Effective Applications of Optimization Methods in the Manufacturing Environment in Turkey

2016 ◽  
pp. 319-335 ◽  
Author(s):  
Omer Faruk Yilmaz ◽  
Hikmet Erbiyik
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
Optimization Methods ◽  
Hybrid Manufacturing ◽  
Manufacturing Environment ◽  
Literature Research ◽  
The Real ◽  
Extant Literature ◽  
Functional Layout ◽  
Manufacturing Environments

In today's manufacturing environment both used equipment and worker resources have become more crucial. Both resource must be used in an effective and appropriate way. Therefore, studies in conjuction with manufacturing environment are actualized under dual resource constrained (DRC). In the extant literature, DRC manufacturing environments place importance on certain dimensions which are surveyed in detail in this study. This literature research is conducted for manufacturing environments where worker planning and product scheduling topics are studied frequently. Our observations reveal that the systems of single conducted do not reflect the real manufacturing environment; hence, hybrid manufacturing systems which consist of functional layout and cells are investigated. The efficiency of hybrid manufacturing systems in the DRC environment are revealed by searching through literature. Therefore, the more effective way of usage of optimization methods are proposed by examining the studies regarding hybrid manufacturing system in terms of usage of optimization methods.

Collaborative Platform for Remote Manufacturing Systems Using Industrial Internet and Digital Twin in the COVID-19 Era

2021 ◽  
Author(s):  
Jay Lee ◽  
Xiaodong Jia ◽  
Qibo Yang ◽  
Keyi Sun ◽  
Xiang Li
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
The Real ◽  
Digital Twin ◽  
Manufacturing Efficiency ◽  
Industrial Internet ◽  
Industrial Operations ◽  
Promising Solution ◽  
Technology Group ◽  
Collaborative Platform

Abstract In the wake of COVID-19, significant influence on the manufacturing industries has been observed in the past year due to the restrictions of in-person communications and interactions. As a consequence, manufacturing efficiency has reduced remarkably all over the world. Despite the great harm to the industrial operations under the pandemic, the opportunities for remote collaborative manufacturing system also arise. Effective and efficient remote manufacturing systems for the real industries have been highly demanded. Through the integration of industrial internet and digital twin systems, the remote manufacturing system can be largely facilitated. This paper proposes a general framework for the remote manufacturing system during the COVID-19 era. The concept of the intelligent collaborative remote manufacturing system is firstly reviewed, as well as discussions of the current pandemic situation and its influence on the industries. The current commercial platforms of the systems are also presented. A case study on the lighthouse factories at the Foxconn Technology Group is finally presented for understanding the implementation of the proposed strategy. The effectiveness of the framework has been validated in the real industrial scenarios, and great economic and operational benefits have been obtained. The proposed framework offers a promising solution for the remote manufacturing system under the current pandemic.

INTEGRATION OF REAL-TIME CONTROL SIMULATION TO A VIRTUAL MANUFACTURING ENVIRONMENT

2002 ◽  
Vol 01 (01) ◽  
pp. 67-87 ◽  
Author(s):  
BYUNG-KWON MIN ◽  
ZHENGDONG HUANG ◽  
ZBIGNIEW J. PASEK ◽  
DEREK YIP-HOI ◽  
FORBES HUSTED ◽  
...  
Keyword(s):  
Machine Tool ◽  
Real Time ◽  
Machine Tools ◽  
Manufacturing Systems ◽  
Early Stage ◽  
Virtual Manufacturing ◽  
System Level ◽  
Manufacturing Environment ◽  
Manufacturing Environments ◽  
Virtual Manufacturing Environment

This paper presents a new integrated approach for simulation developed to improve the accuracy of virtual manufacturing environments. While machine tool simulation and virtual manufacturing for factory simulation have been frequently used in early stage plant development, each of these technique has been researched and implemented separately. This paper focuses on the utilization of real-time simulation of machine tools or active axes in manufacturing systems and integration of this simulation capability with virtual manufacturing environments. Machine-level simulation results are generated in real-time with a real machine tool controller and are fed to a virtual manufacturing environment. To integrate these two simulation techniques, system-level software is utilized as a communication platform. This system-level software was originally developed to control and configure whole manufacturing systems. The method has been successfully implemented within a testbed with full-scale machine tools. The results demonstrate that the proposed method advances the virtual manufacturing environments toward improved accuracy of factory level simulation, reduced effort for modeling and expanded functionality of machine-level simulations.

