Failure prediction in electrical connector assembly: a case in automotive assembly process

2020 ◽  
Vol 40 (6) ◽  
pp. 881-893
Author(s):  
Armagan Altinisik ◽  
Utku Yildirim
Keyword(s):  
Mathematical Model ◽  
Manufacturing Systems ◽  
Model Development ◽  
Assembly Process ◽  
Critical Factors ◽  
Content Type ◽  
New Model ◽  
Electrical Connection ◽  
Electrical Connector ◽  
Process Complexity

Purpose Electrical defects cover an important part of assembly defects and strongly affect the vehicle system performance. Almost 40% of assembly defects are classified as human errors and electrical connection failures represent a significant part of them. Humans still remain a cost-effective solution for the flexible manufacturing systems with increasing product complexity. So, understanding human behaviors is still a challenging task. The purpose of this study is to define, prioritize and validate the critical factors for the complexity of electrical connector plugin process. Design/methodology/approach The critical variables were defined by the expert team members. The required number of measurements and variables were revised resulting preliminary analysis of binary logistic regression. After the revision of measurement plan, the list of critical input variables and the mathematical model were defined. The model has been validated by the fitted values of the residuals (FITS analysis). Findings To the best of the authors’ knowledge, this is one of the limited studies, which defines the critical factors for electrical connection process complexity. Female connector harness length, connector width/height/length differences, operator sense of correct connector matching and ergonomy were defined as the factors with the highest impact on the failure occurrence. The obtained regression equation strongly correlates the failure probability. Practical implications The obtained mathematical model can be used in new model development processes both for the product and assembly process design (ergonomy, accessibility and lay-out). Originality/value The obtained risk factors demonstrated a strong correlation with assembly process complexity and failure rates. The output of this study would be used as an important guide for process (assembly line ergonomy, accessibility and lay-out) and product design in new model development and assembly ramp-up phases.

An integrated mathematical model for production scheduling and preventive maintenance planning

2020 ◽  
Vol 37 (6/7) ◽  
pp. 925-937
Author(s):  
Ahmet Kolus ◽  
Ahmed El-Khalifa ◽  
Umar M. Al-Turki ◽  
Salih Osman Duffuaa
Keyword(s):  
Mathematical Model ◽  
Production Scheduling ◽  
Manufacturing Systems ◽  
Manufacturing Sector ◽  
Maintenance Planning ◽  
Due Dates ◽  
Planning And Scheduling ◽  
Content Type ◽  
Machine Availability ◽  
Simultaneous Scheduling

PurposeThe integration between production scheduling and maintenance planning is attracting the attention of planners in the manufacturing sector with the increase in global competitiveness. Researchers have developed various methodologies to optimize integrated decisions in planning and scheduling, including mathematical modeling under different conditions. This paper considers the simultaneous scheduling of production and maintenance activities with the objective of minimizing the expected total tardiness cost on a single machine (production line).Design/methodology/approachScheduling in these two types of activities, production and maintenance, are traditionally done independently, causing conflicts between the two functional areas. To eliminate or at least reduce conflicts, the scheduling of both activities can be done simultaneously with the objective of meeting due dates and maintaining maximum machine availability. In this paper, a mathematical model for an integrated problem is developed and demonstrated by an example.FindingsThe proposed integrated model shows a high potential for significant improvements in performance with respect to the cost of tardiness in delivery and machine availability. This is demonstrated by an example showing an average savings of approximately 40%.Originality/valueThis substantial saving is owed to the integration of two important decision-making processes in manufacturing systems. Although the integrated problem is complex and difficult to solve, the fact that it is savings driven makes the problem of interest to researchers and practitioners in manufacturing.

scholarly journals Development of mathematical model of Universal modeling method for centrifugal compressors calculation

2019 ◽  
Vol 140 ◽  
pp. 06002 ◽  
Author(s):  
Yuri Galerkin ◽  
Aleksandr Drozdov ◽  
Olga Solovyeva ◽  
Kirill Kabalyk
Keyword(s):  
Mathematical Model ◽  
Factor Model ◽  
Model Development ◽  
Three Dimensional ◽  
Engineering Method ◽  
Head Model ◽  
Vaneless Diffuser ◽  
New Model ◽  
Flow Gradients ◽  
Empirical Coefficients

The heart of the Universal modeling engineering method is the physical model that is based on flow visualization and measurements inside rotating impellers. The experience of its application allowed finding ways of mathematical model development. The loss of a head is a function of flow gradients along a surface and along a normal to it. Necessary calculations were 1-D in the previous models. Quasi-three-dimensional approach is applied in the new model. A new loading factor model was applied. It determines characteristics by the angle of inclination and the value of the loading factor at zero flow rate. This made it possible to abandon the choice of empirical coefficients. A new loss of head model in a vaneless diffuser based on the results of CFD calculations generalization is used. The new model allowed abandoning a number of empirical coefficients of the mathematical models. Identification of the new mathematical model by the characteristics of model tests of centrifugal compressor stages was made. The efficiency calculation accuracy was sufficient for the engineering method.

