Methodology for Solving the Assembly System Reconfiguration Planning Problem

2011 ◽  
Author(s):  
A. Bryan ◽  
S. J. Hu ◽  
Y. Koren
Keyword(s):  
Product Family ◽  
Assembly System ◽  
Assembly Systems ◽  
Planning Problem ◽  
Systems Methodology ◽  
Product Families ◽  
System Reconfiguration ◽  
Reconfiguration Planning ◽  
Successive Generations ◽  
The Cost

The need to cost effectively introduce new generations of product families within ever decreasing time frames have led manufacturers to seek product development strategies with a multigenerational outlook. Co-evolution of product families and assembly systems is a methodology that leads to the simultaneous design of several generations of product families and reconfigurable assembly systems that optimize life cycle costs. Two strategies that are necessary for the implementation of the co-evolution of product families and assembly systems methodology are: (1) The concurrent design of product families and assembly systems and (2) Assembly system reconfiguration planning (ASRP). ASRP is used for the determination of the assembly system reconfiguration plans that minimize the cost of producing several generations of product families. More specifically, the objective of ASRP is to minimize the net present cost of producing successive generations of products. This paper introduces a method for finding optimum solutions to the ASRP problem. The solution methodology involves the generation of a staged network of assembly system plans for all the generations that the product family is expected to be produced. Each stage in the network represents a generation that the product family is produced, while each state within a stage represents a potential assembly system configuration. A novel algorithm for generating the states (i.e. assembly system configurations) within each generation is also introduced. A dynamic program is used to find the cost minimizing path through the network. An example is used to demonstrate the implementation of the ASRP methodology.

Assembly System Reconfiguration Planning Using Genetic Algorithm

2008 ◽  
Author(s):  
A. Bryan ◽  
S. J. Hu ◽  
Y. Koren
Keyword(s):  
Genetic Algorithm ◽  
Manufacturing Systems ◽  
Cost Effective ◽  
New Product ◽  
Assembly System ◽  
Assembly Systems ◽  
Reconfigurable Manufacturing ◽  
Product Families ◽  
System Reconfiguration ◽  
Reconfiguration Planning

Due to increased competition, the rate at which manufacturers introduce new product families to the market is increasing. However, the cost of changing manufacturing facilities to produce new product families can outweigh the benefits obtained from increased revenue. Reconfigurable Manufacturing Systems (RMSs) have been proposed as a cost effective strategy for manufacturing product families. Although methods for measuring RMS scalability and convertibility exist, there is a lack of methods for obtaining reconfiguration plans for assembly systems. This paper introduces assembly system reconfiguration planning (ASRP) as method to obtain reconfiguration plans for assembly systems. A genetic algorithm is developed for solving the ASRP problem.

Assembly System Reconfiguration Planning

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
April Bryan ◽  
S. Jack Hu ◽  
Yoram Koren
Keyword(s):  
Genetic Algorithm ◽  
Life Cycle ◽  
Life Cycle Cost ◽  
Product Family ◽  
Life Cycles ◽  
Dynamic Program ◽  
Assembly System ◽  
Assembly Systems ◽  
System Reconfiguration ◽  
Reconfiguration Planning

Decreasing product life cycles and reduced product development times have led to a need for new strategies for coping with the rapid rate of product family design changes. In this paper, assembly system reconfiguration planning (ASRP) is introduced as a method for cost effectively designing several generations of assembly systems in order to produce a product family that gradually evolves over time. In the ASRP approach, the possible assembly systems for each generation are first considered and then the sequence of assembly system configurations that minimize the life cycle cost of the process are selected. A nonlinear integer optimization formulation is developed for finding the cost minimizing assembly system reconfiguration plan using the ASRP approach. Dynamic programming and genetic algorithm are used to solve the optimization problem. Simulation results indicate that the ASRP approach leads to the minimum life cycle costs of the assembly system, and the relative cost of reconfiguration and production have an impact on the assembly system reconfiguration plan selected. Comparison of the results of the dynamic program and genetic algorithm indicate that the dynamic program is more computationally efficient for small problems and genetic algorithm is preferred for larger problems.

