A methodology for the reconfiguration process in manufacturing systems

2014 ◽  
Vol 25 (6) ◽  
pp. 891-915 ◽  
Author(s):  
Ibrahim H. Garbie
Keyword(s):  
System Design ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Production Systems ◽  
Systems Design ◽  
Production Volume ◽  
Plant Layout ◽  
Content Type ◽  
Handling System

Purpose – The purpose of this paper is to propose a “Reconfiguration Methodology” in manufacturing systems that they can become more economically sustainable and can operate efficiency and effectively. This methodology will allow customized flexibility and capacity not only in producing a variety of products (parts) and with changing market demands, but also in changing and reengineering the system itself. Design/methodology/approach – Reconfigurable manufacturing system (RMS) is a philosophy or strategy which was introduced during the last decade to achieve agility in manufacturing systems. Until now, the RMS philosophy was based changing activities such routing, planning, programming of machines, controlling, scheduling, and physical layout or materials handling system. But the RMS concept can be based on the needed reconfiguration level (NRL), operational status of production systems, and new circumstances (NC). The NRL measure is based on the agility level of the manufacturing systems which is based on technology, people, management, and manufacturing strategies. The components of the manufacturing system design (MSD) consist of production system design, plant layout system, and material handling system. Operational status of production systems includes machine capability (flexibility) and capacity (reliability), production volume or demand, and material handling equipment in addition to the plant layout. The NC are also consisting of new product, developing the existing ones, and changing in demand. Findings – Reconfiguration manufacturing systems from one period to another period is highly desired and is considered as a novel manufacturing philosophy and/or strategy toward creating new sustainable manufacturing systems. A new reconfiguration methodology for the manufacturing systems will be analyzed and proposed. Two Case studies will be introduced. Originality/value – The suggestion of a new methodology of reconfiguration including the NRL (configurability index) and the operational status of manufacturing systems with respect to any circumstance is highly considered. The reconfiguration methodology also provides a framework for sustainability in the manufacturing area which mainly focussed on manufacturing systems design.

A model for reliability analysis of multi-state manufacturing systems

2014 ◽  
Vol 31 (8) ◽  
pp. 938-949 ◽  
Author(s):  
Seyed Ahmad Niknam ◽  
Rapinder Sawhney
Keyword(s):  
Reliability Analysis ◽  
System Reliability ◽  
Design Methodology ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Production Systems ◽  
Case Scenario ◽  
Worst Case ◽  
Content Type ◽  
Proposed Model

Purpose – The purpose of this paper is to investigate the reliability analysis of a multi-state manufacturing system with different performance levels. In, fact, reliability assessment of manufacturing systems gives a reasonable demonstration of system performance. Design/methodology/approach – This research utilizes a multi-state system reliability analysis to develop a new metric for evaluating production systems. Findings – The proposed model provides a sensible measure to assess the system situation against the best-case scenario of a production line. Originality/value – The proposed model incorporates not only failures that stop production but also deals with partial failures where the system continues to operate at reduced performance rates. The analyses are represented in a best-case vs worst-case situation. Each of these cases provides insight for managers with respect to planning operation and maintenance activities.

Setting-up material handling network in manufacturing systems using graph theory

2018 ◽  
Vol 15 (1) ◽  
pp. 58-67 ◽  
Author(s):  
Shashank Gupta ◽  
Piyush Gupta
Keyword(s):  
Spanning Tree ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Distance Matrix ◽  
Shop Floor ◽  
Minimal Spanning Tree ◽  
Content Type ◽  
Minimal Network ◽  
Capital Costs

Purpose Material handling (MH) is an important facility in any manufacturing system. It facilitates the transport of in-process material from one workstation (WS) to another. MH devices do imply incurring capital costs and, therefore, minimizing their deployment without compromising on smooth material flow will ensure savings in addition to the optimal use of productive shop floor space and, avoid space cluttering. The purpose of this paper is to evaluate the minimal network that connects all the WSs, therefore ensuring economic and safe manufacturing operations. Design/methodology/approach Graph theoretical approach and Prim’s algorithm for minimal spanning tree is used to evaluate the minimal span of the MH devices. The algorithm is initialized by translating the graph of WSs into a distance matrix to evaluate the minimal MH network. Findings The minimal length of the MH devices is evaluated for a typical case study. Research limitations/implications The step-by step methodology explained in the manuscript acts as a good guide for practicing operational managers. The shortcoming of the methodology is that, it presumes the use of modular MH devices that will need to be reconfigured based on dynamic changes to the manufacturing system. Practical implications The methodology is explained in detail to enable the practicing managers to use it for designing their MH networks in any manufacturing system. Originality/value There is no evidence to indicate the use of minimal spanning tree algorithm for design of MH networks in a manufacturing system. This paper attempts to fill this gap.

scholarly journals Perancangan Model Stacker Crane Flexible Manufacturing System untuk Pembelajaran di Institusi Pendidikan

2021 ◽  
Vol 10 (1) ◽  
pp. 45-54
Author(s):  
Ari Setiawan
Keyword(s):  
Flexible Manufacturing ◽  
Material Handling ◽  
Manufacturing System ◽  
Flexible Manufacturing System ◽  
Production Systems ◽  
Educational Institution ◽  
Transportation System ◽  
Material Handling System ◽  
Handling System ◽  
Axis Direction

