Abstract: Manufacturing, production and service industries within Libya have struggled with many problems during the past two decades due to many difficulties. These problems have created a negative impact on the productivity and utilization of many industries around the country. This paper studies the implementation levels of the manufacturing control systems known as Manufacturing Resource Planning (MRPII) being adapted within some Libyan industries. A survey methodology has been applied for this research, based on the survey analysis, the results pointed out that the system within these industries has a modest strategy towards most of the areas that are considered as being very crucial in implementing these systems successfully. The findings also show a variation within these implementation levels with a respect to the key-elements that related to MRPII, giving the highest levels in the emphasise on financial data accuracy. The paper has also identified limitations within the investigated manufacturing and managerial areas and has pointed to where senior managers should take immediate actions in order to achieve effective implementation of MRPII within their business area.
Abstract: Virtual Reality Modelling Language (VRML) is description language, which belongs to a field Window on World virtual reality system. The file, which is in VRML format, can be interpreted by VRML explorer in three-dimensional scene. VRML was created with aim to represent virtual reality on Internet easier. Development of 3D graphic is connected with Silicon Graphic Corporation. VRML 2.0 is the file format for describing interactive 3D scenes and objects. It can be used in collaboration with www, can be used for 3D complex representations creating of scenes, products or VR applications VRML 2.0 enables represent static and animated objects too. Interesting application of VRML is in area of manufacturing systems presentation.
Abstract: Despite many success stories of manufacturing safety, many organizations are still reluctant, perceiving it as cost increasing and time consuming. The clear contributor may be due to the use of lagging indicators rather than leading indicator measures. The study therefore proposes a combinatorial model for determining the best safety strategy. A combination theory and cost benefit analysis was employed to develop a monetary saving / loss function in terms value of preventions and cost of prevention strategy. Documentations, interviews and structured questionnaire were employed to collect information on Before-And-After safety programme records from a Tobacco company between periods of 1993-2001(for pre-safety) and 2002-2008 (safety period) for the model application. Three combinatorial alternatives A, B, C were obtained resulting into 4, 6 and 4 strategies respectively with PPE and Training being predominant. A total of 728 accidents were recorded for a 9 year period of pre-safety programme and 163 accidents were recorded for 7 years period of safety programme. Six preventions activities (alternative B) yielded the best results. However, all the years of operation experienced except year 2004. The study provides a leading resources for planning successful safety programme
Abstract: This paper proposes the requirements and design of
RFID based system for SFC (Shop Floor Control) in order to achieve
the factory real time controllability, Allowing to develop EManufacturing
System. The detailed logical specifications of the core
functions and the design diagrams of RFID based system are
developed. Then RFID deployment in E-Manufacturing systems is
investigated..
Abstract: International markets driven forces are changing
continuously, therefore companies need to gain a competitive edge in
such markets. Improving the company's products, processes and
practices is no longer auxiliary. Lean production is a production
management philosophy that consolidates work tasks with minimum
waste resulting in improved productivity. Lean production practices
can be mapped into many production areas. One of these is
Manufacturing Equipment and Technology (MET). Many lean
production practices can be implemented in MET, namely, specific
equipment configurations, total preventive maintenance, visual
control, new equipment/ technologies, production process
reengineering and shared vision of perfection.The purpose of this
paper is to investigate the implementation level of these six practices
in Jordanian industries. To achieve that a questionnaire survey has
been designed according to five-point Likert scale. The questionnaire
is validated through pilot study and through experts review. A sample
of 350 Jordanian companies were surveyed, the response rate was
83%. The respondents were asked to rate the extent of
implementation for each of practices. A relationship conceptual
model is developed, hypotheses are proposed, and consequently the
essential statistical analyses are then performed. An assessment tool
that enables management to monitor the progress and the
effectiveness of lean practices implementation is designed and
presented. Consequently, the results show that the average
implementation level of lean practices in MET is 77%, Jordanian
companies are implementing successfully the considered lean
production practices, and the presented model has Cronbach-s alpha
value of 0.87 which is good evidence on model consistency and
results validation.
Abstract: This is a cross-cultural study that determines South
African multinational enterprises (MNEs) entry strategies as they
invest in Africa. An integrated theoretical framework comprising the
transaction cost theory, Uppsala model, eclectic paradigm and the
distance framework was adopted. A sample of 40 South African
MNEs with 415 existing FDI entries in Africa was drawn. Using an
ordered logistic regression model, the impact of culture on the choice
of degree of control by South African MNEs in Africa was
determined. Cultural distance was one of significant factors that
influenced South African MNEs- choice of degree of control.
Furthermore, South African MNEs are risk averse in all countries in
Africa but minimize the risks differently across sectors. Service
sectors chooses to own their subsidiaries 100% and avoid dealing
with the locals while manufacturing, resources and construction
choose to have a local partner to share the risk.
