A Desktop Application for Sustainability Performance Assessment of Composed Unit-Based Manufacturing Systems

2017 ◽  
Author(s):  
Matteo M. Smullin ◽  
Zahra Iman ◽  
Karl R. Haapala
Keyword(s):  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Sustainability Assessment ◽  
Information Modeling ◽  
Process Models ◽  
System Level ◽  
Manufacturing Processes ◽  
Modeling Framework ◽  
Process Flow ◽  
Desktop Application

Life cycle assessment software packages such as SimaPro, GaBi, and Umberto have become well-established tools for conducting environmental impact analysis. However, applications for broader sustainability assessment are limited. Recent research has developed an information modeling framework to compose models of unit manufacturing processes for sustainability assessment and has led to the definition of unit manufacturing process information modeling concepts. An engineer can use the framework to conduct manufacturing system-level sustainability assessments by composing models of unit manufacturing processes. Assessment results can aid engineers in selecting the superior manufacturing process flow for a given product. To demonstrate usefulness of the information framework, a prototype desktop application has been developed. The application was implemented in Windows Project Foundation (WPF) using C# as the coding language to create a graphical user interface. Mathworks MATLAB serves as the calculation engine. Unit manufacturing process models follow the framework and are read by the application, which produces a sustainability assessment for the manufacturing process flow. A manufacturing process flow for an automobile-like metal product acts is used to demonstrate the software application.

UMP Builder: Capturing and Exchanging Manufacturing Models for Sustainability

2018 ◽  
Author(s):  
William Z. Bernstein ◽  
David Lechevalier ◽  
Don Libes
Keyword(s):  
Environmental Analysis ◽  
Environmental Sustainability ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Information Model ◽  
Process Models ◽  
Data Driven ◽  
Manufacturing Processes ◽  
Initial Layer ◽  
Early Use

Targeting the improvement of environmental analysis of manufacturing systems, ASTM 3012-16 provides guidelines for formally characterizing manufacturing processes. However, the difficulty that has arisen in the early use of the standard illustrates the need for intuitive tools for helping modeling experts to conform to the specified information model. In response, we present the Unit Manufacturing Process (UMP) Builder, a browser-based tool integrating symbolic mathematical and guided textual inputs, helping to consistently record and exchange manufacturing process models for environmental sustainability. The tool provides an initial layer of governance and verification with respect to the conformance to ASTM 3012-16. In this paper, we (1) detail the requirements with developing such a tool, (2) propose an improved schema to represent UMP models accommodating data-driven techniques, and (3) demonstrate the tool using a contributed model from an open challenge for modeling manufacturing processes.

Towards a Standards-Based Methodology for Extending Manufacturing Process Models for Sustainability Assessment

2018 ◽  
Author(s):  
Arvind Shankar Raman ◽  
Karl R. Haapala ◽  
K. C. Morris
Keyword(s):  
Manufacturing Process ◽  
Sustainability Assessment ◽  
Building Blocks ◽  
Cnc Machining ◽  
Process Models ◽  
Machining Processes ◽  
Complex Processes ◽  
Information Models ◽  
Computer Numerically Controlled ◽  
Application Specific

Over the past decade, several efforts have characterized manufacturing processes from a sustainability perspective. In addition, frameworks, methodologies, and standards development for characterizing and linking unit manufacturing process (UMP) models to construct manufacturing system models for supporting sustainability assessment have been pursued. In this paper these research efforts are first briefly reviewed, and then, ASTM standards derived from this work are described and built upon. The contribution of this research is to demonstrate how more formalization of these prior efforts will facilitate systematic reuse of developed models by encapsulating different aspects of complex processes into reusable building blocks. The research proposes a methodology to define template UMP information models, which can further be abstracted and customized to represent an application-specific, upgraded manufacturing process. The methodology developed is based on the ASTM standards of characterizing manufacturing process for sustainability characterization. The approach is demonstrated for analyzing manual and computer numerically controlled (CNC) machining processes.

