Abstract: To investigates the effect of fiberglass clamping
process improvement on drape simulation prediction. This has
great effect on the mould and the fiber during manufacturing
process. This also, improves the fiber strain, the quality of the
fiber orientation in the area of folding and wrinkles formation
during the press-forming process. Drape simulation software
tool was used to digitalize the process, noting the formation
problems on the contour sensitive part. This was compared
with the real life clamping processes using single and double
frame set-ups to observe the effects. Also, restrains are
introduced by using clips, and the G-clamps with predetermine
revolution to; restrain the fabric deformation during the
forming process.The incorporation of clamping and fabric
restrain deformation improved on the prediction of the
simulation tool. Therefore, for effective forming process,
incorporation of clamping process into the drape simulation
process will assist in the development of fiberglass application
in manufacturing process.
Abstract: A product goes through various processes in a production flow which is also known as assembly line in manufacturing process management. Toyota created a new concept which is known as lean concept in manufacturing industry. Today it is the leading model in manufacturing plants through the globe. The linear walking worker assembly line is a flexible assembly system where each worker travels down the line carrying out each assembly task at each station; and each worker accomplishes the assembly of a unit from start to finish. This paper attempts to combine the flexibility of the walking worker and lean in order to quantify the benefits from applying the shop floor principles of lean management.
Abstract: This research presents a fuzzy multi-objective model
for a machine selection problem in a flexible manufacturing system
of a tire company. Two main objectives are minimization of an
average machine error and minimization of the total setup time.
Conventionally, the working team uses trial and error in selecting a
pressing machine for each task due to the complexity and constraints
of the problem. So, both objectives may not satisfy. Moreover, trial
and error takes a lot of time to get the final decision. Therefore, in
this research preemptive fuzzy goal programming model is developed
for solving this multi-objective problem. The proposed model can
obtain the appropriate results that the Decision Making (DM) is
satisfied for both objectives. Besides, alternative choice can be easily
generated by varying the satisfaction level. Additionally, decision
time can be reduced by using the model, which includes all
constraints of the system to generate the solutions. A numerical
example is also illustrated to show the effectiveness of the proposed
model.
Abstract: A new approach to determine the machine layout in flexible manufacturing cell, and to find the feasible robot configuration of the robot to achieve minimum cycle time is presented in this paper. The location of the input/output location and the optimal robot configuration is obtained for all sequences of work tasks of the robot within a specified period of time. A more realistic approach has been presented to model the problem using the robot joint space. The problem is formulated as a nonlinear optimization problem and solved using Sequential Quadratic Programming algorithm.
Abstract: Technology of thin film deposition is of interest in
many engineering fields, from electronic manufacturing to corrosion
protective coating. A typical deposition process, like that developed
at the University of Eindhoven, considers the deposition of a thin,
amorphous film of C:H or of Si:H on the substrate, using the
Expanding Thermal arc Plasma technique. In this paper a computing
procedure is proposed to simulate the flow field in a deposition
chamber similar to that at the University of Eindhoven and a
sensitivity analysis is carried out in terms of: precursor mass flow
rate, electrical power, supplied to the torch and fluid-dynamic
characteristics of the plasma jet, using different nozzles. To this
purpose a deposition chamber similar in shape, dimensions and
operating parameters to the above mentioned chamber is considered.
Furthermore, a method is proposed for a very preliminary evaluation
of the film thickness distribution on the substrate. The computing
procedure relies on two codes working in tandem; the output from
the first code is the input to the second one. The first code simulates
the flow field in the torch, where Argon is ionized according to the
Saha-s equation, and in the nozzle. The second code simulates the
flow field in the chamber. Due to high rarefaction level, this is a
(commercial) Direct Simulation Monte Carlo code. Gas is a mixture
of 21 chemical species and 24 chemical reactions from Argon plasma
and Acetylene are implemented in both codes. The effects of the
above mentioned operating parameters are evaluated and discussed
by 2-D maps and profiles of some important thermo-fluid-dynamic
parameters, as per Mach number, velocity and temperature. Intensity,
position and extension of the shock wave are evaluated and the
influence of the above mentioned test conditions on the film
thickness and uniformity of distribution are also evaluated.
