From Hype to Ignorance – A Review of 30 Years of Lean Production

Lean production (or lean management respectively) gained popularity in several waves. The last three decades have been filled with numerous attempts to apply these concepts in companies. However, this has only been partially successful. The roots of lean production can be traced back to Toyota-s just-in-time production. This concept, which according to Womack-s, Jones- and Roos- research at MIT was employed by Japanese car manufacturers, became popular under its international names “lean production", “lean-manufacturing" and was termed “Schlanke Produktion" in Germany. This contribution shows a review about lean production in Germany over the last thirty years: development, trial & error and implementation as well.

Evolutionary Approach for Automated Discovery of Censored Production Rules

In the recent past, there has been an increasing interest in applying evolutionary methods to Knowledge Discovery in Databases (KDD) and a number of successful applications of Genetic Algorithms (GA) and Genetic Programming (GP) to KDD have been demonstrated. The most predominant representation of the discovered knowledge is the standard Production Rules (PRs) in the form If P Then D. The PRs, however, are unable to handle exceptions and do not exhibit variable precision. The Censored Production Rules (CPRs), an extension of PRs, were proposed by Michalski & Winston that exhibit variable precision and supports an efficient mechanism for handling exceptions. A CPR is an augmented production rule of the form: If P Then D Unless C, where C (Censor) is an exception to the rule. Such rules are employed in situations, in which the conditional statement 'If P Then D' holds frequently and the assertion C holds rarely. By using a rule of this type we are free to ignore the exception conditions, when the resources needed to establish its presence are tight or there is simply no information available as to whether it holds or not. Thus, the 'If P Then D' part of the CPR expresses important information, while the Unless C part acts only as a switch and changes the polarity of D to ~D. This paper presents a classification algorithm based on evolutionary approach that discovers comprehensible rules with exceptions in the form of CPRs. The proposed approach has flexible chromosome encoding, where each chromosome corresponds to a CPR. Appropriate genetic operators are suggested and a fitness function is proposed that incorporates the basic constraints on CPRs. Experimental results are presented to demonstrate the performance of the proposed algorithm.

Modeling and FOS Feedback Based Control of SISO Intelligent Structures with Embedded Shear Sensors and Actuators

Active vibration control is an important problem in structures. The objective of active vibration control is to reduce the vibrations of a system by automatic modification of the system-s structural response. In this paper, the modeling and design of a fast output sampling feedback controller for a smart flexible beam system embedded with shear sensors and actuators for SISO system using Timoshenko beam theory is proposed. FEM theory, Timoshenko beam theory and the state space techniques are used to model the aluminum cantilever beam. For the SISO case, the beam is divided into 5 finite elements and the control actuator is placed at finite element position 1, whereas the sensor is varied from position 2 to 5, i.e., from the nearby fixed end to the free end. Controllers are designed using FOS method and the performance of the designed FOS controller is evaluated for vibration control for 4 SISO models of the same plant. The effect of placing the sensor at different locations on the beam is observed and the performance of the controller is evaluated for vibration control. Some of the limitations of the Euler-Bernoulli theory such as the neglection of shear and axial displacement are being considered here, thus giving rise to an accurate beam model. Embedded shear sensors and actuators have been considered in this paper instead of the surface mounted sensors and actuators for vibration suppression because of lot of advantages. In controlling the vibration modes, the first three dominant modes of vibration of the system are considered.

A High Performance Technique in Harmonic Omitting Based on Predictive Current Control of a Shunt Active Power Filter

The perfect operation of common Active Filters is depended on accuracy of identification system distortion. Also, using a suitable method in current injection and reactive power compensation, leads to increased filter performance. Due to this fact, this paper presents a method based on predictive current control theory in shunt active filter applications. The harmonics of the load current is identified by using o–d–q reference frame on load current and eliminating the DC part of d–q components. Then, the rest of these components deliver to predictive current controller as a Threephase reference current by using Park inverse transformation. System is modeled in discreet time domain. The proposed method has been tested using MATLAB model for a nonlinear load (with Total Harmonic Distortion=20%). The simulation results indicate that the proposed filter leads to flowing a sinusoidal current (THD=0.15%) through the source. In addition, the results show that the filter tracks the reference current accurately.