Evolutionary Algorithms for Multi-Objective Scheduling in a Hybrid Manufacturing System

2018 ◽  
pp. 162-187 ◽  
Author(s):  
Ömer Faruk Yılmaz ◽  
Mehmet Bülent Durmuşoğlu
Keyword(s):  
Genetic Algorithm ◽  
Evolutionary Algorithms ◽  
Manufacturing System ◽  
Optimization Problems ◽  
Multiple Objectives ◽  
Hybrid Manufacturing ◽  
Nsga Ii ◽  
Multi Objective ◽  
Comprehensive Information ◽  
Manufacturing Environments

Problems encountered in real manufacturing environments are complex to solve optimally, and they are expected to fulfill multiple objectives. Such problems are called multi-objective optimization problems(MOPs) involving conflicting objectives. The use of multi-objective evolutionary algorithms (MOEAs) to find solutions for these problems has increased over the last decade. It has been shown that MOEAs are well-suited to search solutions for MOPs having multiple objectives. In this chapter, in addition to comprehensive information, two different MOEAs are implemented to solve a MOP for comparison purposes. One of these algorithms is the non-dominated sorting genetic algorithm (NSGA-II), the effectiveness of which has already been demonstrated in the literature for solving complex MOPs. The other algorithm is fast Pareto genetic algorithm (FastPGA), which has population regulation operator to adapt the population size. These two algorithms are used to solve a scheduling problem in a Hybrid Manufacturing System (HMS). Computational results indicate that FastPGA outperforms NSGA-II.

scholarly journals Development of a Smart Cyber-Physical Manufacturing System in the Industry 4.0 Context

2019 ◽  
Vol 9 (16) ◽  
pp. 3325 ◽  
Author(s):  
Tran ◽  
Park ◽  
Nguyen ◽  
Hoang
Keyword(s):  
Radio Frequency Identification ◽  
Mass Production ◽  
Industry 4.0 ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Shop Floor ◽  
Self Healing ◽  
Manufacturing Environment ◽  
Information And Communication ◽  
Ict Infrastructure

The complexity and dynamic of the manufacturing environment are growing due to the changes of manufacturing demand from mass production to mass customization that require variable product types, small lot sizes, and a short lead-time to market. Currently, the automatic manufacturing systems are suitable for mass production. To cope with the changes of the manufacturing environment, the paper proposes the model and technologies for developing a smart cyber-physical manufacturing system (Smart-CPMS). The transformation of the actual manufacturing systems to the Smart-CPMS is considered as the next generation of manufacturing development in Industry 4.0. The Smart-CPMS has advanced characteristics inspired from biology such as self-organization, self-diagnosis, and self-healing. These characteristics ensure that the Smart-CPMS is able to adapt with continuously changing manufacturing requirements. The model of Smart-CPMS is inherited from the organization of living systems in biology and nature. Consequently, in the Smart-CPMS, each resource on the shop floor such as machines, robots, transporters, and so on, is an autonomous entity, namely a cyber-physical system (CPS) which is equipped with cognitive capabilities such as perception, reasoning, learning, and cooperation. The Smart-CPMS adapts to the changes of manufacturing environment by the interaction among CPSs without external intervention. The CPS implementation uses the cognitive agent technology. Internet of things (IoT) with wireless networks, radio frequency identification (RFID), and sensor networks are used as information and communication technology (ICT) infrastructure for carrying out the Smart-CPMS.

scholarly journals A Multi-Perspective Performance Approach for Complex Manufacturing Environments

2016 ◽  
Vol 4 (2) ◽  
pp. 125-155 ◽  
Author(s):  
António Almeida ◽  
Américo Azevedo
Keyword(s):  
Performance Management ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Feedback Loops ◽  
Decision Makers ◽  
Operational Performance ◽  
Efficiency And Effectiveness ◽  
Performance Drivers ◽  
Manufacturing Environments ◽  
Transformation Systems

Complexity in manufacturing systems appears under a variety of aspects, namely product, processes and operations and systems. Considering that the manufacturing environment is rapidly and constantly changing, with higher levels of customization and complexity, there is higher demand for flexibility and adaptability from companies. In this context, it seems essential to explore new approaches that can support decision-makers to take better decisions concerning the action plans that they need to launch to achieve the expected strategic and operational performance and alignment goals. Companies should become able to analyse their performance drivers, understand their meaning and the feedback loops that affect them. Therefore, decision makers can look into the future, and act even before these causes affect the transformation systems efficiency and effectiveness. This paper presents an approach oriented to multi-performance measurement in complex manufacturing environments. With this approach it is expected to overcome the gap between the operational and strategic layers of a manufacturing system, in order to reduce time when measuring performance and reacting to unexpected behaviours, as well as reduce errors when taking decisions. Moreover, it is expected to decrease the time necessary to calculate an indicator or to introduce a new one into performance management process, reducing the operational costs.

scholarly journals Control architectures for Industrial Additive Manufacturing Systems

2017 ◽  
Vol 232 (10) ◽  
pp. 1767-1777 ◽  
Author(s):  
Daniel Eyers
Keyword(s):  
Additive Manufacturing ◽  
Case Studies ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Sustainable Manufacturing ◽  
Emergent Technologies ◽  
Explicit Consideration ◽  
Research Gap ◽  
Manufacturing Environments

As the emergent technologies of Industrial Additive Manufacturing become increasingly employed in commercial manufacturing environments, challenges arise in terms of how resources of the manufacturing system should be marshalled and controlled for sustainable manufacturing. While control architectures are well established for conventional manufacturing, to-date there has been little explicit consideration for Industrial Additive Manufacturing. This article provides redress for this research gap by exploring four feasible control architectures employed in current manufacturing practice. Drawing upon 12 case studies and the operations of three companies, the relative merits, demerits, and challenges for each architecture are explored in terms of changeability criteria for sustainable manufacturing.

