Abstract: The increasing competitiveness in manufacturing
industry is forcing manufacturers to seek effective processing
schedules. The paper presents an optimization manufacture
scheduling approach for dependent details processing with given
processing sequences and times on multiple machines. By defining
decision variables as start and end moments of details processing it is
possible to use straightforward variables restrictions to satisfy
different technological requirements and to formulate easy to
understand and solve optimization tasks for multiple numbers of
details and machines. A case study example is solved for seven base
moldings for CNC metalworking machines processed on five
different machines with given processing order among details and
machines and known processing time-s duration. As a result of linear
optimization task solution the optimal manufacturing schedule
minimizing the overall processing time is obtained. The
manufacturing schedule defines the moments of moldings delivery
thus minimizing storage costs and provides mounting due-time
satisfaction. The proposed optimization approach is based on real
manufacturing plant problem. Different processing schedules variants
for different technological restrictions were defined and implemented
in the practice of Bulgarian company RAIS Ltd. The proposed
approach could be generalized for other job shop scheduling
problems for different applications.
Abstract: This research explorers the relationship between leadership style and continuous improvement (CI) teams. CI teams have several features that are not always found in other types of teams, including multi-functional members, short time period for performance, positive and actionable results, and exposure to senior leadership. There is no one best style of leadership for these teams. Instead, it is important to select the best leadership style for the situation. The leader must have the flexibility to change styles and the skill to use the chosen style effectively in order to ensure the team’s success.
Abstract: A manufacturing inventory model with shortages with
carrying cost, shortage cost, setup cost and demand quantity as
imprecise numbers, instead of real numbers, namely interval number
is considered here. First, a brief survey of the existing works on
comparing and ranking any two interval numbers on the real line
is presented. A common algorithm for the optimum production
quantity (Economic lot-size) per cycle of a single product (so as
to minimize the total average cost) is developed which works well
on interval number optimization under consideration. Finally, the
designed algorithm is illustrated with numerical example.
Abstract: This paper presents modeling and optimization of two NP-hard problems in flexible manufacturing system (FMS), part type selection problem and loading problem. Due to the complexity and extent of the problems, the paper was split into two parts. The first part of the papers has discussed the modeling of the problems and showed how the real coded genetic algorithms (RCGA) can be applied to solve the problems. This second part discusses the effectiveness of the RCGA which uses an array of real numbers as chromosome representation. The novel proposed chromosome representation produces only feasible solutions which minimize a computational time needed by GA to push its population toward feasible search space or repair infeasible chromosomes. The proposed RCGA improves the FMS performance by considering two objectives, maximizing system throughput and maintaining the balance of the system (minimizing system unbalance). The resulted objective values are compared to the optimum values produced by branch-and-bound method. The experiments show that the proposed RCGA could reach near optimum solutions in a reasonable amount of time.
Abstract: This paper investigates the spatial structure of employment in the Jakarta Metropolitan Area (JMA), with reference to the concept of the Southeast Asian extended metropolitan region (EMR). A combination of factor analysis and local Getis-Ord (Gi*) hot-spot analysis is used to identify clusters of employment in the region, including those of the urban and agriculture sectors. Spatial statistical analysis is further used to probe the spatial association of identified employment clusters with their surroundings on several dimensions, including the spatial association between the central business district (CBD) in Jakarta city on employment density in the region, the spatial impacts of urban expansion on population growth and the degree of urban-rural interaction. The degree of spatial interaction for the whole JMA is measured by the patterns of commuting trips destined to the various employment clusters. Results reveal the strong role of the urban core of Jakarta, and the regional CBD, as the centre for mixed job sectors such as retail, wholesale, services and finance. Manufacturing and local government services, on the other hand, form corridors radiating out of the urban core, reaching out to the agriculture zones in the fringes. Strong associations between the urban expansion corridors and population growth, and urban-rural mix, are revealed particularly in the eastern and western parts of JMA. Metropolitan wide commuting patterns are focussed on the urban core of Jakarta and the CBD, while relatively local commuting patterns are shown to be prevalent for the employment corridors.