Non-negative Principal Component Analysis for Face Recognition

Principle component analysis is often combined with the state-of-art classification algorithms to recognize human faces. However, principle component analysis can only capture these features contributing to the global characteristics of data because it is a global feature selection algorithm. It misses those features contributing to the local characteristics of data because each principal component only contains some levels of global characteristics of data. In this study, we present a novel face recognition approach using non-negative principal component analysis which is added with the constraint of non-negative to improve data locality and contribute to elucidating latent data structures. Experiments are performed on the Cambridge ORL face database. We demonstrate the strong performances of the algorithm in recognizing human faces in comparison with PCA and NREMF approaches.

A Microscopic Simulation Model for Earthmoving Operations

Earthmoving operations are a major part of many construction projects. Because of the complexity and fast-changing environment of such operations, the planning and estimating are crucial on both planning and operational levels. This paper presents the framework ofa microscopic discrete-event simulation system for modeling earthmoving operations and conducting productivity estimations on an operational level.A prototype has been developed to demonstrate the applicability of the proposed framework, and this simulation system is presented via a case study based on an actual earthmoving project. The case study shows that the proposed simulation model is capable of evaluating alternative operating strategies and resource utilization at a very detailed level.

Solving Part Type Selection and Loading Problem in Flexible Manufacturing System Using Real Coded Genetic Algorithms – Part I: Modeling

This paper and its companion (Part 2) deal with modeling and optimization of two NP-hard problems in production planning of flexible manufacturing system (FMS), part type selection problem and loading problem. The part type selection problem and the loading problem are strongly related and heavily influence the system-s efficiency and productivity. The complexity of the problems is harder when flexibilities of operations such as the possibility of operation processed on alternative machines with alternative tools are considered. These problems have been modeled and solved simultaneously by using real coded genetic algorithms (RCGA) which uses an array of real numbers as chromosome representation. These real numbers can be converted into part type sequence and machines that are used to process the part types. This first part of the papers focuses on the modeling of the problems and discussing how the novel chromosome representation can be applied to solve the problems. The second part will discuss the effectiveness of the RCGA to solve various test bed problems.

Quasi Multi-Pulse Back-to-Back Static Synchronous Compensator Employing Line Frequency Switching 2-Level GTO Inverters

Back-to-back static synchronous compensator (BtBSTATCOM) consists of two back-to-back voltage-source converters (VSC) with a common DC link in a substation. This configuration extends the capabilities of conventional STATCOM that bidirectional active power transfer from one bus to another is possible. In this paper, VSCs are designed in quasi multi-pulse form in which GTOs are triggered only once per cycle in PSCAD/EMTDC. The design details of VSCs as well as gate switching circuits and controllers are fully represented. Regulation modes of BtBSTATCOM are verified and tested on a multi-machine power system through different simulation cases. The results presented in the form of typical time responses show that practical PI controllers are almost robust and stable in case of start-up, set-point change, and line faults.

Identifying Significant Factors of Brick Laying Process through Design of Experiment and Computer Simulation: A Case Study

Improving performance measures in the construction processes has been a major concern for managers and decision makers in the industry. They seek for ways to recognize the key factors which have the largest effect on the process. Identifying such factors can guide them to focus on the right parts of the process in order to gain the best possible result. In the present study design of experiment (DOE) has been applied to a computer simulation model of brick laying process to determine significant factors while productivity has been chosen as the response of the experiment. To this end, four controllable factors and their interaction have been experimented and the best factor level has been calculated for each one. The results indicate that three factors, namely, labor of brick, labor of mortar and inter arrival time of mortar along with interaction of labor of brick and labor of mortar are significant.

Intelligent Heart Disease Prediction System Using CANFIS and Genetic Algorithm

Heart disease (HD) is a major cause of morbidity and mortality in the modern society. Medical diagnosis is an important but complicated task that should be performed accurately and efficiently and its automation would be very useful. All doctors are unfortunately not equally skilled in every sub specialty and they are in many places a scarce resource. A system for automated medical diagnosis would enhance medical care and reduce costs. In this paper, a new approach based on coactive neuro-fuzzy inference system (CANFIS) was presented for prediction of heart disease. The proposed CANFIS model combined the neural network adaptive capabilities and the fuzzy logic qualitative approach which is then integrated with genetic algorithm to diagnose the presence of the disease. The performances of the CANFIS model were evaluated in terms of training performances and classification accuracies and the results showed that the proposed CANFIS model has great potential in predicting the heart disease.