Investigating the Flexibility of a Hybrid Manufacturing System Using Simulation Approach

2013 ◽  
Vol 465-466 ◽  
pp. 672-676
Author(s):  
Ping Yu Chang
Keyword(s):  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Simulation Models ◽  
Setup Time ◽  
Simulation Approach ◽  
Key Characteristics ◽  
Manufacturing System Design ◽  
Demand Fluctuations ◽  
Manufacturing Environments

Different designs of manufacturing systems are adopted in industry today. A good manufacturing design should be flexible to compensate for uncertainties such as demand fluctuations and machine breakdowns. A new conceptual manufacturing system called Multi-Channel Manufacturing (MCM) is expected to provide flexibility and efficiency under uncertainties. This paper proposes the first approach to address the usefulness of MCM. This research tries to identify the key characteristics of MCM and the manufacturing environments for which MCM should perform well. Through simulation models, different manufacturing scenarios are analyzed and a suitable manufacturing system design for each scenario is identified. The simulation results illustrate that with limited material handling capacity and opportunities for setup time reduction, MCM can outperform other manufacturing formations.

Hybrid Manufacturing System Modeling and Development

2012 ◽  
Author(s):  
Jacquelyn K. S. Nagel ◽  
Frank W. Liou
Keyword(s):  
Hybrid System ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
System Modeling ◽  
Production Costs ◽  
Production Model ◽  
Hybrid Manufacturing ◽  
Lamp System ◽  
Metallic Parts

Reliable and economical fabrication of metallic parts with complicated geometries is of considerable interest for the aerospace, medical, automotive, tooling and consumer products industries. In an effort to shorten the time-to-market, decrease the manufacturing process chain, and cut production costs of products produced by these industries, research has focused on the integration of multiple unit manufacturing processes into one machine. The end goal is to reduce production space, time, and manpower requirements. Our research into hybrid manufacturing systems has lead to the integration of additive and subtractive processes within a single machine footprint such that both processes are leveraged during fabrication. The laser aided manufacturing process (LAMP) system provides a rapid prototyping and rapid manufacturing infrastructure for research and education. The LAMP system creates fully dense, metallic parts and provides all the advantages of commercial laser metal deposition (LMD) systems. This hybrid system is a very competitive and economical approach to fabricating metallic structures. Hybrid manufacturing systems facilitate a sustainable and intelligent production model and offer flexibility of infrastructure to adapt with emergent technology, customization, and changing market needs. This paper summarizes the salient research activities and the findings of those activities related to the modeling and development of the hybrid manufacturing system. Our qualitative and quantitative modeling efforts, as well as the resultant system architecture are described. The approach and strategies utilized in this research coalesce to facilitate an interdisciplinary approach to the development a hybrid manufacturing system to produce metal parts that are not only functional but also processed to the final desired surface-finished and tolerance. Furthermore, the approach to hybrid system modeling and development can assist in general with integrated manufacturing systems.

Virtual Fusion: Hybrid Process Simulation and Emulation-in-the-Loop

2008 ◽  
Author(s):  
William S. Harrison ◽  
Dawn Tilbury
Keyword(s):  
Simulation Model ◽  
Process Simulation ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Virtual Machines ◽  
Hybrid Process ◽  
University Of Michigan ◽  
The Real ◽  
Test And Evaluation ◽  
The University

When developing a new manufacturing system or reconfiguring an existing system, it is desirable to have a simulation model for test and evaluation. However, there is often a disconnect between the real system and the simulation model; it is difficult for them to have exactly equivalent behavior. The highest-fidelity “model” is always the system itself. In this paper we propose a framework in which modular models of the manufacturing system components (robots, machines, conveyors, controllers) can be interchanged with their real counterparts, forming a hybrid process. We focus on both the connections between components and the most pertinent aspects of the processed parts. The transfer of parts between the real and virtual domains is particularly challenging; we describe how parts can transition between real and virtual without making substantial changes to the system itself. We discuss how the proposed hybrid process simulation can be used for the design of new manufacturing systems. As the new machines and components are built and installed, they can be “swapped” in for the virtual machines, and testing can be done incrementally. We also discuss how the proposed hybrid process simulation can be used for the upgrade or reconfiguration of existing manufacturing systems. When a new machine or cell is added, or the part flow is reconfigured, the relevant new parts of the system can first be built in simulation and tested as part of the hybrid process, with the new machines. A case study describing the implementation of the hybrid process simulation on the Reconfigurable Factory Testbed at the University of Michigan is presented.

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.

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