scholarly journals Simulation Method for Evaluation of Productivity and Energy Consumption Concerning Production Line for Injection Molding Machines

2017 ◽  
pp. 496-504
Author(s):  
Rio Takasaki ◽  
Hironori Hibino ◽  
Kazuhide Kaifuku ◽  
Keitaro Nishitani
Keyword(s):  
Energy Consumption ◽  
Injection Molding ◽  
Production Line ◽  
Simulation Method

Layout design of a mixed-flow production line based on processing energy consumption and buffer configuration

2021 ◽  
Author(s):  
Cai-Xia Zhang ◽  
Shu-Lin Dong ◽  
Hong-Yan Chu ◽  
Guo-Zhi Ding ◽  
Zhi-Feng Liu ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Production Line ◽  
Layout Design ◽  
Mixed Flow ◽  
Processing Energy

scholarly journals Energy and Eco-Impact Evaluation of Fused Deposition Modeling and Injection Molding of Polylactic Acid

2021 ◽  
Vol 13 (4) ◽  
pp. 1875
Author(s):  
Emmanuel Ugo Enemuoh ◽  
Venkata Gireesh Menta ◽  
Abdulaziz Abutunis ◽  
Sean O’Brien ◽  
Labiba Imtiaz Kaya ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Injection Molding ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Plastic Injection Molding ◽  
Measurement Models ◽  
Fused Deposition ◽  
Dog Bone ◽  
Deposition Modeling ◽  
Plastic Injection

There is limited knowledge about energy and carbon emission performance comparison between additive fused deposition modeling (FDM) and consolidation plastic injection molding (PIM) forming techniques, despite their recent high industrial applications such as tools and fixtures. In this study, developed empirical models focus on the production phase of the polylactic acid (PLA) thermoplastic polyester life cycle while using FDM and PIM processes to produce American Society for Testing and Materials (ASTM) D638 Type IV dog bone samples to compare their energy consumption and eco-impact. It was established that energy consumption by the FDM layer creation phase dominated the filament extrusion and PLA pellet production phases, with, overwhelmingly, 99% of the total energy consumption in the three production phases combined. During FDM PLA production, about 95.5% of energy consumption was seen during actual FDM part building. This means that the FDM process parameters such as infill percentage, layer thickness, and printing speed can be optimized to significantly improve the energy consumption of the FDM process. Furthermore, plastic injection molding consumed about 38.2% less energy and produced less carbon emissions per one kilogram of PLA formed parts compared to the FDM process. The developed functional unit measurement models can be employed in setting sustainable manufacturing goals for PLA production.

scholarly journals Optimization of injection molding process for car fender in consideration of energy efficiency and product quality

2014 ◽  
Vol 1 (4) ◽  
pp. 256-265 ◽  
Author(s):  
Hong Seok Park ◽  
Trung Thanh Nguyen
Keyword(s):  
Energy Efficiency ◽  
Energy Consumption ◽  
Injection Molding ◽  
Product Quality ◽  
Process Parameters ◽  
Optimization Problems ◽  
Computational Cost ◽  
Injection Molding Process ◽  
Molding Process ◽  
Nsga Ii

Abstract Energy efficiency is an essential consideration in sustainable manufacturing. This study presents the car fender-based injection molding process optimization that aims to resolve the trade-off between energy consumption and product quality at the same time in which process parameters are optimized variables. The process is specially optimized by applying response surface methodology and using nondominated sorting genetic algorithm II (NSGA II) in order to resolve multi-object optimization problems. To reduce computational cost and time in the problem-solving procedure, the combination of CAE-integration tools is employed. Based on the Pareto diagram, an appropriate solution is derived out to obtain optimal parameters. The optimization results show that the proposed approach can help effectively engineers in identifying optimal process parameters and achieving competitive advantages of energy consumption and product quality. In addition, the engineering analysis that can be employed to conduct holistic optimization of the injection molding process in order to increase energy efficiency and product quality was also mentioned in this paper.

scholarly journals Optimal Buffer Allocation For Unpaced Balanced And Unbalanced Mean Processing Time

2012 ◽  
Author(s):  
Zalinda Othman ◽  
Shahrul Kamaruddin ◽  
Mohd. Shihabudin Ismail
Keyword(s):  
Key Words ◽  
Coefficient Of Variation ◽  
Production Line ◽  
Processing Time ◽  
Simulation Method ◽  
Buffer Allocation ◽  
Throughput Rate ◽  
Processing Times ◽  
The Mean