Abstract: The indistinctness of the manufacturing processes makes that a parts cannot be realized in an absolutely exact way towards the specifications on the dimensions. It is thus necessary to assume that the effectively realized product has to belong in a very strict way to compatible intervals with a correct functioning of the parts. In this paper we present an approach based on mixing tow different characteristics theories, the fuzzy system and Petri net system. This tool has been proposed to model and control the quality in an assembly system. A robust command of a mechanical assembly process is presented as an application. This command will then have to maintain the specifications interval of parts in front of the variations. It also illustrates how the technique reacts when the product quality is high, medium, or low.
Abstract: Higher productivity and less cost in the ship
manufacturing process are required to maintain the international
competitiveness of morden manufacturing industries. In shipbuilding,
however, the Engineering To Order (ETO) production method and
production process is very difficult. Thus, designs change frequently.
In accordance with production, planning should be set up according
to scene changes. Therefore, fixed production planning is very
difficult. Thus, a scheduler must first make sketchy plans, then
change the plans based on the work progress and modifications.
Thus, data sharing in a shipbuilding block assembly shop is very
important. In this paper, we proposed to scheduling method
applicable to the shipbuilding industry and decision making support
system through web based visualization system.
Abstract: Drilling is the most common machining operation and it forms the highest machining cost in many manufacturing activities including automotive engine production. The outcome of this operation depends upon many factors including utilization of proper cutting tool geometry, cutting tool material and the type of coating used to improve hardness and resistance to wear, and also cutting parameters. With the availability of a large array of tool geometries, materials and coatings, is has become a challenging task to select the best tool and cutting parameters that would result in the lowest machining cost or highest profit rate. This paper describes an algorithm developed to help achieve good performances in drilling operations by automatically determination of proper cutting tools and cutting parameters. It also helps determine machining sequences resulting in minimum tool changes that would eventually reduce machining time and cost where multiple tools are used.
Abstract: Model Predictive Control (MPC) is increasingly being
proposed for real time applications and embedded systems. However
comparing to PID controller, the implementation of the MPC in
miniaturized devices like Field Programmable Gate Arrays (FPGA)
and microcontrollers has historically been very small scale due to its
complexity in implementation and its computation time requirement.
At the same time, such embedded technologies have become an
enabler for future manufacturing enterprises as well as a transformer
of organizations and markets. Recently, advances in microelectronics
and software allow such technique to be implemented in embedded
systems. In this work, we take advantage of these recent advances
in this area in the deployment of one of the most studied and
applied control technique in the industrial engineering. In fact in
this paper, we propose an efficient framework for implementation
of Generalized Predictive Control (GPC) in the performed STM32
microcontroller. The STM32 keil starter kit based on a JTAG interface
and the STM32 board was used to implement the proposed GPC
firmware. Besides the GPC, the PID anti windup algorithm was
also implemented using Keil development tools designed for ARM
processor-based microcontroller devices and working with C/Cµ
langage. A performances comparison study was done between both
firmwares. This performances study show good execution speed and
low computational burden. These results encourage to develop simple
predictive algorithms to be programmed in industrial standard hardware.
The main features of the proposed framework are illustrated
through two examples and compared with the anti windup PID
controller.
Abstract: Amongst the consistently fluctuating conditions
prevailing today, changeability represents a strategic key factor for a
manufacturing company to achieve success on the international
markets. In order to cope with turbulences and the increasing level of
incalculability, not only the flexible design of production systems but
in particular the employee as enabler of change provide the focus
here. It is important to enable employees from manufacturing
companies to participate actively in change events and in change
decisions. To this end, the learning factory has been created, which is
intended to serve the development of change-promoting competences
and the sensitization of employees for the necessity of changes.
Abstract: Throughput is an important measure of performance of production system. Analyzing and modeling of production throughput is complex in today-s dynamic production systems due to uncertainties of production system. The main reasons are that uncertainties are materialized when the production line faces changes in setup time, machinery break down, lead time of manufacturing, and scraps. Besides, demand changes are fluctuating from time to time for each product type. These uncertainties affect the production performance. This paper proposes Bayesian inference for throughput modeling under five production uncertainties. Bayesian model utilized prior distributions related to previous information about the uncertainties where likelihood distributions are associated to the observed data. Gibbs sampling algorithm as the robust procedure of Monte Carlo Markov chain was employed for sampling unknown parameters and estimating the posterior mean of uncertainties. The Bayesian model was validated with respect to convergence and efficiency of its outputs. The results presented that the proposed Bayesian models were capable to predict the production throughput with accuracy of 98.3%.
Abstract: In modern telecommunications industry, demand &
supply chain management (DSCM) needs reliable design and
versatile tools to control the material flow. The objective for efficient
DSCM is reducing inventory, lead times and related costs in order to
assure reliable and on-time deliveries from manufacturing units
towards customers. In this paper the multi-rate expert system based
methodology for developing simulation tools that would enable
optimal DSCM for multi region, high volume and high complexity
manufacturing environment was proposed.