Abstract: In this document, we have proposed a robust
conceptual strategy, in order to improve the robustness against the manufacturing defects and thus the reliability of logic CMOS circuits. However, in order to enable the use of future CMOS
technology nodes this strategy combines various types of design:
DFR (Design for Reliability), techniques of tolerance: hardware
redundancy TMR (Triple Modular Redundancy) for hard error
tolerance, the DFT (Design for Testability. The Results on largest ISCAS and ITC benchmark circuits show that our approach improves
considerably the reliability, by reducing the key factors, the area costs and fault tolerance probability.
Abstract: In automatic manufacturing and assembling of mechanical, electrical and electronic parts one needs to reliably identify the position of components and to extract the information of these components. Data Matrix Codes (DMC) are established by these days in many areas of industrial manufacturing thanks to their concentration of information on small spaces. In today’s usually order-related industry, where increased tracing requirements prevail, they offer further advantages over other identification systems. This underlines in an impressive way the necessity of a robust code reading system for detecting DMC on the components in factories. This paper compares two methods for estimating the angle of orientation of Data Matrix Codes: one method based on the Hough Transform and the other based on the Mean Shift Algorithm. We concentrate on Data Matrix Codes in industrial environment, punched, milled, lasered or etched on different materials in arbitrary orientation.
Abstract: Integrated Total Quality Management (TQM) with
Lean Manufacturing (LM) is a system comprises of TQM with LM
principles and is associated with financial and nonfinancial
performance measurement indicators. The ultimate goal of this
system is to focus on achieving total customer satisfaction by
removing eight wastes available in any process in an organization.
A survey questionnaire was developed and distributed to 30 highly
active automotive vendors in Malaysia and analyzed by PASW
Statistics 18. It was found out that these vendors have been
practicing and measuring the effectiveness TQM and LM
implementation. More involvement of all Malaysian automotive
vendors will represent the exact status of current Malaysian
automotive industry in implementing TQM and LM and can
determine whether the industry is ready for integrated TQM and
LM system. This is the first study that combined 4 awards
practices, ISO/TS16949, Toyota Production System and
SAEJ4000.
Abstract: The manufacturing transmission line tower parts has
being generated hazardous waste which is required proper disposal
of waste for protection of land pollution. Manufacturing Process in
the manufacturing of steel angle, plates, pipes, channels are passes
through conventional, semi automatic and CNC machines for
cutting, marking, punching, drilling, notching, bending operations.
All fabricated material Coated with thin layer of Zinc in Galvanizing
plant where molten zinc is used for coating. Prior to Galvanizing,
chemical like 33% concentrated HCl Acid, ammonium chloride and
d-oil being used for pretreatment of iron. The bath of water with
sodium dichromate is used for cooling and protection of the
galvanized steel. For the heating purpose the furnace oil burners are
used. These above process the Zinc dross, Zinc ash, ETP sludge and
waste pickled acid generated as hazardous waste. The RPG has
made captive secured land fill site, since 1997 since then it was
using for disposal of hazardous waste after completion of SLF
(Secured land fill) site. The RPG has raised height from ground
level then now it is being used for disposal of waste as he designed
the SLF after in creasing height of from GL it is functional without
leach ate or adverse impacts in the environment.
Abstract: Quality costs are the costs associated with preventing,
finding, and correcting defective work. Since the main language of
corporate management is money, quality-related costs act as means of
communication between the staff of quality engineering departments
and the company managers. The objective of quality engineering is to
minimize the total quality cost across the life of product. Quality
costs provide a benchmark against which improvement can be
measured over time. It provides a rupee-based report on quality
improvement efforts. It is an effective tool to identify, prioritize and
select quality improvement projects. After reviewing through the
literature it was noticed that a simplified methodology for data
collection of quality cost in a manufacturing industry was required.
The quantified standard methodology is proposed for collecting data
of various elements of quality cost categories for manufacturing
industry. Also in the light of research carried out so far, it is felt
necessary to standardise cost elements in each of the prevention,
appraisal, internal failure and external failure costs. . Here an attempt
is made to standardise the various cost elements applicable to
manufacturing industry and data is collected by using the proposed
quantified methodology. This paper discusses the case study carried
in luggage manufacturing industry.