Artikel ini membincangkan peruntukan penampan optimum untuk talian pengeluaran unpaced yang pendek dan boleh diharap (tiada mesin rosak). Parameter utama yang mempengaruhi talian dalam kajian ini adalah min masa pemprosesan (μ) dan pekali variasinya (Cv). Lapan taburan min masa pemprosesan telah dikaji. Setiap taburan dipadankan dengan 15 konfigurasi peruntukan penampan. Kaedah simulasi digunakan bagi menganggar kadar keluaran talian untuk setiap kes. Keputusan kajian menunjukkan peruntukan penampan tertentu mempengaruhi kadar keluaran talian. Bagi talian yang boleh diharap dan min seimbang, peruntukan penampan yang optima adalah dengan mengagihkan bilangan penampan secara sama rata ke setiap slot penampan. Jika penampan tambahan diperlukan selepas agihan dilakukan, letakkan penampan tambahan tersebut pada slot penampan yang di tengah. Manakala bentuk peruntukan penampan yang baik bagi talian yang mempunyai min tidak seimbang (dengan anggapan setiap stesen mempunyai Cv tetap dan boleh diharap) ialah mengikut bentuk taburan min masa pemprosesan talian tersebut. Kata kunci: Talian pengeluaran unpaced, min tidak seimbang, peruntukan penampan optima, talian seimbang, talian pengeluaran unpaced boleh diharap This article discusses an optimal buffer allocation for short unpaced production line and it is assumed reliable (no machines breakdown). The main parameters that affect the line are mean processing time (μ) and its coefficient of variation (Cv). Eight different mean processing time distributions were studied. Each distribution was matched with 15 different buffer allocations. Simulation method was used to estimate the line throughput rate. The results showed that the allocation of buffers affect the throughput rate. For a reliable and balanced line, the optimum buffer allocation is by equally distributing the number of buffers to each buffer slot. In the case of an extra buffer is needed after equally distribution, it is placed at the center buffer slot. Meanwhile, the best buffer allocation shape for a line with unbalanced mean (with the assumption that each station is having fixed Cv and is reliable) follows the shape of the mean processing times of that line. Key words: Unpaced production line, unbalanced mean, optimal buffer allocation, balanced line, reliable unpaced production line

Simulation of M/M/1 Queue Model Based on WITNESS

2011 ◽  
Vol 261-263 ◽  
pp. 753-756
Author(s):  
Hua Meng ◽  
Hua Wang ◽  
Jian Jun Wang
Keyword(s):  
Complex System ◽  
Production Line ◽  
Queuing Theory ◽  
Simulation Method ◽  
System Optimization ◽  
Theory Method ◽  
Steel Making ◽  
Queue Model ◽  
System Characteristics ◽  
Static Simulation

The techno-interface of BF-BOF region is an important stage that connects iron making procedure with steel making procedure in the production line, acting as a connecting link between the preceding and the following procedure. It is also the key region to optimize the iron making and steel making process as a whole. In this paper, based on queuing theory method for BF-BOF region simulation, a static simulation method is presented to realize the simulation of dynamic system, WITNESS is used to simulate the M/M/1 queue model. The number of different transportation ladles has been analyzed to influence the BF-BOF region, the best ladles were obtained in order to improve production rate. The results show that the modeling method can reflect the complex system characteristics of BF-BOF region and provide the advice for system optimization.

scholarly journals A Systematic Methodology for Accurate Design-Stage Estimation of Energy Consumption for Injection Molded Parts

2010 ◽  
Author(s):  
Alexander Weissman ◽  
Arvind Ananthanarayanan ◽  
Satyandra K. Gupta ◽  
Ram D. Sriram
Keyword(s):  
Energy Consumption ◽  
Injection Molding ◽  
Product Design ◽  
Flow Simulation ◽  
Setup Time ◽  
Analytical Models ◽  
Design Stage ◽  
Limited Information ◽  
Energy Estimation ◽  
Time Required

Today’s ubiquitous use of plastics in product design and manufacturing presents significant environmental and human health challenges. Injection molding, one of the most commonly used processes for making plastic products, consumes a significant amount of energy. A methodology for accurately estimating the energy consumed to injection-mold a part would enable environmentally conscious decision making during the product design. Unfortunately, only limited information is available at the design stage. Therefore, accurately estimating energy consumption before the part has gone into production can be challenging. In this paper, we describe a methodology for energy estimation that works with the limited amount of data available during the design stage, namely the CAD model of the part, the material name, and the production requirements. The methodology uses this data to estimate the parameters of the runner system and an appropriately sized molding machine. It then uses these estimates to compute the machine setup time and the cycle time required for the injection molding operation. This is done by appropriately abstracting information available from the mold flow simulation tools and analytical models that are traditionally used during the manufacturing stage. These times are then multiplied by the power consumed by the appropriately sized machine during each stage of the molding cycle to compute the estimated energy consumption per part.

scholarly journals Evaluation of SME (Small Medium Enterprise) production system with discrete system simulation method

2018 ◽  
Vol 154 ◽  
pp. 01067
Author(s):  
Reno Dias Anggara Purba ◽  
M Iqbal Sabit ◽  
Joko Sulistio
Keyword(s):  
Production Line ◽  
Discrete System ◽  
System Simulation ◽  
Waiting Times ◽  
Minimum Cost ◽  
Poor Performance ◽  
Simulation Method ◽  
Manufacturing Companies ◽  
Production Lines ◽  
Best Response

Like manufacturing companies that have flowshop production lines, SME facing the amount of flow time and makespan. Unfulfilled production targets, buildup on some machines that result in other machines being idle, increasing waiting times across multiple machines, and poor performance of workers are a series of problems facing SME. This article uses a discrete system simulation method to analyze and evaluate SME production lines to improve performance. Simulation is an appropriate tool used when experiments are needed in order to find the best response from system components. From the results of modeling and simulation done found the root of the problem is due to accumulation that occurs in one machine and the lack of utility of the operator in producing bags. So do the experimental design with 3 scenarios on the system that have been modeled and obtained some solutions that can be offered to solve the problem. Furthermore, after the alternative selection is obtained the best scenario based on the alternative selection test is the scenario3 by adding 2 new machines and 1 new operator on the production line obtained a significant output increase compared to other scenarios of approximately 30%. While the best scenario based on the minimum cost is the scenario2 by adding 2 new operators obtained output that is not much different than the scenario3. However, it has not been able to solve a series of problems facing SME. Therefore, the results of this study to solve a series of problems faced by SME is to add facilities in the production line of 2 new machines and 1 operator (scenario3).

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