing data for parts and tooling visibility in manufacturing industry. Simulation analyses are prepared by extracting and formatting data from real world production databases. This includes automatic data processing, automatic curve fitting for distribution functions, automatic CMSD file generation, and finally data is automatically fed to simulations.

Technological cycles and their impact on science, engineering and engineering education

Abstract: Large information systems involving mechanisms of duplicating and selecting information have an important common feature -- their cyclic behavior. Technological development does not occur at a continuous steady pace but involves technological leaps and revolutions when an old technology is replaced by a technology of new generation within relatively short period of time. A technological revolution is followed by a longer period of more steady, incremental development. Similar cycles are known in economics, science, history, biology and other areas. We discuss the cyclic nature of the evolution of human knowledge and find that the inventiveness and flexibility of the engineering approach has played a highly positive role at the turning points of technological development. Engineering methodology has to adapt to changing conditions and its ability to learn quickly from both science and environment is one of the main recipes for overall success of engineering. The inventive and active nature of engineering profession is reflected in the realities of engineering education: future engineers do need to be taught science and economics but the styles of education adopted in science and engineering are not the same.

On engineering cost management

Abstract: In order to realize effective control and proper determination of engineering cost the ideas to perfect engineering cost management system and ways to improve the management of engineering cost are elaborated in order to make full use of limit labor and material resources to receive satisfied economic and social benefits for projects.

Evaluation of environmentally benign production program in the textile-dyeing industry (II): a multi-objective programming approach

Abstract: The ways for improving a cost-effective industrial production program described in an earlier paper primarily focused on the quality assurance/quality control (QA/QC) schemes within the manufacturing stage. However, industry with high demand of resources input must evolve the essential production strategies to meet the goals in an environmentally benign production program. This paper describes the method and procedure for optimizing a textile-dyeing manufacturing process with respect to the potential impact of pollution charges, resources conservation fees, production cost, inventory cost, and the limitations of production capacity simultaneously. The optimal production strategy concerning numerous screening processes of those production alternatives in terms of market demand, production technology, and resources allocation is treated as an integral part in the multi-objective decision analysis. Facing the growing impact of rising environmental costs and the awareness of implications of industria...

Collaborative Engineering and Product Quality Assurance based on Integrated Engineering Information Management

Abstract: Engineering collaboration is inevitable in the various engineering phases including product design phase, analysis phase, inspection phase, and so on. However, sharing engineering data generated from CAD/CAE/CAI systems is technically very difficult due to the complexity and size of the data. Besides, heterogeneous CAD/CAE/CAI systems make it difficult to accomplish data sharing for engineering collaboration purpose. We propose a new integrated engineering data representation scheme and developed visualization and real-time conference system for remote engineering collaboration and sharing information between companies. The system's capability includes data translation, visualization and conference using engineering information generated from the various commercial engineering systems. It supports integrated history management for product design information along with other engineering information such as analysis data, inspection data, and manufacturing data. The developed system is used as a basis of the infrastructure for the collaborative product lifecycle management.

Intuitive Visualization and Interactive Analysis of Pareto Sets Applied on Production Engineering System

Abstract: Summary. Applying multi-objective optimization algorithms to practical optimization problems, a high number of multi-dimensional data has to be handled: data of the genotype and phenotype as well as additional information of the optimization problem. This chapter gives an overview of several methods for visualization and analysis which are combined with regard to the characteristics of solution sets generated by evolutionary algorithms in order to get an intuitive instrument for decision making and gaining insight into both - the problem and the algorithm. They are discussed by means of two current production engineering problems providing a high economic potential: the optimization of the five-axis milling process and the design of cooling duct layouts.