Abstract: For the electrical metrics that describe photovoltaic
cell performance are inherently multivariate in nature, use of a
univariate, or one variable, statistical process control chart can have
important limitations. Development of a comprehensive process
control strategy is known to be significantly beneficial to reducing
process variability that ultimately drives up the manufacturing cost
photovoltaic cells. The multivariate moving average or MMA chart,
is applied to the electrical metrics of photovoltaic cells to illustrate
the improved sensitivity on process variability this method of control
charting offers. The result show the ability of the MMA chart to
expand to as any variables as needed, suggests an application
with multiple photovoltaic electrical metrics being used in
concert to determine the processes state of control.
Abstract: We consider a typical problem in the assembly of
printed circuit boards (PCBs) in a two-machine flow shop system to
simultaneously minimize the weighted sum of weighted tardiness and
weighted flow time. The investigated problem is a group scheduling
problem in which PCBs are assembled in groups and the interest is to
find the best sequence of groups as well as the boards within each
group to minimize the objective function value. The type of setup
operation between any two board groups is characterized as carryover
sequence-dependent setup time, which exactly matches with the real
application of this problem. As a technical constraint, all of the
boards must be kitted before the assembly operation starts (kitting
operation) and by kitting staff. The main idea developed in this paper
is to completely eliminate the role of kitting staff by assigning the
task of kitting to the machine operator during the time he is idle
which is referred to as integration of internal (machine) and external
(kitting) setup times. Performing the kitting operation, which is a
preparation process of the next set of boards while the other boards
are currently being assembled, results in the boards to continuously
enter the system or have dynamic arrival times. Consequently, a
dynamic PCB assembly system is introduced for the first time in the
assembly of PCBs, which also has characteristics similar to that of
just-in-time manufacturing. The problem investigated is
computationally very complex, meaning that finding the optimal
solutions especially when the problem size gets larger is impossible.
Thus, a heuristic based on Genetic Algorithm (GA) is employed. An
example problem on the application of the GA developed is
demonstrated and also numerical results of applying the GA on
solving several instances are provided.
Abstract: Green supply chain management is an increasingly recognized practice among companies that are seeking to improve environmental performance. Of particular concern is how to arouse organizational awareness and put green activities into practice in
order to enhance manufacturing performances. This paper investigates the correlation of green supply chain practices and
manufacturing performances in Malaysian certified MS ISO 14000 manufacturing firms. The findings shows that green supply chain
practices which that can be denominated product recycling, environmental compliance and optimization have significant influence to some of the manufacturing performances.
Abstract: As product life cycle becomes less and less every day,
having flexible manufacturing processes for any companies seems more demanding. In the assembling of closures, i.e. opening parts in
car body, hemming process is the one which needs more attention. This paper focused on the robot roller hemming process and how to
reduce its cycle time by introducing a fast roller hemming process. A
robot roller hemming process of a tailgate of Saab 93 SportCombi
model is investigated as a case study in this paper. By applying task
separation, robot coordination, and robot cell configuration principles in the roller hemming process, three alternatives are
proposed, developed, and remarkable reduction in cycle times achieved [1].
Abstract: In this paper, some common gearboxes vibration analysis methods and condition monitoring systems are explained. In addition, an experimental gearbox vibration analysis is discussed through a critical case history for a mixer gearbox related to Iran oil industry. The case history also consists of gear manufacturing (machining) recommendations, lubrication condition of gearbox and machinery maintenance activities that caused reduction in noise and vibration of the gearbox. Besides some of the recent patents and innovations in gearboxes, lubrication and vibration monitoring systems explained. Finally micro pitting and surface fatigue in pinion and bevel of mentioned horizontal to vertical gearbox discussed in details.
Abstract: The objective of this work which is based on the
approach of simultaneous engineering is to contribute to the
development of a CIM tool for the synthesis of functional design
dimensions expressed by average values and tolerance intervals. In
this paper, the dispersions method known as the Δl method which
proved reliable in the simulation of manufacturing dimensions is
used to develop a methodology for the automation of the simulation.
This methodology is constructed around three procedures. The first
procedure executes the verification of the functional requirements by
automatically extracting the functional dimension chains in the
mechanical sub-assembly. Then a second procedure performs an
optimization of the dispersions on the basis of unknown variables.