Analyses of peg‐hole jamming in automatic assembly machines

2011 ◽  
Vol 31 (4) ◽  
pp. 358-362 ◽  
Author(s):  
Ryspek Usubamatov ◽  
K.W. Leong
Keyword(s):  
Mathematical Model ◽  
Boundary Condition ◽  
Design Methodology ◽  
Manufacturing Industry ◽  
Critical Depth ◽  
Assembly Process ◽  
Automatic Assembly ◽  
Content Type ◽  
The Mathematical Model ◽  
Practical Implications

PurposeThe purpose of this paper is to investigate theoretically the process of jamming in the peg‐hole type parts and to derive a mathematical model of jamming.Design/methodology/approachThe mathematical model of the jamming of the peg‐hole type parts in assembly process was performed and its boundary conditions, which lead to jamming, defined.FindingsThe equation of the critical angles of declination for the peg, which leads to the peg‐hole jam, was derived. The boundary condition of the angles of declination and the depth of the peg insertion into the hole were defined.Research limitations/implicationsA mathematical model is developed for rigid parts with a hole and for the peg clamped in the rigid assembly mechanisms. The research has not considered flexible deformations and stiffness of the assembly mechanisms, which result in the peg's declination in the assembly process.Practical implicationsThe results are represented in the form of the peg's critical angles of declination and critical depth of insertion into the hole, which leads to jamming of the peg‐hole type parts to be assembled. On the basis of the obtained results, it is possible to formulate the tolerances of the declination angles for the assembly mechanisms, which clamp the peg‐type parts.Originality/valueThe proposed method calculating the critical angles of the peg's declination and critical depth of the peg's insertion into the hole for assembly of the peg‐hole type parts, enables one to increase the reliability of the assembly process in the manufacturing industry.

Mathematical Model of Flat Surface Machining Inaccuracies due to Elastic Strains of Technological System

2018 ◽  
pp. 1-14 ◽  
Author(s):  
I. I. Kravchenko
Keyword(s):  
Mathematical Model ◽  
Vector Field ◽  
Model Development ◽  
Technological System ◽  
Mutual Arrangement ◽  
Real Surface ◽  
Main Bearing ◽  
Flat Surfaces ◽  
Internal Surfaces ◽  
Elastic Strains

The paper considers the mathematical model development technique to build a vector field of the shape deviations when machining flat surfaces of shell parts on multi-operational machines under conditions of anisotropic rigidity in technological system (TS). The technological system has an anisotropic rigidity, as its elastic strains do not obey the accepted concepts, i.e. the rigidity towards the coordinate axes of the machine is the same, and they occur only towards the external force. The record shows that the diagrams of elastic strains of machine units are substantially different from the circumference. The issues to ensure the specified accuracy require that there should be mathematical models describing kinematic models and physical processes of mechanical machining under conditions of the specific TS. There are such models for external and internal surfaces of rotation [2,3], which are successfully implemented in practice. Flat surfaces (FS) of shell parts (SP) are both assembly and processing datum surfaces. Therefore, on them special stipulations are made regarding deviations of shape and mutual arrangement. The axes of the main bearing holes are coordinated with respect to them. The joints that ensure leak tightness and distributed load on the product part are closed on these surfaces. The paper deals with the analytical construction of the vector field F, which describes with appropriate approximation the real surface obtained as a result of modeling the process of machining flat surfaces (MFS) through face milling under conditions of anisotropic properties.

scholarly journals A mathematical model for designing a reliable cellular hybrid manufacturing-remanufacturing system considering alternative and contingency process routings

2021 ◽  
Vol 3 (3) ◽  
Author(s):  
Amirreza Hooshyar Telegraphi ◽  
Akif Asil Bulgak
Keyword(s):  
Mathematical Model ◽  
Supply Chain ◽  
Manufacturing Systems ◽  
Closed Loop ◽  
Sustainable Manufacturing ◽  
Critical Issue ◽  
Economic Benefits ◽  
Mixed Integer ◽  
Hybrid Manufacturing ◽  
Closed Loop Supply Chain

AbstractDue to the stringent awareness toward the preservation and resuscitation of natural resources and the potential economic benefits, designing sustainable manufacturing enterprises has become a critical issue in recent years. This presents different challenges in coordinating the activities inside the manufacturing systems with the entire closed-loop supply chain. In this paper, a mixed-integer mathematical model for designing a hybrid-manufacturing-remanufacturing system in a closed-loop supply chain is presented. Noteworthy, the operational planning of a cellular hybrid manufacturing-remanufacturing system is coordinated with the tactical planning of a closed-loop supply chain. To improve the flexibility and reliability in the cellular hybrid manufacturing-remanufacturing system, alternative process routings and contingency process routings are considered. The mathematical model in this paper, to the best of our knowledge, is the first integrated model in the design of hybrid cellular manufacturing systems which considers main and contingency process routings as well as reliability of the manufacturing system.

scholarly journals Ambidexterity and organizational learning: revisiting and reconnecting the literatures

2019 ◽  
Vol 26 (4) ◽  
pp. 337-351 ◽  
Author(s):  
Jacob Brix
Keyword(s):  
Organizational Learning ◽  
Absorptive Capacity ◽  
Empirical Data ◽  
Design Methodology ◽  
Organizational Ambidexterity ◽  
Exploration And Exploitation ◽  
Seminal Paper ◽  
Content Type ◽  
New Model ◽  
Multiple Levels

PurposeThe purpose of the study is to investigate how the processes of exploration and exploitation have developed in parallel in the literature of organizational ambidexterity and organizational learning, since James March published his seminal paper in 1991. The goal of the paper is to provide a synthesis of exploration and exploitation based on the two areas of literature.Design/methodology/approachThe study is conceptual and no empirical data have been used.FindingsThe study advances current understanding of exploration and exploitation by building a new model for organizational ambidexterity that takes into account multiple levels of learning, perspectives from absorptive capacity and inter-organizational learning.Originality/valueThe study’s novelty lies in the creation and discussion of a synthesis of exploration and exploitation stemming from organizational ambidexterity and organizational learning.

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