Face Recognition with Image Rotation Detection, Correction and Reinforced Decision using ANN

Rotation or tilt present in an image capture by digital means can be detected and corrected using Artificial Neural Network (ANN) for application with a Face Recognition System (FRS). Principal Component Analysis (PCA) features of faces at different angles are used to train an ANN which detects the rotation for an input image and corrected using a set of operations implemented using another system based on ANN. The work also deals with the recognition of human faces with features from the foreheads, eyes, nose and mouths as decision support entities of the system configured using a Generalized Feed Forward Artificial Neural Network (GFFANN). These features are combined to provide a reinforced decision for verification of a person-s identity despite illumination variations. The complete system performing facial image rotation detection, correction and recognition using re-enforced decision support provides a success rate in the higher 90s.

Measurement of Small PD-S in Compressed SF6(10%) - N2(90%) Gas Mixture

Partial Discharge measurement is a very important means of assessing the integrity of insulation systems in a High Voltage apparatus. In compressed gas insulation systems, floating particles can initiate partial discharge activities which adversely affect the working of insulation. Partial Discharges below the inception voltage also plays a crucial in damaging the integrity of insulation over a period of time. This paper discusses the effect of loose and fixed Copper and Nichrome wire particles on the PD characteristics in SF6-N2 (10:90) gas mixtures at a pressure of 0.4MPa. The Partial Discharge statistical parameters and their correlation to the observed results are discussed.

The Spanning Laceability of k-ary n-cubes when k is Even

Qk n has been shown as an alternative to the hypercube family. For any even integer k ≥ 4 and any integer n ≥ 2, Qk n is a bipartite graph. In this paper, we will prove that given any pair of vertices, w and b, from different partite sets of Qk n, there exist 2n internally disjoint paths between w and b, denoted by {Pi | 0 ≤ i ≤ 2n-1}, such that 2n-1 i=0 Pi covers all vertices of Qk n. The result is optimal since each vertex of Qk n has exactly 2n neighbors.

Gradual Shot Boundary Detection and Classification Based on Fractal Analysis

Shot boundary detection is a fundamental step for the organization of large video data. In this paper, we propose a new method for video gradual shots detection and classification, using advantages of fractal analysis and AIS-based classifier. Proposed features are “vertical intercept" and “fractal dimension" of each frame of videos which are computed using Fourier transform coefficients. We also used a classifier based on Clonal Selection Algorithm. We have carried out our solution and assessed it according to the TRECVID2006 benchmark dataset.

The Willingness of Business Students on T Innovative Behavior within the Theory of Planned Behavior

Classes on creativity, innovation, and entrepreneurship are becoming quite popular at universities throughout the world. However, it is not easy for business students to get involved to innovative activities, especially patent application. The present study investigated how to enhance business students- intention to participate in innovative activities and which incentives universities should consider. A 22-item research scale was used, and confirmatory factor analysis was conducted to verify its reliability and validity. Multiple regression and discriminant analyses were also conducted. The results demonstrate the effect of growth-need strength on innovative behavior and indicate that the theory of planned behavior can explain and predict business students- intention to participate in innovative activities. Additionally, the results suggest that applying our proposed model in practice would effectively strengthen business students- intentions to engage in innovative activities.

Integrating Big Island Layout with Pull System for Production Optimization

Lean manufacturing is a production philosophy made popular by Toyota Motor Corporation (TMC). It is globally known as the Toyota Production System (TPS) and has the ultimate aim of reducing cost by thoroughly eliminating wastes or muda. TPS embraces the Just-in-time (JIT) manufacturing; achieving cost reduction through lead time reduction. JIT manufacturing can be achieved by implementing Pull system in the production. Furthermore, TPS aims to improve productivity and creating continuous flow in the production by arranging the machines and processes in cellular configurations. This is called as Cellular Manufacturing Systems (CMS). This paper studies on integrating the CMS with the Pull system to establish a Big Island-Pull system production for High Mix Low Volume (HMLV) products in an automotive component industry. The paper will use the build-in JIT system steps adapted from TMC to create the Pull system production and also create a shojinka line which, according to takt time, has the flexibility to adapt to demand changes simply by adding and taking out manpower. This will lead to optimization in production.