Abstract: A data cutting and sorting method (DCSM) is proposed
to optimize the performance of data mining. DCSM reduces the
calculation time by getting rid of redundant data during the data
mining process. In addition, DCSM minimizes the computational units
by splitting the database and by sorting data with support counts. In the
process of searching for the relationship between metabolic syndrome
and lifestyles with the health examination database of an electronics
manufacturing company, DCSM demonstrates higher search
efficiency than the traditional Apriori algorithm in tests with different
support counts.
Abstract: In the past years, the world has witnessed significant work in the field of Manufacturing. Special efforts have been made in the implementation of new technologies, management and control systems, among many others which have all evolved the field. Closely following all this, due to the scope of new projects and the need of turning the existing flexible ideas into more autonomous and intelligent ones, i.e.: moving toward a more intelligent manufacturing, the present paper emerges with the main aim of contributing to the analysis and a few customization issues of a new iCIM 3000 system at the IPSAM. In this process, special emphasis in made on the material flow problem. For this, besides offering a description and analysis of the system and its main parts, also some tips on how to define other possible alternative material flow scenarios and a partial analysis of the combinatorial nature of the problem are offered as well. All this is done with the intentions of relating it with the use of simulation tools, for which these have been briefly addressed with a special focus on the Witness simulation package. For a better comprehension, the previous elements are supported by a few figures and expressions which would help obtaining necessary data. Such data and others will be used in the future, when simulating the scenarios in the search of the best material flow configurations.
Abstract: Lately, significant work in the area of Intelligent
Manufacturing has become public and mainly applied within the
frame of industrial purposes. Special efforts have been made in the
implementation of new technologies, management and control
systems, among many others which have all evolved the field. Aware
of all this and due to the scope of new projects and the need of
turning the existing flexible ideas into more autonomous and
intelligent ones, i.e.: Intelligent Manufacturing, the present paper
emerges with the main aim of contributing to the design and analysis
of the material flow in either systems, cells or work stations under
this new “intelligent" denomination. For this, besides offering a
conceptual basis in some of the key points to be taken into account
and some general principles to consider in the design and analysis of
the material flow, also some tips on how to define other possible
alternative material flow scenarios and a classification of the states a
system, cell or workstation are offered as well. All this is done with
the intentions of relating it with the use of simulation tools, for which
these have been briefly addressed with a special focus on the Witness
simulation package. For a better comprehension, the previous
elements are supported by a detailed layout, other figures and a few
expressions which could help obtaining necessary data. Such data and
others will be used in the future, when simulating the scenarios in the
search of the best material flow configurations.
Abstract: Pharmaceutical industries and effluents of sewage treatment plants are the main sources of residual pharmaceuticals in water resources. These emergent pollutants may adversely impact the biophysical environment. Pharmaceutical industries often generate wastewater that changes in characteristics and quantity depending on the used manufacturing processes. Carbamazepine (CBZ), {5Hdibenzo [b,f]azepine-5-carboxamide, (C15H12N2O)}, is a significant non-biodegradable pharmaceutical contaminant in the Jordanian pharmaceutical wastewater, which is not removed by the activated sludge processes in treatment plants. Activated carbon may potentially remove that pollutant from effluents, but the high cost involved suggests that more attention should be given to the potential use of low-cost materials in order to reduce cost and environmental contamination. Powders of Jordanian non-metallic raw materials namely, Azraq Bentonite (AB), Kaolinite (K), and Zeolite (Zeo) were activated (acid and thermal treatment) and evaluated by removing CBZ. The results of batch and column techniques experiments showed around 46% and 67% removal of CBZ respectively.
Abstract: As the gradual increase of the enterprise scale, the
firms may possess many manufacturing plants located in different
places geographically. This change will result in the multi-site
production planning problems under the environment of multiple
plants or production resources. Our research proposes the structural
framework to analyze the multi-site planning problems. The analytical
framework is composed of six elements: multi-site conceptual model,
product structure (bill of manufacturing), production strategy,
manufacturing capability and characteristics, production planning
constraints, and key performance indicators. As well as the discussion
of these six ingredients, we also review related literatures in this paper
to match our analytical framework. Finally we take a real-world
practical example of a TFT-LCD manufacturer in Taiwan to explain
our proposed analytical framework for the multi-site production
planning problems.
Abstract: The term hybrid composite refers to the composite
containing more than one type of fiber material as reinforcing fillers.
