Abstract: Designing modern machine tools is a complex task. A
simulation tool to aid the design work, a virtual machine, has
therefore been developed in earlier work. The virtual machine
considers the interaction between the mechanics of the machine
(including structural flexibility) and the control system. This paper
exemplifies the usefulness of the virtual machine as a tool for product
development. An optimisation study is conducted aiming at
improving the existing design of a machine tool regarding weight and
manufacturing accuracy at maintained manufacturing speed. The
problem can be categorised as constrained multidisciplinary multiobjective
multivariable optimisation. Parameters of the control and
geometric quantities of the machine are used as design variables. This
results in a mix of continuous and discrete variables and an
optimisation approach using a genetic algorithm is therefore
deployed. The accuracy objective is evaluated according to
international standards. The complete systems model shows nondeterministic
behaviour. A strategy to handle this based on statistical
analysis is suggested. The weight of the main moving parts is reduced
by more than 30 per cent and the manufacturing accuracy is
improvement by more than 60 per cent compared to the original
design, with no reduction in manufacturing speed. It is also shown
that interaction effects exist between the mechanics and the control,
i.e. this improvement would most likely not been possible with a
conventional sequential design approach within the same time, cost
and general resource frame. This indicates the potential of the virtual
machine concept for contributing to improved efficiency of both
complex products and the development process for such products.
Companies incorporating such advanced simulation tools in their
product development could thus improve its own competitiveness as
well as contribute to improved resource efficiency of society at large.
Abstract: Shipping comb is mounted on Head Stack Assembly
(HSA) to prevent collision of the heads, maintain the gap between
suspensions and protect HSA tips from unintentional contact
damaged in the manufacturing process. Failure analysis of shipping
comb in hard disk drive production processes is proposed .Field
observations were performed to determine the fatal areas on shipping
comb and their failure fraction. Root cause failure analysis (RCFA) is
applied to specify the failure causes subjected to various loading
conditions. For reliability improvement, failure mode and effects
analysis (FMEA) procedure to evaluate the risk priority is performed.
Consequently, the more suitable information design criterions were
obtained.
Abstract: In recent years, environment regulation forcing
manufactures to consider recovery activity of end-of- life products
and/or return products for refurbishing, recycling,
remanufacturing/repair and disposal in supply chain management. In
this paper, a mathematical model is formulated for single product
production-inventory system considering remanufacturing/reuse of
return products and rate of return products follows a demand like
function, dependent on purchasing price and acceptance quality level.
It is useful in decision making to determine whether to go for
remanufacturing or disposal of returned products along with newly
produced products to satisfy a stationary demand. In addition, a
modified genetic algorithm approach is proposed, inspired by particle
swarm optimization method. Numerical analysis of the case study is
carried out to validate the model.
Abstract: This paper identifies five key design characteristics of
production scheduling software systems in printed circuit board (PCB) manufacturing. The authors consider that, in addition to an effective scheduling engine, a scheduling system should be able to
process a preventative maintenance calendar, to give the user the
flexibility to handle data using a variety of electronic sources, to run
simulations to support decision-making, and to have simple and
customisable graphical user interfaces. These design considerations
were the result of a review of academic literature, the evaluation of
commercial applications and a compilation of requirements of a PCB manufacturer. It was found that, from those systems that were evaluated, those that effectively addressed all five characteristics
outlined in this paper were the most robust of all and could be used in
PCB manufacturing.
Abstract: Rapid prototyping (RP) techniques are a group of
advanced manufacturing processes that can produce custom made
objects directly from computer data such as Computer Aided Design
(CAD), Computed Tomography (CT) and Magnetic Resonance
Imaging (MRI) data. Using RP fabrication techniques, constructs
with controllable and complex internal architecture with appropriate
mechanical properties can be achieved. One of the attractive and
promising utilization of RP techniques is related to tissue engineering
(TE) scaffold fabrication. Tissue engineering scaffold is a 3D
construction that acts as a template for tissue regeneration. Although
several conventional techniques such as solvent casting and gas
forming are utilized in scaffold fabrication; these processes show
poor interconnectivity and uncontrollable porosity of the produced
scaffolds. So, RP techniques become the best alternative fabrication
methods of TE scaffolds. This paper reviews the current state of the
art in the area of tissue engineering scaffolds fabrication using
advanced RP processes, as well as the current limitations and future
trends in scaffold fabrication RP techniques.