scholarly journals A Similarity-Based Hierarchical Clustering Method for Manufacturing Process Models

2019 ◽  
Vol 11 (9) ◽  
pp. 2560
Author(s):  
Hyun Ahn ◽  
Tai-Woo Chang
Keyword(s):  
Hierarchical Clustering ◽  
Operations Management ◽  
Manufacturing Process ◽  
Manufacturing Industry ◽  
Clustering Algorithm ◽  
Process Models ◽  
Manufacturing Processes ◽  
Manufacturing Companies ◽  
Agglomerative Clustering ◽  
Clustering Method

As the adoption of information technologies increases in the manufacturing industry, manufacturing companies should efficiently manage their data and manufacturing processes in order to enhance their manufacturing competency. Because smart factories acquire processing data from connected machines, the business process management (BPM) approach can enrich the capability of manufacturing operations management. Manufacturing companies could benefit from the well-defined methodologies and process-centric engineering practices of this BPM approach for optimizing their manufacturing processes. Based on the approach, this paper proposes a similarity-based hierarchical clustering method for manufacturing processes. To this end, first we describe process modeling based on the BPM-compliant standard so that the manufacturing processes can be controlled by BPM systems. Second, we present similarity measures for manufacturing process models that serve as a criterion for the hierarchical clustering. Then, we formulate the hierarchical clustering problem and describe an agglomerative clustering algorithm using the measured similarities. Our contribution is considered on the assumption that a manufacturing company adopts the BPM approach and it operates various manufacturing processes. We expect that our method enables manufacturing companies to design and manage a vast amount of manufacturing processes at a coarser level, and it also can be applied to various process (re)engineering problems.

Sustainability Assessment Methodology for Concrete Manufacturing Process: A Fuzzy Inference System Approach

2013 ◽  
Vol 845 ◽  
pp. 814-818 ◽  
Author(s):  
Pouyan Rezvan ◽  
Amir Hossein Azadnia ◽  
Mohd Yusof Noordin ◽  
Seyed Navid Seyedi
Keyword(s):  
Portland Cement ◽  
Fuzzy Inference System ◽  
Manufacturing Process ◽  
Sustainability Assessment ◽  
Fuzzy Inference ◽  
Hybrid Approach ◽  
Three Dimensions ◽  
Manufacturing Processes ◽  
Slag Cement ◽  
Inference System

Sustainability assessment of concrete manufacturing processes has recently received great attention among scholars and practitioners. While most of the studies on sustainability assessment of concrete manufacturing processes focus on economic and environmental issues, those which consider all three dimensions of sustainability (social, economic, and environmental) simultaneously are rather limited. In this study, a hybrid approach of fuzzy inference system and analytical hierarchy process (AHP) is proposed in order to evaluate the sustainability level of concrete manufacturing processes based on Life Cycle Assessment (LCA) principals. AHP is applied to weight the selected sustainability elements and sub elements. Afterward, fuzzy inference system is used to evaluate the sustainability level of concrete manufacturing processes. The practicality and applicability of the proposed approach are examined by conducting sustainability assessments of four different concrete manufacturing processes: (1) 100% of Portland cement (2) 35 % slag cement and 65% Portland cement (3) 50% slag cement and 50% Portland cement (4) 20% fly ash and 80% Portland cement. The results disclose the more sustainable concrete manufacturing process which is 50 % of Slag cement and 50% Portland cement.

scholarly journals Novel Complexity Indicator of Manufacturing Process Chains and Its Relations to Indirect Complexity Indicators

Complexity ◽  
2017 ◽  
Vol 2017 ◽  
pp. 1-15 ◽  
Author(s):  
Vladimir Modrak ◽  
Zuzana Soltysova
Keyword(s):  
Manufacturing Process ◽  
Material Flow ◽  
Manufacturing Systems ◽  
Job Shop ◽  
Flow Shop ◽  
Manufacturing Processes ◽  
Process Chains