It has become attractive structural material due to the ability of
providing better combination of properties with respect to single fiber
containing composite. The eco-friendly nature as well as processing
advantage, light weight and low cost have enhanced the attraction
and interest of natural fiber reinforced composite. The objective of
present research is to study the mechanical properties of jute-coir
fiber reinforced hybrid polypropylene (PP) composite according to
filler loading variation. In the present work composites were
manufactured by using hot press machine at four levels of fiber
loading (5, 10, 15 and 20 wt %). Jute and coir fibers were utilized at a
ratio of (1:1) during composite manufacturing. Tensile, flexural,
impact and hardness tests were conducted for mechanical
characterization. Tensile test of composite showed a decreasing trend
of tensile strength and increasing trend of the Young-s modulus with
increasing fiber content. During flexural, impact and hardness tests,
the flexural strength, flexural modulus, impact strength and hardness
were found to be increased with increasing fiber loading. Based on
the fiber loading used in this study, 20% fiber reinforced composite
resulted the best set of mechanical properties.
Abstract: The topic of surface flattening plays a vital role in the field of computer aided design and manufacture. Surface flattening enables the production of 2D patterns and it can be used in design and manufacturing for developing a 3D surface to a 2D platform, especially in fashion design. This study describes surface flattening based on minimum energy methods according to the property of different fabrics. Firstly, through the geometric feature of a 3D surface, the less transformed area can be flattened on a 2D platform by geodesic. Then, strain energy that has accumulated in mesh can be stably released by an approximate implicit method and revised error function. In some cases, cutting mesh to further release the energy is a common way to fix the situation and enhance the accuracy of the surface flattening, and this makes the obtained 2D pattern naturally generate significant cracks. When this methodology is applied to a 3D mannequin constructed with feature lines, it enhances the level of computer-aided fashion design. Besides, when different fabrics are applied to fashion design, it is necessary to revise the shape of a 2D pattern according to the properties of the fabric. With this model, the outline of 2D patterns can be revised by distributing the strain energy with different results according to different fabric properties. Finally, this research uses some common design cases to illustrate and verify the feasibility of this methodology.
Abstract: This paper presents a novel two-phase hybrid optimization algorithm with hybrid genetic operators to solve the optimal control problem of a single stage hybrid manufacturing system. The proposed hybrid real coded genetic algorithm (HRCGA) is developed in such a way that a simple real coded GA acts as a base level search, which makes a quick decision to direct the search towards the optimal region, and a local search method is next employed to do fine tuning. The hybrid genetic operators involved in the proposed algorithm improve both the quality of the solution and convergence speed. The phase–1 uses conventional real coded genetic algorithm (RCGA), while optimisation by direct search and systematic reduction of the size of search region is employed in the phase – 2. A typical numerical example of an optimal control problem with the number of jobs varying from 10 to 50 is included to illustrate the efficacy of the proposed algorithm. Several statistical analyses are done to compare the validity of the proposed algorithm with the conventional RCGA and PSO techniques. Hypothesis t – test and analysis of variance (ANOVA) test are also carried out to validate the effectiveness of the proposed algorithm. The results clearly demonstrate that the proposed algorithm not only improves the quality but also is more efficient in converging to the optimal value faster. They can outperform the conventional real coded GA (RCGA) and the efficient particle swarm optimisation (PSO) algorithm in quality of the optimal solution and also in terms of convergence to the actual optimum value.
Abstract: In this paper, a particle swarm optimization (PSO)
algorithm is proposed to solve machine loading problem in flexible
manufacturing system (FMS), with bicriterion objectives of
minimizing system unbalance and maximizing system throughput in
the occurrence of technological constraints such as available
machining time and tool slots. A mathematical model is used to
select machines, assign operations and the required tools. The
performance of the PSO is tested by using 10 sample dataset and the
results are compared with the heuristics reported in the literature. The
results support that the proposed PSO is comparable with the
algorithms reported in the literature.
Abstract: Recently, the advanced technologies that offer high
precision product, relative easy, economical process and also rapid
production are needed to realize the high demand of ultra precision
micro part. In our research, micromanufacturing based on soft
lithography and nanopowder injection molding was investigated. The
silicone metal pattern with ultra thick and high aspect ratio succeeds to
fabricate Polydimethylsiloxane (PDMS) micro mold. The process
followed by nanopowder injection molding (PIM) by a simple vacuum
hot press. The 17-4ph nanopowder with diameter of 100 nm, succeed
to be injected and it forms green sample microbearing with thickness,
microchannel and aspect ratio is 700μm, 60μm and 12, respectively.
