Abstract: The capability of CNC gantry milling machines in
manufacturing long components has caused the expanded use of such
machines. On the other hand, the machines’ gantry rigidity can
reduce under severe loads or vibration during operation. Indeed, the
quality of machining is dependent on the machine’s dynamic
behavior throughout the operating process. For this reason, these
types of machines have always been used widely and are not
efficient. Therefore, they can usually be employed for rough
machining and may not produce adequate surface finishing. In this
paper, a CNC gantry milling machine with the potential to produce
good surface finish has been designed and analyzed. The lowest
natural frequency of this machine is 202 Hz corresponding to 12000
rpm at all motion amplitudes with a full range of suitable frequency
responses. Meanwhile, the maximum deformation under dead loads
for the gantry machine is 0.565*m, indicating that this machine tool
is capable of producing higher product quality.
Abstract: Knowledge is considered as an important asset which
can help organizations to create competitive advantage. The necessity
of taking care of these assets is more important in these days – in
days of turbulent changes in business environment. Knowledge could
facilitate adaption to constant changes. The aim of this paper is to
describe how the knowledge sharing can be supported in the
manufacturing companies. The methods of case studies and grounded
theory were used to present information gained by carrying out semistructured
interviews. Results show that knowledge sharing is
supported in very similar ways in respondent companies.
Abstract: MSMEs are regarded as the sunrise sector of the
Indian economy in view of its large potential for growth and likely
socio economic impact specifically on employment and income
generation. In today’s competitive business environment, global
competition forces companies to continuously seek ways of
improving their products and services. The pressure on organizations
to adapt to new technologies and external threats requires
resourcefulness, creativity and innovation. Market has become more
open, competitive and customers more demanding. Without
continuous technology innovation, no organization can ever remain
competitive. Innovations reflect a critical way in which organizations
respond to either technological or market challenges. The need of the
market is to deliver high quality products through continuous
changing in features in product, improve existing products, reduce
their cost, and improve employee skills, training, technology
infrastructure and financial policies. Therefore, the key factor of
organization’s ability to change is innovation. The study presents a
detailed review of literature on the role of technology innovation in
improving manufacturing performance of industries.
Abstract: A well designed and executed Production Planning
and Control (PPC) system is one of the key levers for superior
performance in the current manufacturing set-up. Hence, measuring
the PPC system performance has become a necessity for long term
success. The present study examined PPC related issues which
impact the production capacity and productivity of leather companies
with special focus on Kombolcha Tannery Share Company (KTSC),
Ethiopia. Physical observation, interview, and questionnaire were
used to generate necessary information from the respondents and
reach valid conclusions. Company annual reports were referred and
analyzed to triangulate primary data. Consequently, the study
revealed that KTSC runs below its capacity due to its inefficient PPC
system being in use for which the root causes were identified. The
study thereby conceptualizes a PPC system improvement framework
comprising three pillars viz., management culture, internal capability
and performance measurement together with key considerations in
each case. The study findings enable the company to recognize the
importance of efficient PPC system as a source of competitive
advantage. It also aid managers in evaluating various PPC execution
schemes to enhance productivity.
Abstract: In this paper, performances of shuffled frog leaping
algorithm was investigated on the stealth laser dicing process. Effect
of problem on the performance of the algorithm was based on the
tolerance of meandering data. From the customer specification it
could be less than five microns with the target of zero microns.
Currently, the meandering levels are unsatisfactory when compared
to the customer specification. Firstly, the two-level factorial design
was applied to preliminarily study the statistically significant effects
of five process variables. In this study one influential process variable
is integer. From the experimental results, the new operating condition
from the algorithm was superior when compared to the current
manufacturing condition.
Abstract: Micro-alloyed steel components are used in
automotive industry for the necessity to make the manufacturing
process cycles shorter when compared to conventional steel by
eliminating heat treatment cycles, so an important saving of costs and
energy can be reached by reducing the number of operations. Microalloying
elements like vanadium, niobium or titanium have been
added to medium carbon steels to achieve grain refinement with or
without precipitation strengthening along with uniform
microstructure throughout the matrix. Present study reports the
applicability of medium carbon vanadium micro-alloyed steel in hot
forging. Forgeability has been determined with respect to different
cooling rates, after forging in a hydraulic press at 50% diameter
reduction in temperature range of 900-11000C. Final microstructures,
hardness, tensile strength, and impact strength have been evaluated.