Concurrent Design of Product Families and Assembly Systems

2007 ◽  
Author(s):  
A. Bryan ◽  
S. J. Hu ◽  
Y. Koren
Keyword(s):  
System Design ◽  
Concurrent Engineering ◽  
Product Family ◽  
Cost Effective ◽  
Product Variety ◽  
Assembly System ◽  
Concurrent Design ◽  
Assembly Systems ◽  
Product Families ◽  
Assembly System Design

In order to gain competitive advantage, manufacturers require cost effective methods for developing a variety of products within short time periods. Product families, reconfigurable assembly systems and concurrent engineering are frequently used to achieve this desired cost effective and rapid supply of product variety. The independent development of methodologies for product family design and assembly system design has led to a sequential approach to the design of product families and assembly systems. However, the designs of product families and assembly systems are interdependent and efficiencies can be gained through their concurrent design. There are no quantitative concurrent engineering techniques that address the problem of the concurrent design of product families and assembly systems. In this paper, a non-linear integer programming formulation for the concurrent design of a product family and assembly system is introduced. The problem is solved with a genetic algorithm. An example is used to demonstrate the advantage of the concurrent approach to product family and assembly system design over the existing sequential methodology.

scholarly journals COST OPTIMIZATION OF PRODUCT FAMILIES USING SOLUTION SPACES

2020 ◽  
Vol 1 ◽  
pp. 1087-1094
Author(s):  
S. Rötzer ◽  
D. Thoma ◽  
M. Zimmermann
Keyword(s):  
Optimal Design ◽  
Economies Of Scale ◽  
Cost Optimization ◽  
Product Family ◽  
Product Families ◽  
Material Cost ◽  
The Cost

AbstractMaximizing the number of shared components does not always produce cost-optimal product families. Shared components can yield economies of scale due to reuse of components, but also increases material cost due to over dimensioning. In this paper, we present an approach to identify a cost-optimal design for product families. It consists of two steps: (1) identifying a scheme to share components in the product family and (2) finding the cost optimal design for the product family.

scholarly journals INTRODUCING A FRAMEWORK TO GENERATE AND EVALUATE THE COST EFFECTS OF PRODUCT (FAMILY) CONCEPTS

2021 ◽  
Vol 1 ◽  
pp. 1907-1916
Author(s):  
Kai G. Mertens ◽  
Mark Schmidt ◽  
Tugba Yildiz ◽  
Matthias Meyer
Keyword(s):  
Selection Criteria ◽  
Product Family ◽  
New Product ◽  
Economic Consequences ◽  
Concept Generation ◽  
Product Families ◽  
Product Concept ◽  
Virtual Testbed ◽  
The Cost ◽  
Product Concepts

AbstractProduct concept generation and evaluation are critical for the success of new product developments (NPD) because managers need to select the most profitable product concepts. However, current approaches can be restricted to single products and do not cover product families' effects. Similarly, they do not necessarily capture all requirements and usually lack extensive cost analyses. Thus, this paper proposes a framework supporting product concept generation and evaluation by providing an accessible conceptualization to overcome the limitations. Using the so-called Extended Axiomatic Design (EAD) supports designers and managers to configure the requirements across product concepts' various domains while concurrently evaluating their economic consequences. The study applies the framework on a simplified case of a bottle manufacturer to conceptualize four product concepts. The case illustrates how the EAD can be used as a virtual testbed to generate and evaluate new product concepts. Finally, designers and managers can make more informed decisions about product concepts by considering their economic and engineering selection criteria to select the most profitable NPD project configuration.

scholarly journals Design of Personalized Devices—The Tradeoff between Individual Value and Personalization Workload