Abstract: The objective of positioning the fixture elements in
the fixture is to make the workpiece stiff, so that geometric errors in
the manufacturing process can be reduced. Most of the work for
optimal fixture layout used the minimization of the sum of the nodal
deflection normal to the surface as objective function. All deflections
in other direction have been neglected. We propose a new method for
fixture layout optimization in this paper, which uses the element
strain energy. The deformations in all the directions have been
considered in this way. The objective function in this method is to
minimize the sum of square of element strain energy. Strain energy
and stiffness are inversely proportional to each other. The
optimization problem is solved by the sequential quadratic
programming method. Three different kinds of case studies are
presented, and results are compared with the method using nodal
deflections as objective function to verify the propose method.
Abstract: Radio Frequency Identification (RFID) initially introduced
during WW-II, has revolutionized the world with its numerous
benefits and plethora of implementations in diverse areas ranging
from manufacturing to agriculture to healthcare to hotel management.
This work reviews the current research in this area with emphasis
on applications for supply chain management and to develop a
taxonomic framework to classify literature which will enable swift
and easy content analysis and also help identify areas for future
research.
Abstract: Green Lean Total Quality Management (LTQM) Human Resource Management (HRM) System is a system comprises of HRM in Environmental Management System (EMS) practices which is integrated to TQM with Lean Manufacturing (LM) principles. HRM is essential especially in dealing with low motivation and less productive employees. The ultimate goal of this system is to focus on achieving total human resource development that is motivated and capable to optimize their creativity to be a part of Green and Lean TQM organization. A survey questionnaire was developed and distributed to 30 highly active automotive vendors in Malaysia and analyzed by Minitab v16 and SPSS v17. It was found out companies that are practicing Green LTQM HRM practices have generated more revenue and have RND capability. However, years of company establishment do not affect the openness of the company to adapt new initiatives that can help to improve the effectiveness of the operations. It was also found out the importance of training, communication and rewards for employees. The Green LTQM HRM practices framework model established in this study hopefully will give preliminary insight especially to companies that are still looking for system that can improve their productivity from managing human resource. This is preliminary study that combined 4 awards practices, ISO/TS16949, Toyota Production System SAEJ4000, MAJAICO Lean Production System and EMS focusing on highly active companies that have been involved in MAJAICO Program and Proton Vendor Development Program. Future study can be conducted to know the status at other industry as well as case study pertaining to this system.
Abstract: This paper was aimed at developing a computer aided
design and manufacturing system for spatial cylindrical cams. In the
proposed system, a milling tool with a diameter smaller than that of the
roller, instead of the standard cutter for traditional machining process,
was used to generate the tool path for spatial cams. To verify the
feasibility of the proposed method, a multi-axis machining simulation
software was further used to simulate the practical milling operation of
spatial cams. It was observed from computer simulation that the tool
path of small-sized cutter were within the motion range of a standard
cutter, no occurrence of overcutting. Examination of a finished cam
component clearly verifies the accuracy of the tool path generated for
small-sized milling tool. It is believed that the use of small-sized cutter
for the machining of the spatial cylindrical cams can generate a better
surface morphology with higher accuracy. The improvement in
efficiency and cost for the manufacturing of the spatial cylindrical cam
can be expected through the proposed method.