The friction coefficients of different lubricating conditions, viz.,
graphite in hydraulic oil, graphite in furnace oil, DF 150 (Graphite,
Water-Based) die lubricant and dry or without any lubrication were
obtained from the ring compression test for the above micro-alloyed
steel. Results of ring compression tests indicate that graphite in
hydraulic oil lubricant is preferred for free forging and dry lubricant
is preferred for die forging operation. Exceptionally good forgeability
and high resistance to fracture, especially for faster cooling rate has
been observed for fine equiaxed ferrite-pearlite grains, some amount
of bainite and fine precipitates of vanadium carbides and
carbonitrides. The results indicated that the cooling rate has a
remarkable effect on the microstructure and mechanical properties at
room temperature.
Abstract: Sandwich structure composites produced by epoxy
core and aluminium skin were developed as potential building
materials. Interface bonding between core and skin was controlled by
varying kenaf content. Five different weight percentage of kenaf
loading ranging from 10 wt% to 50 wt% were employed in the core
manufacturing in order to study the mechanical properties of the
sandwich composite. Properties of skin aluminium with epoxy were
found to be affected by drying time of the adhesive. Mechanical
behavior of manufactured sandwich composites in relation with
properties of constituent materials was studied. It was found that 30
wt% of kenaf loading contributed to increase the flexural strength and
flexural modulus up to 102 MPa and 32 GPa, respectively. Analysis
were done on the flatwise and edgewise compression test. For
flatwise test, it was found that 30 wt% of fiber loading could
withstand maximum force until 250 kN, with compressive strength
results at 96.94 MPa. However, at edgewise compression test, the
sandwich composite with same fiber loading only can withstand 31
kN of the maximum load with 62 MPa of compressive strength
results.
Abstract: The industrial process adds to engineering wood
products features absent in solid wood, with homogeneous structure
and reduced defects, improved physical and mechanical properties,
bio-deterioration, resistance and better dimensional stability,
improving quality and increasing the reliability of structures wood.
These features combined with using fast-growing trees, make them
environmentally ecological products, ensuring a strong consumer
market. The wood I-joists are manufactured by the industrial profiles
bonding flange and web, an important aspect of the production of
wooden I-beams is the adhesive joint that bonds the web to the
flange. Adhesives can effectively transfer and distribute stresses,
thereby increasing the strength and stiffness of the composite. The
objective of this study is to evaluate different resins in a shear strain
specimens with the aim of analyzing the most efficient resin and
possibility of using national products, reducing the manufacturing
cost. First was conducted a literature review, where established the
geometry and materials generally used, then established and analyzed
8 national resins and produced six specimens for each.
Abstract: Managing and improving efficiency in the current
highly competitive global automotive industry demands that those
companies adopt leaner and more flexible systems. During the past
20 years the domestic automotive industry in North America has been
focusing on establishing new management strategies in order to meet
market demands. The lean management process also known as
Toyota Manufacturing Process (TPS) or lean manufacturing
encompasses tools and techniques that were established in order to
provide the best quality product with the fastest lead time at the
lowest cost. The following paper presents a study that focused on
improving labor efficiency at one of the Big Three (Ford, GM,
Chrysler LLC) domestic automotive facility in North America. The
objective of the study was to utilize several lean management tools in
order to optimize the efficiency and utilization levels at the “Pre-
Marriage” chassis area in a truck manufacturing and assembly
facility. Utilizing three different lean tools (i.e. Standardization of
work, 7 Wastes, and 5S) this research was able to improve efficiency
by 51%, utilization by 246%, and reduce operations by 14%. The
return on investment calculated based on the improvements made
was 284%.
Abstract: This study is used as a definition method to the value
and function in manufacturing sector. In concurrence of discussion
about present condition of modeling method, until now definition of
1D-CAE is ambiguity and not conceptual. Across all the physic fields,
those methods are defined with the formulation of differential
algebraic equation which only applied time derivation and simulation.
At the same time, we propose semi-acausal modeling concept and
differential algebraic equation method as a newly modeling method
which the efficiency has been verified through the comparison of
numerical analysis result between the semi-acausal modeling
calculation and FEM theory calculation.
Abstract: Kazakhstan is currently one of the dynamically
developing states in its region. The stable growth in all sectors of the
economy leads to a corresponding increase in energy consumption.
Thus country consumes significant amount of energy due to the high
level of industrialisation and the presence of energy-intensive
manufacturing such as mining and metallurgy which in turn leads to
low energy efficiency. With allowance for this the Government has
set several priorities to adopt a transition of Republic of Kazakhstan
to a “green economy”. This article provides an overview of
Kazakhstan’s energy efficiency situation in for the period of 1991-
2014. First, the dynamics of production and consumption of
conventional energy resources are given. Second, the potential of
renewable energy sources is summarised followed by the description
of GHG emissions trends in the country. Third, Kazakhstan’ national
initiatives, policies and locally implemented projects in the field of
energy efficiency are described.