Manufacturing systems can be considered as a network of machines/workstations, where parts are produced in flow shop or job shop environment, respectively. Such network of machines/workstations can be depicted as a graph, with machines as nodes and material flow between the nodes as links. The aim of this paper is to use sequences of operations and machine network to measure static complexity of manufacturing processes. In this order existing approaches to measure the static complexity of manufacturing systems are analyzed and subsequently compared. For this purpose, analyzed competitive complexity indicators were tested on two different manufacturing layout examples. A subsequent analysis showed relevant potential of the proposed method.

Developing a Capability-Based Similarity Metric for Manufacturing Processes

2017 ◽  
Author(s):  
Kevin Li ◽  
William Z. Bernstein
Keyword(s):  
Decision Making ◽  
Manufacturing Process ◽  
Product Life Cycle ◽  
Process Model ◽  
Die Casting ◽  
Process Models ◽  
Manufacturing Processes ◽  
Design Phase ◽  
Similarity Metric ◽  
On Line

Manufacturing taxonomies and accompanying metadata of manufacturing processes have been catalogued in both reference books and databases on-line. However, such information remains in a form that is uninformative to the various stages of the product life cycle, including the design phase and manufacturing-related activities. This challenge lies in the varying nature in how the data is captured and represented. In this paper, we explore measures for comparing manufacturing data with the goal of developing a capability-based similarity metric for manufacturing processes. To judge the effectiveness of these metrics, we apply permutations of them to 26 manufacturing process models, such as blow molding, die casting, and milling, that were created based on the ASTM E3012-16 standard. Furthermore, we provide directions towards the development of an aggregate similarity metric considering multiple capability features. In the future, this work will contribute to a broad vision of a manufacturing process model repository by helping ease decision-making for engineering design and planning.

Composability of Unit Manufacturing Process Models for Manufacturing Systems Analysis

2016 ◽  
Author(s):  
Matteo M. Smullin ◽  
Ian C. Garretson ◽  
Karl R. Haapala
Keyword(s):  
Systems Analysis ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Sustainable Manufacturing ◽  
The United States ◽  
Decision Makers ◽  
Process Models ◽  
Manufacturing Processes ◽  
Sustainability Performance ◽  
Information Repository

Manufacturing accounts for 31% of all energy consumed in the United States. Of increasing concern to industry decision makers is how to make their manufacturing processes more sustainable. Current sustainable assessment methods do not consider the parameters of unit manufacturing processes (UMPs) and, thus, do not provide the granular level of modeling required for accurate sustainability performance assessment. Further, there is little research within the field of sustainable manufacturing into how to recompose UMPs to form a unified model of a manufacturing system. This research attempts to rectify this deficiency by investigating the feasibility of composing (linking) disparate processes by incorporating the workpiece as an information repository. This enables modeling the information flows between processes as a co-product of the transformations imparted to the workpiece by the selected manufacturing processes. The result is a method for assessing the sustainability performance of a manufacturing system. This method would provide value to decision makers through more capable tools to better understand the sustainability performance of their manufacturing system.

Unit Manufacturing Process Models for Ferromagnetic and Non-Ferromagnetic Alloy Surface Inspection Methods

2015 ◽  
Author(s):  
Ian C. Garretson ◽  
Kevin W. Lyons ◽  
Mahesh Mani ◽  
Swee Leong ◽  
Matthew D. Carter ◽  
...  
Keyword(s):  
Continuous Improvement ◽  
Manufacturing Process ◽  
Performance Metrics ◽  
Process Models ◽  
Manufacturing Processes ◽  
Mathematical Basis ◽  
Sustainability Performance ◽  
Ferromagnetic Alloys ◽  
Individual Unit ◽  
Aircraft Component