Abstract: In recent years, scanning probe atomic force
microscopy SPM AFM has gained acceptance over a wide spectrum
of research and science applications. Most fields focuses on physical,
chemical, biological while less attention is devoted to manufacturing
and machining aspects. The purpose of the current study is to assess
the possible implementation of the SPM AFM features and its
NanoScope software in general machining applications with special
attention to the tribological aspects of cutting tool. The surface
morphology of coated and uncoated as-received carbide inserts is
examined, analyzed, and characterized through the determination of
the appropriate scanning setting, the suitable data type imaging
techniques and the most representative data analysis parameters
using the MultiMode SPM AFM in contact mode. The NanoScope
operating software is used to capture realtime three data types
images: “Height", “Deflection" and “Friction". Three scan sizes are
independently performed: 2, 6, and 12 μm with a 2.5 μm vertical
range (Z). Offline mode analysis includes the determination of three
functional topographical parameters: surface “Roughness", power
spectral density “PSD" and “Section". The 12 μm scan size in
association with “Height" imaging is found efficient to capture every
tiny features and tribological aspects of the examined surface. Also,
“Friction" analysis is found to produce a comprehensive explanation
about the lateral characteristics of the scanned surface. Configuration
of many surface defects and drawbacks has been precisely detected
and analyzed.
Abstract: A simple mobile engine-driven pneumatic paddy
collector made of locally available materials using local
manufacturing technology was designed, fabricated, and tested for
collecting and bagging of paddy dried on concrete pavement. The
pneumatic paddy collector had the following major components:
radial flat bladed type centrifugal fan, power transmission system,
bagging area, frame and the conveyance system. Results showed
significant differences on the collecting capacity, noise level, and fuel
consumption when rotational speed of the air mover shaft was varied.
Other parameters such as collecting efficiency, air velocity,
augmented cracked grain percentage, and germination rate were not
significantly affected by varying rotational speed of the air mover
shaft. The pneumatic paddy collector had a collecting efficiency of
99.33 % with a collecting capacity of 2685.00 kg/h at maximum
rotational speed of centrifugal fan shaft of about 4200 rpm. The
machine entailed an investment cost of P 62,829.25. The break-even
weight of paddy was 510,606.75 kg/yr at a collecting cost of 0.11
P/kg of paddy. Utilizing the machine for 400 hours per year
generated an income of P 23,887.73. The projected time needed to
recover cost of the machine based on 2685 kg/h collecting capacity
was 2.63 year.
Abstract: Business rules are widely used within the services
sector. They provide consistency and allow relatively unskilled staff
to process complex transactions correctly. But there are many
examples where the rules themselves have an impact on the costs and
profits of an organisation. Financial services, transport and human
services are areas where the rules themselves can impact the bottom
line in a predictable way. If this is the case, how can we find that set
of rules that maximise profit, performance or customer service, or
any other key performance indicators? The manufacturing, energy
and process industries have embraced mathematical optimisation
techniques to improve efficiency, increase production and so on. This
paper explores several real world (but simplified) problems in the
services sector and shows how business rules can be optimised. It
also examines the similarities and differences between the service
and other sectors, and how optimisation techniques could be used to
deliver similar benefits.
Abstract: A new generation product made from bamboo strips,
known as laminated bamboo, has gained importance. The objective
of this research was to experiment the effect of three factors on the
mechanical property of laminated bamboo. The interested factors for
experimental design were (A) four bamboo species, namely Bambusa
blumeana Schultes (Pai See Suk), Dendrocalamus asper Backer (Pai
Tong), Dendrocalamus hamiltonii Nees (Pai Hok) and
Dendrocalamus sericeus Munro (Pai Sang Mon), (B) two types of
glue adhesive, polyvinyl acetate emulsion (PVAC) fortified with
urea-formaldehyde (UF) and urea-formaldehyde (UF) to make
parallel-oriented bamboo strips laminates and (C) glue weight per
strip area, 150 g/m2 and 190 g/m2. Experimental results showed that
Dendrocalamus asper Backer (Pai Tong) and Dendrocalamus
sericeus Munro (Pai Sang Mon) were best used for manufacturing
due to their highest MOR and MOE. The amount of glue weight 150
g/m2 yielded higher MOR and MOE than the amount of glue weight
190 g/m2. At the conclusion, the laminated bamboo manufacturers
can benefit from this research in order to select right materials
according to strength, cost and accessibility.
Abstract: The right information at the right time influences the
enterprise and technical success. Sharing knowledge among members
of a big organization may be a complex activity. And as long as the
knowledge is not shared, can not be exploited by the organization.
There are some mechanisms which can originate knowledge sharing.