Abstract: Company managers are always looking for more and
more opportunities to succeed in today's fiercely competitive market.
To maintain your place among the successful companies on the
market today or to come up with a revolutionary business idea is
much more difficult than before. Each new or improved method, tool,
or approach that can improve the functioning of business processes or
even of the entire system is worth checking and verification. The use
of simulation in the design of manufacturing systems and their
management in practice is one of the ways without increased risk,
which makes it possible to find the optimal parameters of
manufacturing processes and systems. The paper presents an example
of use of simulation for solution of the bottleneck problem in the
concrete company.
Abstract: Composite materials, due to their unique properties
such as high strength to weight ratio, corrosion resistance, and impact
resistance have huge potential as structural materials in automotive,
construction and transportation applications. However, these
properties often come at higher cost owing to complex design
methods, difficult manufacturing processes and raw material cost.
Traditionally, tapered laminated composite structures are
manufactured using autoclave manufacturing process by ply drop off
technique. Autoclave manufacturing though very powerful suffers
from high capital investment and higher energy consumption. As per
the current trends in composite manufacturing, Out of Autoclave
(OoA) processes are looked as emerging technologies for
manufacturing the structural composite components for aerospace
and defense applications. However, there is a need for improvement
among these processes to make them reliable and consistent. In this
paper, feasibility of using out of autoclave process to manufacture the
variable thickness cantilever beam is discussed. The minimum weight
design for the composite beam is obtained using constant stress beam
concept by tailoring the thickness of the beam. Ply drop off
techniques was used to fabricate the variable thickness beam from
glass/epoxy prepregs. Experiments were conducted to measure
bending stresses along the span of the cantilever beam at different
intervals by applying the concentrated load at the free end.
Experimental results showed that the stresses in the bean at different
intervals were constant. This proves the ability of OoA process to
manufacture the constant stress beam. Finite element model for the
constant stress beam was developed using commercial finite element
simulation software. It was observed that the simulation results
agreed very well with the experimental results and thus validated
design and manufacturing approach used.
Abstract: Chemical Reaction Optimization (CRO) is an
optimization metaheuristic inspired by the nature of chemical
reactions as a natural process of transforming the substances from
unstable to stable states. Starting with some unstable molecules with
excessive energy, a sequence of interactions takes the set to a state of
minimum energy. Researchers reported successful application of the
algorithm in solving some engineering problems, like the quadratic
assignment problem, with superior performance when compared with
other optimization algorithms. We adapted this optimization
algorithm to the Printed Circuit Board Drilling Problem (PCBDP)
towards reducing the drilling time and hence improving the PCB
manufacturing throughput. Although the PCBDP can be viewed as
instance of the popular Traveling Salesman Problem (TSP), it has
some characteristics that would require special attention to the
transactions that explore the solution landscape. Experimental test
results using the standard CROToolBox are not promising for
practically sized problems, while it could find optimal solutions for
artificial problems and small benchmarks as a proof of concept.
Abstract: In the scope of application of technical textiles, Non-
Crimp Fabrics are increasingly used. In general, NCF exhibit
excellent load bearing properties, but caused by the manufacturing
process, there are some remaining disadvantages which have to be
reduced. Regarding to this, a novel technique of processing NCF was
developed substituting the binding-thread by an adhesive. This stitchfree
method requires new manufacturing concept as well as new basic
methods to prove adhesion of glue at fibres and textiles. To improve
adhesion properties and the wettability of carbon-fibres by the
adhesive, oxy-fluorination was used. The modification of carbonfibres
by oxy-fluorination was investigated via scanning electron
microscope, X-ray photoelectron spectroscopy and single fibre
tensiometry. Special tensile tests were developed to determine the
maximum force required for detachment.