The third procedure uses the optimized values of the dispersions to
compute the optimized average values and tolerances of the
functional dimensions in the chains. A statistical and cost based
approach is integrated in the methodology in order to take account of
the capabilities of the manufacturing processes and to distribute
optimal values among the individual components of the chains.
Abstract: Cutting tools are widely used in manufacturing processes and drilling is the most commonly used machining process. Although drill-bits used in drilling may not be expensive, their breakage can cause damage to expensive work piece being drilled and at the same time has major impact on productivity. Predicting drill-bit breakage, therefore, is important in reducing cost and improving productivity. This study uses twenty features extracted from two degradation signals viz., thrust force and torque. The methodology used involves developing and comparing decision tree, random forest, and multinomial logistic regression models for classifying and predicting drill-bit breakage using degradation signals.
Abstract: Today, the central role of industrial robots in automation in general and in material handling in particular is crystal clear. Based on the current status of Photovoltaics and by focusing on lightweight material handling, PV industry has turned into a potential candidate for introducing a fresh “pick and place" robot technology. Thus, to examine the industry needs in this regard, firstly the best suited applications for such robotic automation,and then the essential prerequisites in PV industry should be identified. The objective of this paper is to present holistic views on the industry trends, general automation status and existing challenges facing lightweight robotic material handling in PV Silicon Wafer and Thin Film technologies. The results of this study show that currently no uniform pick and place solution prevails among PV Silicon Wafer manufacturers and the industry calls for a new robot solution to satisfy its needs in new directions.
Abstract: FW4 is a newly developed hot die material widely
used in Forging Dies manufacturing. The right selection of the
machining conditions is one of the most important aspects to take
into consideration in the Electrical Discharge Machining (EDM) of
FW4. In this paper an attempt has been made to develop
mathematical models for relating the Material Removal Rate (MRR),
Tool Wear Ratio (TWR) and surface roughness (Ra) to machining
parameters (current, pulse-on time and voltage). Furthermore, a study
was carried out to analyze the effects of machining parameters in
respect of listed technological characteristics. The results of analysis
of variance (ANOVA) indicate that the proposed mathematical
models, can adequately describe the performance within the limits of
the factors being studied.
Abstract: The Institute of Product Development is dealing
with the development, design and dimensioning of micro components
and systems as a member of the Collaborative Research
Centre 499 “Design, Production and Quality Assurance of
Molded micro components made of Metallic and Ceramic Materials".
Because of technological restrictions in the miniaturization
of conventional manufacturing techniques, shape and
material deviations cannot be scaled down in the same proportion
as the micro parts, rendering components with relatively
wide tolerance fields. Systems that include such components
should be designed with this particularity in mind, often requiring
large clearance. On the end, the output of such systems
results variable and prone to dynamical instability. To save
production time and resources, every study of these effects
should happen early in the product development process and
base on computer simulation to avoid costly prototypes. A
suitable method is proposed here and exemplary applied to a
micro technology demonstrator developed by the CRC499. It
consists of a one stage planetary gear train in a sun-planet-ring
configuration, with input through the sun gear and output
through the carrier. The simulation procedure relies on ordinary
Multi Body Simulation methods and subsequently adds
other techniques to further investigate details of the system-s
behavior and to predict its response. The selection of the relevant
parameters and output functions followed the engineering
standards for regular sized gear trains. The first step is to
quantify the variability and to reveal the most critical points of
the system, performed through a whole-mechanism Sensitivity
Analysis. Due to the lack of previous knowledge about the system-s
behavior, different DOE methods involving small and
large amount of experiments were selected to perform the SA.
In this particular case the parameter space can be divided into
two well defined groups, one of them containing the gear-s profile
information and the other the components- spatial location.
This has been exploited to explore the different DOE techniques
more promptly. A reduced set of parameters is derived for
further investigation and to feed the final optimization process,
whether as optimization parameters or as external perturbation
collective. The 10 most relevant perturbation factors and 4 to 6
prospective variable parameters are considered in a new, simplified
model. All of the parameters are affected by the mentioned
production variability. The objective functions of interest
are based on scalar output-s variability measures, so the
problem becomes an optimization under robustness and reliability constrains. The study shows an initial step on the development
path of a method to design and optimize complex micro
mechanisms composed of wide tolerated elements accounting
for the robustness and reliability of the systems- output.