Industrial use of natural resources are increasing at an alarming rate. Engineering and decision support tools are needed for analyzing and curbing industrial consumption of resources. Further, assessment methods to measure and indicate continuous improvement are also needed. Modeling individual manufacturing processes facilitates the generation of quantifiable evidence that improvements are being made. Such a modeling approach is developed and demonstrated in this paper to characterize sustainability performance of two metals inspection processes: magnetic particle inspection for ferromagnetic alloys and penetrant inspection for non-ferromagnetic alloys. Individual unit manufacturing process (UMP) models were developed by observing the inspection practices at an aircraft component manufacturer, and a mathematical basis for comparison with other inspection processes was identified. The paper further demonstrates the aggregation of performance metrics from all UMPs across a manufacturing process flow thus providing a basis for generating detailed sustainability performance assessments of manufactured products. By developing and documenting a comprehensive set of UMP models, more complete knowledge of manufacturing processes can be gained by industry practitioners, leading to continuous improvement of sustainability performance.

Modeling of Complex Manufacturing Processes by Hierarchical Fuzzy Basis Function Networks With Application to Grinding Processes

2004 ◽  
Vol 126 (4) ◽  
pp. 880-890 ◽  
Author(s):  
Cheol W. Lee ◽  
Yung C. Shin
Keyword(s):  
Least Squares ◽  
Hierarchical Structure ◽  
Basis Function ◽  
Least Squares Method ◽  
Fuzzy Neural Networks ◽  
Process Models ◽  
Manufacturing Processes ◽  
Training Algorithm ◽  
Modeling Framework ◽  
Grinding Processes

A framework for modeling complex manufacturing processes using fuzzy neural networks is presented with a novel training algorithm. In this study, a hierarchical structure that consists of fuzzy basis function networks (FBFN) is proposed to construct comprehensive models of the complex processes. A new adaptive least-squares (ALS) algorithm, based on the least-squares method and genetic algorithm (GA), is proposed for autonomous learning and construction of FBFNs without any human intervention. Simulation studies are performed to demonstrate advantages of the proposed modeling framework with the training algorithm in modeling complex manufacturing processes. The proposed method is implemented for the surface grinding processes based on the hierarchical structure of FBFNs. Process models for surface roughness and residual stress are developed based on the available grinding model structures with a small number of experimental data to demonstrate the concept. The accuracy of developed models is validated through independent sets of grinding experiments.

A Software Tool for Unit Process-Based Sustainable Manufacturing Assessment of Metal Components and Assemblies

2014 ◽  
Author(s):  
Ian C. Garretson ◽  
Christopher J. Eastwood ◽  
Michael D. Eastwood ◽  
Karl R. Haapala
Keyword(s):  
Manufacturing Process ◽  
Impact Analysis ◽  
Sustainability Assessment ◽  
Sustainable Manufacturing ◽  
Software Tool ◽  
Supply Chain Design ◽  
Process Models ◽  
Inventory Analysis ◽  
Unit Process ◽  
Cradle To Gate

While environmental impact analysis is standard in accordance with ISO 14040:2006 using life cycle assessment software, such as GaBi and SimaPro, software tools supporting broader sustainability assessment are limited. Recent research has developed methods for sustainable manufacturing assessment and has led to unit manufacturing process models that can be used to quantify sustainability metrics. In spite of these advances, engineering designers must apply such methods in an ad hoc manner, which increases engineering analysis time and limits the utility of sustainability assessment in early design. Thus, manufacturing process models and supporting software tool are developed to assist design for manufacturing efforts pursuing sustainability performance improvement. The software is constructed using Visual Basic to create a graphical user interface for an MS Excel calculation engine. Using unit manufacturing process models, a product sustainability assessment can be generated by chaining together a sequential manufacturing process flow. In this way, cradle-to-gate assessments can support decisions made during product, process, and supply chain design. The method combines upstream inventory analysis and in-house unit process modeling to perform cradle-to-gate sustainability assessment. The utility of the approach is demonstrated for the assessment of an aircraft-like metal product assembly.

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