Functional Synthesis of Manufacturing Systems Using Co-Platforming to Minimize Cost of Machines and System Changes

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Mohamed Abbas ◽  
Hoda ElMaraghy
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
System Level ◽  
Mixed Integer ◽  
Industrial Case Study ◽  
Product Families ◽  
Total Capital ◽  
Total Investment ◽  
The Cost

Manufacturing systems need to be designed to cope with products’ variety and frequent changes in market requirements. Switching between product families in different production periods often requires reconfiguration of the manufacturing system with associated additional cost and interruption of production. A mixed integer linear programing (MILP) model is proposed to synthesize manufacturing systems based on the co-platforming methodology taking into consideration machine level changes including addition or removal of machine axes and changing setup as well as system level changes such as addition or removal of machines. The objective is to minimize the cost of change needed for transition between product families and production periods. An illustrative numerical example and an industrial case study from tier I automotive supplier are used for verification. Finally, the effect of maintaining a common core of machines in the manufacturing system on the total capital and change cost is investigated. It has been demonstrated that synthesizing manufacturing systems designed using the co-platforming strategy reduces the total investment cost including initial cost of machines and cost of reconfiguration.

scholarly journals Automation possibilities in a low rotation warehouse of a Belgian manufacturing plant. A case study

2019 ◽  
Vol 290 ◽  
pp. 02006
Author(s):  
Anca Mocan ◽  
Anca Draghici
Keyword(s):  
Management Team ◽  
Management Teams ◽  
Manufacturing Plant ◽  
Health Statistics ◽  
Doing Business ◽  
Investment Cost ◽  
Total Investment ◽  
The Cost ◽  
Best Fit

Lack of appropriate warehouse ergonomics is one of the leading causes of worker injuries in industry environments. As management teams are trying to reduce the cost of doing business, they look to worker’s health statistics and realize they must improve their way of operating. The paper presents a warehouse analysis done at the request of the management team of a Belgian manufacturing plant. The factory’s warehouse was audited with focus on Kanban bin weight, storage rack height and rack width to assess the ergonomic strain it causes on workers. The paper then presents possible automation options in order to find the best fit to reduce ergonomic impact, while also optimizing the total investment cost.

Energy Consumption Reduction for Sustainable Manufacturing Systems Considering Machines With Multiple-Power States

2011 ◽  
Author(s):  
Zeyi Sun ◽  
Stephan Biller ◽  
Fangming Gu ◽  
Lin Li
Keyword(s):  
Energy Efficiency ◽  
Manufacturing Systems ◽  
Large Scale ◽  
Manufacturing System ◽  
Production Systems ◽  
Sustainable Manufacturing ◽  
System Level ◽  
Model Estimate ◽  
Improve Energy Efficiency ◽  
Multiple Power

Due to rapid consumption of world’s fossil fuel resources and impracticality of large-scale application and production of renewable energy, the significance of energy efficiency improvement of current available energy modes has been widely realized by both industry and academia. A great deal of research has been implemented to identify, model, estimate, and optimize energy efficiency of single-machine manufacturing system [1–5], but very little work has been done towards achieving the optimal energy efficiency for a typical manufacturing system with multiple machines. In this paper, we analyze the opportunity of energy saving on the system level and propose a new approach to improve energy efficiency for sustainable production systems considering the fact that more and more modern machines have multiple power states. Numerical case based on simulation model of an automotive assembly line is used to illustrate the effectiveness of the proposed approach.