It is intended, in this paper, to trigger these mechanisms by using
semantic nets. Moreover, the intersection and overlapping of terms
and sub-terms, as well as their relationships will be described through
the mereology science for the whole knowledge sharing system. It is
proposed a knowledge system to supply to operators with the right
information about a specific process and possible risks, e.g. at the
assembly process, at the right time in an automated manufacturing
environment, such as at the automotive industry.
Abstract: The concept of flexible manufacturing is highly
appealing in gaining a competitive edge in the market by quickly
adapting to the changing customer needs. Scheduling jobs on flexible
manufacturing systems (FMSs) is a challenging task of managing the
available flexibility on the shop floor to react to the dynamics of the
environment in real-time. In this paper, an agent-oriented scheduling
framework that can be integrated with a real or a simulated FMS is
proposed. This framework works in stochastic environments with a
dynamic model of job arrival. It supports a hierarchical cooperative
scheduling that builds on the available flexibility of the shop floor.
Testing the framework on a model of a real FMS showed the
capability of the proposed approach to overcome the drawbacks of
the conventional approaches and maintain a near optimal solution
despite the dynamics of the operational environment.
Abstract: The fact that traditional food safety system in the
absence of food safety culture is inadequate has recently become a
cause of concern for food safety professionals and other stakeholders.
Focusing on implementation of traditional food safety system i.e
HACCP prerequisite program and HACCP without the presence of
food safety culture in the food industry has led to the processing,
marketing and distribution of contaminated foods. The results of this
are regular out breaks of food borne illnesses and recalls of foods
from retail outlets with serious consequences to the consumers and
manufacturers alike. This article will consider the importance of food
safety culture, the cases of outbreaks and recalls that occurred when
companies did not make food safety culture a priority. Most
importantly, the food safety cultures of some food industries in South
Africa were assessed from responses to questionnaires from food
safety/food industry professionals in Durban South Africa. The
article was concluded by recommending that both food
industry employees and employers alike take food safety culture
seriously.
Abstract: Modern manufacturing facilities are large scale,
highly complex, and operate with large number of variables under
closed loop control. Early and accurate fault detection and diagnosis
for these plants can minimise down time, increase the safety of plant
operations, and reduce manufacturing costs. Fault detection and
isolation is more complex particularly in the case of the faulty analog
control systems. Analog control systems are not equipped with
monitoring function where the process parameters are continually
visualised. In this situation, It is very difficult to find the relationship
between the fault importance and its consequences on the product
failure. We consider in this paper an approach to fault detection and
analysis of its effect on the production quality using an adaptive
centring and scaling in the pickling process in cold rolling. The fault
appeared on one of the power unit driving a rotary machine, this
machine can not track a reference speed given by another machine.
The length of metal loop is then in continuous oscillation, this affects
the product quality. Using a computerised data acquisition system,
the main machine parameters have been monitored. The fault has
been detected and isolated on basis of analysis of monitored data.
Normal and faulty situation have been obtained by an artificial neural
network (ANN) model which is implemented to simulate the normal
and faulty status of rotary machine. Correlation between the product
quality defined by an index and the residual is used to quality
classification.
Abstract: This is an applied research to propose the method for
price quotation for a contract electronics manufacturer. It has had a
precise price quoting method but such method could not quickly
provide a result as the customer required. This reduces the ability of
company to compete in this kind of business. In this case, the cause
of long time quotation process was analyzed. A lot of product
features have been demanded by customer. By checking routine
processes, it was found that high fraction of quoting time was used
for production time estimating which has effected to the
manufacturing or production cost. Then the historical data of
products including types, number of components, assembling
method, and their assembling time were used to analyze the key
components affecting to production time. The price quoting model
then was proposed. The implementation of proposed model was able
to remarkably reduce quoting time with an acceptable required
precision.
Abstract: The paper provides a literature review of the STEPNC
compliant research around the world. The first part of this paper
focuses on projects based on STEP compliance followed by research
and development in this area based on machining operations. Review
the literature relating to relevant STEP standards and application in
the area of turning centers. This research will review the various
research work, carried out from the evolution of STEP-NC of the
CNC manufacturing activities. The paper concludes with discussion
of the applications in this particular area.
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.