Abstract: Environmental impacts of six 3D printers using
various materials were compared to determine if material choice
drove sustainability, or if other factors such as machine type, machine
size, or machine utilization dominate. Cradle-to-grave life-cycle
assessments were performed, comparing a commercial-scale FDM
machine printing in ABS plastic, a desktop FDM machine printing in
ABS, a desktop FDM machine printing in PET and PLA plastics, a
polyjet machine printing in its proprietary polymer, an SLA machine
printing in its polymer, and an inkjet machine hacked to print in salt
and dextrose. All scenarios were scored using ReCiPe Endpoint H
methodology to combine multiple impact categories, comparing
environmental impacts per part made for several scenarios per
machine. Results showed that most printers’ ecological impacts were
dominated by electricity use, not materials, and the changes in
electricity use due to different plastics was not significant compared
to variation from one machine to another. Variation in machine idle
time determined impacts per part most strongly. However, material
impacts were quite important for the inkjet printer hacked to print in
salt: In its optimal scenario, it had up to 1/38th the impacts coreper
part as the worst-performing machine in the same scenario. If salt
parts were infused with epoxy to make them more physically robust,
then much of this advantage disappeared, and material impacts
actually dominated or equaled electricity use. Future studies should
also measure DMLS and SLS processes / materials.
Abstract: This work was one of the tasks of the
Manufacturing2Client project, whose objective was to develop a
frontal deflector to be commercialized in the automotive industry,
using new project and manufacturing methods. In this task, in
particular, it was proposed to develop the ability to predict
computationally the aerodynamic influence of flow in vehicles, in an
effort to reduce fuel consumption in vehicles from class 3 to 8. With
this aim, two deflector models were developed and their aerodynamic
performance analyzed. The aerodynamic study was done using the
Computational Fluid Dynamics (CFD) software Ansys CFX and
allowed the calculation of the drag coefficient caused by the vehicle
motion for the different configurations considered. Moreover, the
reduction of diesel consumption and carbon dioxide (CO2) emissions
associated with the optimized deflector geometry could be assessed.
Abstract: Machining parameters are very important in
determining the surface quality of any material. In the past decade,
some new engineering materials were developed for the
manufacturing industry which created a need to conduct an
investigation on the impact of the said parameters on their surface
roughness. Polyurethane (PU) block is widely used in the automotive
industry to manufacture parts such as checking fixtures that are used
to verify the dimensional accuracy of automotive parts. In this paper,
the design of experiment (DOE) was used to investigate on the effect
of the milling parameters on the PU block. Furthermore, an analysis
of the machined surface chemical composition was done using
scanning electron microscope (SEM). It was found that the surface
roughness of the PU block is severely affected when PU undergoes a
flood machining process instead of a dry condition. In addition the
stepover and the silicon content were found to be the most significant
parameters that influence the surface quality of the PU block.
Abstract: Non-destructive testing and evaluation techniques for
assessing the integrity of composite structures are essential to both
reduce manufacturing costs and out of service time of transport means
due to maintenance. In this study, Analyze into non-destructive test
characterization of carbon fiber reinforced plastics (CFRP) internal
and external defects using thermo-graphic camera and transient
thermography method. non-destructive testing were characterized by
defect size (Ø8, Ø10, Ø12, Ø14) and depth (1.2mm, 2.4mm).
Abstract: The Smart Help for persons with disability (PWD) is a
part of the project SMARTDISABLE which aims to develop relevant
solution for PWD that target to provide an adequate workplace
environment for them. It would support PWD needs smartly through
smart help to allow them access to relevant information and
communicate with other effectively and flexibly, and smart editor
that assist them in their daily work. It will assist PWD in knowledge
processing and creation as well as being able to be productive at the
work place. The technical work of the project involves design of a
technological scenario for the Ambient Intelligence (AmI) - based
assistive technologies at the workplace consisting of an integrated
universal smart solution that suits many different impairment
conditions and will be designed to empower the Physically disabled
persons (PDP) with the capability to access and effectively utilize the
ICTs in order to execute knowledge rich working tasks with
minimum efforts and with sufficient comfort level. The proposed
technology solution for PWD will support voice recognition along
with normal keyboard and mouse to control the smart help and smart
editor with dynamic auto display interface that satisfies the
requirements for different PWD group. In addition, a smart help will
provide intelligent intervention based on the behavior of PWD to
guide them and warn them about possible misbehavior. PWD can
communicate with others using Voice over IP controlled by voice
recognition. Moreover, Auto Emergency Help Response would be
supported to assist PWD in case of emergency. This proposed
technology solution intended to make PWD very effective at the
work environment and flexible using voice to conduct their tasks at
the work environment. The proposed solution aims to provide
favorable outcomes that assist PWD at the work place, with the
opportunity to participate in PWD assistive technology innovation
market which is still small and rapidly growing as well as upgrading
their quality of life to become similar to the normal people at the
workplace. Finally, the proposed smart help solution is applicable in
all workplace setting, including offices, manufacturing, hospital, etc.