Performance Metrics for Product Flow Configuration in a Reconfigurable Manufacturing System (RMS)

2019 ◽  
Author(s):  
Prince Pal Singh ◽  
Jatinder Madan ◽  
Harwinder Singh
Keyword(s):  
Manufacturing System ◽  
Performance Metrics ◽  
Reconfigurable Manufacturing ◽  
Reconfigurable Manufacturing System ◽  
Industrial Case Study ◽  
Flow Configuration ◽  
Product Flow ◽  
Performance Metric ◽  
Hierarchy Process

Abstract We propose a systematic approach for product flow configuration selection for reconfigurable manufacturing system (RMS) that considers ten industrially relevant most important factors. The paper first defines performance metrics for the identified factors. A composite performance metric (CPM) has been proposed, which accounts for all ten-performance metrics to assess the performance of RMS with the help of a combined score. The methodology of developing CPM applies analytical hierarchy process (AHP) approach where weightage to each of the performance metric is also considered. To showcase the usefulness and feasibility of the CPM, it has been applied in an industrial environment with the help of an industrial case study. Both the CPM and other metric scores were found to be quite useful to identify a suitable configuration out of the available alternatives.

An integrated fuzzy-based multi-criteria decision-making approach for the selection of an effective manufacturing system

2018 ◽  
Vol 25 (1) ◽  
pp. 280-296 ◽  
Author(s):  
Ram Prakash ◽  
Sandeep Singhal ◽  
Ashish Agarwal
Keyword(s):  
Decision Making ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Research Work ◽  
Sustainable Growth ◽  
Multi Criteria Decision Making ◽  
Content Type ◽  
Manufacturing Company ◽  
Selection Of

Purpose The research paper presents analysis and prioritization of barriers influencing the improvement in the effectiveness of manufacturing system. The purpose of this paper is to develop an integrated fuzzy-based multi-criteria decision-making (F-MCDM) framework to assist management of the case company in the selection of most effective manufacturing system. The framework helps in prioritizing the manufacturing systems on the basis of their effectiveness affected by the barriers. Design/methodology/approach In this paper, on the basis of experts’ opinion, five barriers have been identified in a brain-storming session. The problem of prioritization of manufacturing system is a multi-criteria decision-making (MCDM) problem and hence is solved by using the F-MCDM approach using dominance matrix. Findings Manufacturing systems’ effectiveness for Indian industries is influenced by barriers. The prioritization of manufacturing systems depends on qualitative factor decision-making criteria. Among the manufacturing systems, leagile manufacturing system is given the highest priority followed by lean manufacturing system, agile manufacturing system, flexible manufacturing system and cellular manufacturing system. Research limitations/implications The selection of an appropriate manufacturing system plays a vital role for sustainable growth of the manufacturing company. In the present work, barriers which influence the effectiveness of manufacturing system have been identified. On the basis of degree of influence of barriers on the effectiveness of the manufacturing system, five alternative manufacturing systems are prioritized. The framework will help the management of the case company to take reasonable decision for the adoption of the appropriate manufacturing system. Practical implications The results of the research work are very useful for the manufacturing companies interested in analyzing the alternative manufacturing systems on the basis of their effectiveness and their sensitivity toward various barriers. The management of Indian manufacturing company will take decision to adopt a manufacturing system whose effectiveness is least sensitive toward barriers. Effectiveness of such manufacturing system will improve with time without having retardation due to barriers. With improved effectiveness of the manufacturing system, the manufacturing company would be able to survive with global competition. The result of the present work is based on the inputs from the case company and may vary for the other manufacturing company. In the present work, only five alternative manufacturing systems and five barriers have been considered. To obtain the better result, MCDM approach with more number of alternative manufacturing systems and barriers might be considered. Originality/value The research work is based on the fuzzy analytic hierarchy process framework and on the case study conducted by the authors. The work carried out is original in nature and based on the real-life case study.