Abstract: The paper gives the pilot results of the project that is
oriented on the use of data mining techniques and knowledge
discoveries from production systems through them. They have been
used in the management of these systems. The simulation models of
manufacturing systems have been developed to obtain the necessary
data about production. The authors have developed the way of
storing data obtained from the simulation models in the data
warehouse. Data mining model has been created by using specific
methods and selected techniques for defined problems of production
system management. The new knowledge has been applied to
production management system. Gained knowledge has been tested
on simulation models of the production system. An important benefit
of the project has been proposal of the new methodology. This
methodology is focused on data mining from the databases that store
operational data about the production process.
Abstract: The principal focus of this study is on the
measurement and analysis of labor learnings in Pakistan. The study
at the aggregate economy level focus on the labor productivity
movements and at large-scale manufacturing level focus on the cost
structure, with isolating the contribution of the learning curve. The
analysis of S-shaped curve suggests that learnings are only below one
half of aggregate learning curve and other half shows the retardation
in learning, hence retardation in productivity movements. The study
implies the existence of learning economies in term of cost reduction
that is input cost per unit produced decreases by 0.51 percent every
time the cumulative production output doubles.
Abstract: This paper implements the inventory model developed in the first part of this paper in a simplified problem to simultaneously reduce costs and risks in JIT systems. This model is developed to ascertain an optimal ordering strategy for procuring raw materials by using regular multi-external and local backup suppliers to reduce the total cost of the products, and at the same time to reduce the risks arising from this cost reduction within production systems. A comparison between the cost of using the JIT system and using the proposed inventory model shows the superiority of the use of the inventory model.
Abstract: Organizational culture fosters innovation, and innovation is the main engine to be sustained within the uncertainty market. Like other countries, the construction industry significantly contributes to the economy, society and technology of Malaysia, yet, innovation is still considered slow compared to other industries such as manufacturing. Given the important role of an architect as the key player and the contributor of new ideas in the construction industry, there is a call to identify the issue and improve the current situation by focusing on the architectural firms. In addition, the existing studies tend to focus only on a few dimensions of organizational culture and very few studies consider whether innovation is being generated or adopted. Hence, the present research tends to fill in the gap by identifying the organizational cultures that foster or hinder innovation generation and/or innovation adoption, and propose a model of organizational culture and innovation generation and/or adoption.
Abstract: All around the world pulp and paper industries are the
biggest plant production with the environmental pollution as the
biggest challenge facing the pulp manufacturing operations. The
concern among these industries is to produce a high volume of papers
with the high quality standard and of low cost without affecting the
environment. This result obtained from this bleaching study show
that the activation of peroxide was an effective method of reducing
the total applied charge of chlorine dioxide which is harmful to our
environment and also show that softwood and hardwood Kraft pulps
responded linearly to the peroxide treatments. During the bleaching
process the production plant produce chlorines. Under the trial stages
chloride dioxide has been reduced by 3 kg/ton to reduce the
brightness from 65% ISO to 60% ISO of pulp and the dosing point
returned to the E stage charges by pre-treating Kraft pulps with
hydrogen peroxide. The pulp and paper industry has developed
elemental chlorine free (ECF) and totally chlorine free (TCF)
bleaching, in their quest for being environmental friendly, they have
been looking at ways to turn their ECF process into a TCF process
while still being competitive. This prompted the research to
investigate the capability of the hydrogen peroxide as catalyst to
reduce chloride dioxide.
Abstract: This study reports the implementation of Good
Manufacturing Practice (GMP) in a polycarbonate film processing
plant. The implementation of GMP took place with the creation of a
multidisciplinary team. It was carried out in four steps: conduct gap
assessment, create gap closure plan, close gaps, and follow up the
GMP implementation. The basis for the gap assessment is the
guideline for GMP for plastic materials and articles intended for Food
Contact Material (FCM), which was edited by Plastic Europe. The
effective results of the GMP implementation in this study showed
100% completion of gap assessment. The key success factors for
implementing GMP in production process are the commitment,
intention and support of top management.
Abstract: Sub-prime mortgage crisis which began in the US is
regarded as the most economic crisis since the Great Depression in the
early 20th century. Especially, hidden problems on efficient operation
of a business were disclosed at a time and many financial institutions
went bankrupt and filed for court receivership. The collapses of
physical market lead to bankruptcy of manufacturing and construction
businesses. This study is to analyze dynamic efficiency of construction
businesses during the five years at the turn of the global financial
crisis. By discovering the trend and stability of efficiency of a
construction business, this study-s objective is to improve
management efficiency of a construction business in the
ever-changing construction market. Variables were selected by
analyzing corporate information on top 20 construction businesses in
Korea and analyzed for static efficiency in 2008 and dynamic
efficiency between 2006 and 2010. Unlike other studies, this study
succeeded in deducing efficiency trend and stability of a construction
business for five years by using the DEA/Window model. Using the
analysis result, efficient and inefficient companies could be figured
out. In addition, relative efficiency among DMU was measured by
comparing the relationship between input and output variables of
construction businesses. This study can be used as a literature to
improve management efficiency for companies with low efficiency
based on efficiency analysis of construction businesses.