Kinematic Modeling and Workspace Analysis of a Spatial Cable Suspended Robot as Incompletely Restrained Positioning Mechanism

This article proposes modeling, simulation and kinematic and workspace analysis of a spatial cable suspended robot as incompletely Restrained Positioning Mechanism (IRPM). These types of robots have six cables equal to the number of degrees of freedom. After modeling, the kinds of workspace are defined then an statically reachable combined workspace for different geometric structures of fixed and moving platform is obtained. This workspace is defined as the situations of reference point of the moving platform (center of mass) which under external forces such as weight and with ignorance of inertial effects, the moving platform should be in static equilibrium under conditions that length of all cables must not be exceeded from the maximum value and all of cables must be at tension (they must have non-negative tension forces). Then the effect of various parameters such as the size of moving platform, the size of fixed platform, geometric configuration of robots, magnitude of applied forces and moments to moving platform on workspace of these robots with different geometric configuration are investigated. Obtained results should be effective in employing these robots under different conditions of applied wrench for increasing the workspace volume.

Thermal Treatment Influence on the Quality of Rye Bread Packaged in Different Polymer Films

this study was carried out to investigate the changes in quality parameters of rye bread packaged in different polymer films during convection air-flow thermal treatment process. Whole loafs of bread were placed in polymer pouches, which were sealed in reduced pressure air ambiance, bread was thermally treated in at temperature +(130; 140; and 150) ± 5 ºC within 40min, as long as the core temperature of the samples have reached accordingly +80±1 ºC. For bread packaging pouches were used: anti-fog Mylar®OL12AF and thermo resistant combined polymer material. Main quality parameters was analysed using standard methods: temperature in bread core, bread crumb and crust firmness value, starch granules volume and microflora. In the current research it was proved, that polymer films significantly influence rye bread quality parameters changes during thermal treatment. Thermo resistant combined polymer material film could be recommendable for packaged rye bread pasteurization, for maximal bread quality parameter keeping.

Study on the Effect of Weight Percentage Variation and Size Variation of Magnesium Ferrosilicon Added, Gating System Design and Reaction Chamber Design on Inmold Process

This research focuses on the effect of weight percentage variation and size variation of MgFeSi added, gating system design and reaction chamber design on inmold process. By using inmold process, well-known problem of fading is avoided because the liquid iron reacts with magnesium in the mold and not, as usual, in the ladle. During the pouring operation, liquid metal passes through the chamber containing the magnesium, where the reaction of the metal with magnesium proceeds in the absence of atmospheric oxygen [1].In this paper, the results of microstructural characteristic of ductile iron on this parameters are mentioned. The mechanisms of the inmold process are also described [2]. The data obtained from this research will assist in producing the vehicle parts and other machinery parts for different industrial zones and government industries and in transferring the technology to all industrial zones in Myanmar. Therefore, the inmold technology offers many advantages over traditional treatment methods both from a technical and environmental, as well as an economical point of view. The main objective of this research is to produce ductile iron castings in all industrial sectors in Myanmar more easily with lower costs. It will also assist the sharing of knowledge and experience related to the ductile iron production.

Simulation Study on the Indoor Thermal Comfort with Insulation on Interior Structural Components of Super High-Rise Residences

In this study, we discussed the effects on the thermal comfort of super high-rise residences that how effected by the high thermal capacity structural components. We considered different building orientations, structures, and insulation methods. We used the dynamic simulation software THERB (simulation of the thermal environment of residential buildings). It can estimate the temperature, humidity, sensible temperature, and heating/cooling load for multiple buildings. In the past studies, we examined the impact of air-conditioning loads (hereinafter referred to as AC loads) on the interior structural parts and the AC-usage patterns of super-high-rise residences. Super-high-rise residences have more structural components such as pillars and beams than do ordinary apartment buildings. The skeleton is generally made of concrete and steel, which have high thermal-storage capacities. The thermal-storage capacity of super-high-rise residences is considered to have a larger impact on the AC load and thermal comfort than that of ordinary residences. We show that the AC load of super-high-rise units would be reduced by installing insulation on the surfaces of interior walls that are not usually insulated in Japan.