Comparison of Different Scenarios Using Computer Simulation to Improve the Manufacturing System Productivity: Case Study

2013 ◽  
Vol 845 ◽  
pp. 770-774 ◽  
Author(s):  
Seyed Mojib Zahraee ◽  
Milad Hatami ◽  
J.M. Rohani ◽  
H. Mihanzadeh ◽  
Mohammadreza Haghighi
Keyword(s):  
Computer Simulation ◽  
Production Line ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Manufacturing System ◽  
Waiting Times ◽  
Manufacturing Companies ◽  
System Productivity ◽  
High Resource

In the manufacturing industry, managers and engineers are seeking to find methods in order to eliminate the common problems in manufacturing systems such as bottlenecks and waiting times. This is because that all of these kinds of problems impose extra cost to the companies. In addition, manufacturing companies are striving to sustain their competitiveness by improving productivity, efficiency and quality of manufacturing industry for instance high throughput and high resource utilization. The paper concentrates on the application of computer simulation to analysis manufacturing system in order to improve the productivity. Therefore, this study introduces a color manufacturing line as a case study and the basic application of arena 13.9 software. The goal of this paper is to improve the productivity and efficiency of the production line by using computer simulation. To achieve this goal, first the basic model of the current situation of production line was simulated. Second, three different alternatives were simulated and modified to find the best scenario based on the maximum productivity and minimum total cost.

Modelling and Design of Closed-Loop Manufacturing Systems

2013 ◽  
Vol 378 ◽  
pp. 367-374 ◽  
Author(s):  
Andrey A. Kutin ◽  
Mikhail Turkin
Keyword(s):  
Analytical Method ◽  
Flexible Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Flexible Manufacturing System ◽  
Closed Loop ◽  
Production Systems ◽  
Finite Buffers ◽  
Unreliable Machines

This paper introduces an analytical method for evaluating the performance of closed loop manufacturing systems with unreliable machines and finite buffers. The method involves transforming an arbitrary loop into one without thresholds and then evaluating the transformed loop using a new set of decomposition equations. It is more accurate than existing methods and is effective for a wider range of cases. The convergence reliability, and speed of the method are also discussed. In addition, observations are made on the behavior of closed loop production systems under various conditions. Finally, the method is used in a case study to design a flexible manufacturing system for production of aerospace parts.

scholarly journals Avaliação de Desempenho do Processo de Manufatura do Café

2015 ◽  
Author(s):  
L. Morais ◽  
R. Massa ◽  
E. Tavares ◽  
E. Andrade
Keyword(s):  
Manufacturing Firms ◽  
Production Cycle ◽  
Advanced Manufacturing ◽  
Industrial Case Study ◽  
Advanced Manufacturing Technologies ◽  
Increase Productivity ◽  
Reducing Costs ◽  
Manufacturing Technologies ◽  
The Cost

Globalization and advanced manufacturing technologies have forced manufacturing firms to increase productivity while reducing costs. At the same time, customers are increasingly demanding better products considering tangi- ble (e.g., smell, color, taste) and intangible (e.g., mark, fair treading, and envi- ronmental responsability) attributes. Currently, Brazil consolidates a position as the largest producer and exporter of coffee, accounting for 30% of the inter- national coffee market. This paper presents a stochastic model for performance evaluation and planning of coffee manufacturing process aiming at reducing the cost and time of the production cycle. An industrial case study shows the practical usability of the proposed models and techniques.

A Customer-Driven Approach to One-of-a-Kind Product Design

2007 ◽  
Author(s):  
Huijun Song ◽  
Deyi Xue ◽  
Yiliu Tu
Keyword(s):  
Product Design ◽  
Technical Level ◽  
Customer Requirements ◽  
Industrial Case Study ◽  
Product Families ◽  
Decomposition Approach ◽  
Function Decomposition ◽  
Optimal Product Design ◽  
Different Levels

This research addresses the issues to identify the optimal product design based on individual customer requirements in one-of-a-kind production (OKP). In this work, a function decomposition approach is introduced for modeling the variations of design functions, configurations, and parameters in generic OKP product families. Requirements of individual customers are modeled at two different levels: function level and technical level. Customized OKP products are created from the generic OKP product families based on customer requirements. The optimal product design is identified from feasible design candidates through optimization. An industrial case study is given to demonstrate the effectiveness of the introduced approach.

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