Flexible Manufacturing System (FMS) is one of the modern production systems that support the implementation of Industry 4.0. An educational institution plans to build an FMS model for learning the modern production systems. The FMS is a manufacturing system consisting of a set of automatic workstations connected to a material handling system where all activities are controlled by a computer system. The material handling system consists of a material storage system and a transportation system, one example of a transportation system is the stacker crane. In this research, the stacker crane model has been built which consists of three main components, which are the bottom frame, the mast, and the carriage. This component is equipped with stepper motors, leadscrews that are controlled by the micro controller and an application on Android. The stacker crane model is tested to retrieve and deliver the stereofoam material model to the destination which is controlled by the user using an application on Android. The characteristics of the stacker crane model can move the workpiece with a maximum error of 2 mm in the positive x-axis direction, 2 mm in the negative x-axis movement, up to 2 mm positive y-axis, downward at negative y-axis direction 2 mm.  

Production models of multiple products using a single machine under quality screening and reworking policies

2019 ◽  
Vol 14 (1) ◽  
pp. 232-259 ◽  
Author(s):  
Ata Allah Taleizadeh ◽  
Mahshid Yadegari ◽  
Shib Sankar Sana
Keyword(s):  
Single Machine ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Production Costs ◽  
High Tech ◽  
Screening Process ◽  
Automatic Production ◽  
Content Type ◽  
Economic Production ◽  
Imperfect Items

Purpose The purpose of this study is to formulate two multi-product single-machine economic production quantity (EPQ) models by considering imperfect products. Two policies are assumed to deal with imperfect products: selling them at discount and applying a reworking process. Design/methodology/approach A screening process is used to identify imperfect items during and after production. Selling the imperfect items at a discount is examined in the first model and the reworking policy in the second model. In both models, demand during the production process is satisfied only by perfect items. Data collected from a case company are used to illustrate the performance of the two models. Moreover, a sensitivity analysis is carried out by varying the most important parameters of the models. Findings The case study in this research is used to demonstrate the applicability of the proposed models, i.e. the EPQ model with salvaging and reworking imperfect items. The models are applied to a high-tech un-plasticized polyvinyl chloride (UPVC) doors and windows manufacturer that produces different types of doors and windows. ROGAWIN Co. is a privately owned company that started in 2001 with fully automatic production lines. Finally, the results of applying the different ways of handling the imperfect items are discussed, along with managerial insights. Originality/value In real-world production systems, manufacturing imperfect products is unavoidable. That is why, it is important to make a proper decision about imperfect products to reduce overall production costs. Recently, applying a reworking strategy has gained the most interest when it comes to handling this problem. The principal idea of this research is to maximize the total profit of manufacturing systems by optimizing the period length under some capacity constraints. The proposed models were applied to a company of manufacturing UPVC doors and windows.

scholarly journals Minimization of acquisition and operational costs in horizontal material handling system design

1999 ◽  
Vol 31 (7) ◽  
pp. 679-693 ◽  
Author(s):  
J.W. HERRMANN ◽  
G. IOANNOU ◽  
I. MINIS ◽  
J.M. PROTH
Keyword(s):  
System Design ◽  
Material Handling ◽  
Material Handling System ◽  
Handling System ◽  
Operational Costs

scholarly journals The flexibility of industrial additive manufacturing systems

2018 ◽  
Vol 38 (12) ◽  
pp. 2313-2343 ◽  
Author(s):  
Daniel R. Eyers ◽  
Andrew T. Potter ◽  
Jonathan Gosling ◽  
Mohamed M. Naim
Keyword(s):  
Additive Manufacturing ◽  
Operations Management ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Detailed Examination ◽  
Multiple Sources ◽  
Content Type ◽  
Commercial Practice ◽  
Systems Perspective ◽  
Manufacturing Operations

Purpose Flexibility is a fundamental performance objective for manufacturing operations, allowing them to respond to changing requirements in uncertain and competitive global markets. Additive manufacturing machines are often described as “flexible,” but there is no detailed understanding of such flexibility in an operations management context. The purpose of this paper is to examine flexibility from a manufacturing systems perspective, demonstrating the different competencies that can be achieved and the factors that can inhibit these in commercial practice. Design/methodology/approach This study extends existing flexibility theory in the context of an industrial additive manufacturing system through an investigation of 12 case studies, covering a range of sectors, product volumes, and technologies. Drawing upon multiple sources, this research takes a manufacturing systems perspective that recognizes the multitude of different resources that, together with individual industrial additive manufacturing machines, contribute to the satisfaction of demand. Findings The results show that the manufacturing system can achieve seven distinct internal flexibility competencies. This ability was shown to enable six out of seven external flexibility capabilities identified in the literature. Through a categorical assessment the extent to which each competency can be achieved is identified, supported by a detailed explanation of the enablers and inhibitors of flexibility for industrial additive manufacturing systems. Originality/value Additive manufacturing is widely expected to make an important contribution to future manufacturing, yet relevant management research is scant and the flexibility term is often ambiguously used. This research contributes the first detailed examination of flexibility for industrial additive manufacturing systems.

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