Sintering process was done in 1200 C for 2 hours and heating rate
0.83oC/min. Since low powder load (45% PL) was applied to achieve
green sample fabrication, ~15% shrinkage happen in the 86% relative
density. Several improvements should be done to produce high
accuracy and full density sintered part.
Abstract: ISO 9000 is the most popular and widely adopted meta-standard for quality and operational improvements. However, only limited empirical research has been conducted to examine the impact of ISO 9000 on operational performance based on objective and longitudinal data. To reveal any causal relationship between the adoption of ISO 9000 and operational performance, we examined the timing and magnitude of change in time-based performance as a result of ISO 9000 adoption. We analyzed the changes in operating cycle, inventory days, and account receivable days prior and after the implementation of ISO 9000 in 695 publicly listed manufacturing firms. We found that ISO 9000 certified firms shortened their operating cycle time by 5.28 days one year after the implementation of ISO 9000. In the long-run (3 years after certification), certified firms showed continuous improvement in time-based efficiency, and experienced a shorter operating cycle time of 11 days than that of non-certified firms. There was an average of 6.5% improvement in operating cycle time for ISO 9000 certified firms. Both inventory days and account receivable days showed similar significant improvements after the implementation of ISO 9000, too.
Abstract: Design for Disassembly (DfD) aims to reuse the
structural components instead of demolition followed by recycling of
the demolition debris. This concept preserves the invested embodied
energy of materials, thus reducing inputs of new embodied energy
during materials reprocessing or remanufacturing. Both analytical and
experimental research on a proposed DfD beam-column connection
for use in residential apartments is currently investigated at the
National University of Singapore in collaboration with the Housing
and Development Board of Singapore. The present study reports on
the results of a numerical analysis of the proposed connection utilizing
finite element analysis. The numerical model was calibrated and
validated by comparison against experimental results. Results of a
parametric study will also be presented and discussed.
Abstract: In this paper is study the possibility of successfully
implementing of hollow roller concept in order to minimize inertial
mass of the large bearings, with major results in diminution of the
material consumption, increasing of power efficiency (in wind power
station area), increasing of the durability and life duration of the large
bearings systems, noise reduction in working, resistance to
vibrations, an important diminution of losses by abrasion and
reduction of the working temperature. In this purpose was developed
an original solution through which are reduced mass, inertial forces
and moments of large bearings by using of hollow rollers. The
research was made by using the method of finite element analysis
applied on software type Solidworks - Nastran. Also, is study the
possibility of rapidly changing the manufacturing system of solid and
hollow cylindrical rollers.
Abstract: As business environments are rapidly changing,
the manufacturing system must be reconfigured to adapt to
various customer needs. In order to cope with this challenge, it
is quintessential to test industrial control logic rapidly and
easily in the design time, and monitor operational behavior in
the run time of automated manufacturing system. Proposed
integrated model for virtual prototyping and operational
monitoring of industrial control logic is to improve limitations
of current ladder programming practices and general discrete
event simulation method. Each plant layout model using HMI
package and object-oriented control logic model is designed
independently and is executed simultaneously in integrated
manner to reflect design practices of automation system in the
design time. Control logic is designed and executed using UML
activity diagram without considering complicated control
behavior to deal with current trend of reconfigurable
manufacturing. After the physical installation, layout model of
virtual prototype constructed in the design time is reused for
operational monitoring of system behavior during run time.
Abstract: In today-s global and competitive market,
manufacturing companies are working hard towards improving their
production system performance. Most companies develop production
systems that can help in cost reduction. Manufacturing systems
consist of different elements including production methods,
machines, processes, control and information systems. Human issues
are an important part of manufacturing systems, yet most companies
do not pay sufficient attention to them. In this paper, a workforce
planning (WP) model is presented. A non-linear programming model
is developed in order to minimize the hiring, firing, training and
overtime costs. The purpose is to determine the number of workers
for each worker type, the number of workers trained, and the number
of overtime hours. Moreover, a decision support system (DSS) based
on the proposed model is introduced using the Excel-Lingo software
interfacing feature. This model will help to improve the interaction
between the workers, managers and the technical systems in
manufacturing.