2020 ◽  
Vol 11 (1) ◽  
pp. 241
Author(s):  
Juliane Kuhl ◽  
Andreas Ding ◽  
Ngoc Tuan Ngo ◽  
Andres Braschkat ◽  
Jens Fiehler ◽  
...  
Keyword(s):  
Customer Value ◽  
Early Stage ◽  
Treatment Success ◽  
Product Family ◽  
Flow Diverter ◽  
New Method ◽  
Product Families ◽  
Wide Range ◽  
The Individual ◽  
Individual Value

Personalized medical devices adapted to the anatomy of the individual promise greater treatment success for patients, thus increasing the individual value of the product. In order to cater to individual adaptations, however, medical device companies need to be able to handle a wide range of internal processes and components. These are here referred to collectively as the personalization workload. Consequently, support is required in order to evaluate how best to target product personalization. Since the approaches presented in the literature are not able to sufficiently meet this demand, this paper introduces a new method that can be used to define an appropriate variety level for a product family taking into account standardized, variant, and personalized attributes. The new method enables the identification and evaluation of personalizable attributes within an existing product family. The method is based on established steps and tools from the field of variant-oriented product design, and is applied using a flow diverter—an implant for the treatment of aneurysm diseases—as an example product. The personalization relevance and adaptation workload for the product characteristics that constitute the differentiating product properties were analyzed and compared in order to determine a tradeoff between customer value and personalization workload. This will consequently help companies to employ targeted, deliberate personalization when designing their product families by enabling them to factor variety-induced complexity and customer value into their thinking at an early stage, thus allowing them to critically evaluate a personalization project.

Agile Montage*/Agile assembly – Assembly planning and assembly system as integral elements of factory planning

2019 ◽  
Vol 109 (09) ◽  
pp. 622-627
Author(s):  
P. Burggräf ◽  
M. Dannapfel ◽  
T. Adlon ◽  
A. Riegauf ◽  
K. Müller ◽  
...  
Keyword(s):  
Product Development ◽  
Assembly Planning ◽  
Assembly System ◽  
Agile Methods ◽  
Assembly Systems ◽  
Manufacturing Companies ◽  
Economic Optimization ◽  
Customer Needs ◽  
Factory Planning ◽  
Solution Approach

Produzierende Unternehmen intensivieren aufgrund zunehmend volatiler Kundenbedürfnisse die Anwendung agiler Produktentwicklungsansätze. Ziel des Beitrags ist die Einführung eines Konzepts zur Befähigung dieser dynamischen Produktentwicklung in der Montage. Der integrative Lösungsansatz basiert auf der wirtschaftlichen Optimierung des Agilitätsgrades von Montagesystemen sowie dem selektiven Einsatz agiler Methoden in der traditionell plangetriebenen Montageplanung als Teil der Fabrikplanung.   To meet more volatile customer needs, manufacturing companies increasingly make use of agile product development approaches. This article aims to introduce a concept to enable for dynamic product development in assembly. This integrative solution approach is based on the economic optimization of the degree of agility of assembly systems and on the selective use of agile methods in traditional, plan-driven assembly planning as part of factory planning.

ASSESSMENT OF THE RELATIONSHIP BETWEEN THE INNOVATION LEVEL AND THE PROCESS OF DISTRIBUTING GENERATIONS OF AN INDUSTRIAL PRODUCT

2021 ◽  
Vol 7 (1) ◽  
pp. 146-162
Author(s):  
Albert E. Brand ◽  
Vladimir N. KUTRUNOV ◽  
Yuriy E. YAKUBOVSKIY
Keyword(s):  
Research Literature ◽  
Industrial Product ◽  
Next Generation ◽  
Rate Of Spread ◽  
Modeling And Forecasting ◽  
Game Console ◽  
Mathematical Formalization ◽  
Successive Generations ◽  
The Cost ◽  
The Relationship

This article assesses the relationship between the level of innovation and the process of spreading generations of an industrial product among the consumers on the example of generations of a stationary game console from Sony. This work follows the scientific direction of modeling and forecasting the spread of innovations; it contains the results of the analysis of the dynamics in the change of successive generations of an industrial product. The relevance of the research topic lies in the increased competition between companies engaged in innovative activities. This results in the need to determine the reasonable directions of technical, technological, and market development of the developed innovations in the form of new and improved products. This study uses the mathematical model by F. Bass, supplemented by the provisions of T. Islam and N. Meade on the variability of consumer behavior of different generations. The conducted review of research literature has revealed an insufficient elaboration of the issue of a qualitative and quantitative assessment of the relationship between the rate of spread of generations and the changes made to them. The authors draw hypotheses about the independence of the market potentials of successive generations from each other and the dependence of the level of innovativeness of the next generation of industrial products on technological, consumer and marketing changes. As a set of changes, this article proposes parameters of the purchase price and the cost of operating each generation. The authors have tested the hypothesis on statistical data of generational sales for 1994-2019 using correlation analysis. The results have shown the absence of the influence of the market potentials of successive generations from each other, as well as the presence of a connection and its strength between the level of innovativeness of the next generation and the changes made in the generations. The data obtained can be used for further mathematical formalization of the influence of the level of innovativeness of generations on the process of their distribution.

Algorithm-Based Support for the Redesign of Product Variants

2020 ◽  
Author(s):  
Julian Redeker ◽  
Philipp Gebhardt ◽  
Thomas Vietor
Keyword(s):  
Economies Of Scale ◽  
Graph Matching ◽  
Product Family ◽  
Automated Analysis ◽  
Production Volume ◽  
Scale Production ◽  
Product Families ◽  
First Case ◽  
Subtractive Manufacturing ◽  
Definition Of

Abstract Incremental Manufacturing is a novel manufacturing approach where product variants are manufactured based on a finalization of pre-produced parts through additive and subtractive manufacturing processes. This approach allows a multi-scale production with the possibility to scale product variants as well as the production volume. In order to ensure high economic efficiency of the manufacturing concept, there is a need for pre-produced parts that come as close as possible to the final variant geometries to ensure that only variant-specific features need to be added by additive or subtractive manufacturing steps. Furthermore, to ensure high economies of scale, a high degree of commonality should be ensured for the pre-produced parts manufactured in mass production. In this context, a graph-based method is developed that enables an automated analysis of product families, based on physical and functional attributes, for standardization potentials. The method thus provides support for the strategic definition of pre-produced parts and is embedded in an overall approach for the redesign of products for Incremental Manufacturing. For the demonstration of the approach, which is based on 3D Shape and Graph Matching methods, a first case study is carried out using a guiding bush product family as an example.

scholarly journals A Framework for Development Architecture for Modular Products: Cross-Domain Variety Management Perspective

2019 ◽  
Vol 1 (1) ◽  
pp. 2921-2930 ◽  
Author(s):  
Kwansuk Oh ◽  
Jong Wook Lim ◽  
Seongwon Cho ◽  
Junyeol Ryu ◽  
Yoo S. Hong
Keyword(s):  
Product Family ◽  
Development Stage ◽  
Real Field ◽  
Reference Architecture ◽  
Product Families ◽  
Cross Domain ◽  
Architecture Framework ◽  
Management Perspective ◽  
Domain Mapping ◽  
The Cross

AbstractVariety management is a cross-domain issue in product family design. In the real field, the relationships across the domains are so complex for most of the existing product families that they cannot be easily identified without proper reference architecture. This reference architecture should provide the cross- domain mapping mechanisms in an explicit manner and be able to identify the proper units for management. From this perspective of cross-domain framework, this paper introduces development architecture (DA) to describe the relationships between elements in market, design, and production domains and to give insights for the cross-domain variety management in the product development stage. DA has three parts: (1) the arrangement of elements in each domain, (2) the mapping between elements, and (3) the identification of management sets and key interfaces which are the proper units for variety management. The proposed development architecture framework is applied to the case of front chassis family of modules of an automobile.

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