Abstract: In production planning (PP) periods with excess capacity
and growing demand, the manufacturers have two options to use the excess capacity. First, it could do more changeovers and thus reduce lot sizes, inventories, and inventory costs. Second, it could produce in excess of demand in the period and build additional inventory that can be used to satisfy future demand increments, thus
delaying the purchase of the next machine that is required to meet the growth in demand. In this study we propose an enhanced supply
chain planning model with flexible planning capability. In addition, a 3D supply chain planning system is illustrated.
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: During the last decade ultrafine grained (UFG) and nano-structured (NS) materials have experienced a rapid development. In this research work finite element analysis has been carried out to investigate the plastic strain distribution in equal channel angular process (ECAP). The magnitudes of Standard deviation (S. D.) and inhomogeneity index (Ci) were compared for different ECAP passes. Verification of a three-dimensional finite element model was performed with experimental tests. Finally the mechanical property including impact energy of ultrafine grained pure commercially pure Aluminum produced by severe plastic deformation method has been examined. For this aim, equal channel angular pressing die with the channel angle, outer corner angle and channel diameter of 90°, 20° and 20mm had been designed and manufactured. Commercial pure Aluminum billets were ECAPed up to four passes by route BC at the ambient temperature. The results indicated that there is a great improvement at the hardness measurement, yield strength and ultimate tensile strength after ECAP process. It is found that the magnitudes of HV reach 67HV from 21HV after the final stage of process. Also, about 330% and 285% enhancement at the YS and UTS values have been obtained after the fourth pass as compared to the as-received conditions, respectively. On the other hand, the elongation to failure and impact energy have been reduced by 23% and 50% after imposing four passes of ECAP process, respectively.
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: Hardness of the widely used structural steel is of vital
importance since it may help in the determination of many
mechanical properties of a material under loading situations. In order
to obtain reliable information for design, properties homogeneity
should be validated. In the current study the hardness variation over
the different diameters of the same AISI 4140 bar is investigated.
Measurements were taken on the two faces of the stock at equally
spaced eight sectors and fifteen layers. Statistical and graphical
analysis are performed to asses the distribution of hardness
measurements over the specified area. Hardness measurements
showed some degree of dispersion with about ± 10% of its nominal
value provided by manufacturer. Hardness value is found to have a
slight decrease trend as the diameter is reduced. However, an
opposite behavior is noticed regarding the sequence of the sector
indicating a nonuniform distribution over the same area either on the
same face or considering the corresponding sector on the other face
(cross section) of the same material bar.
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: The psychological and physical trauma associated with the loss of a human limb can severely impact on the quality of life of an amputee rendering even the most basic of tasks very difficult. A prosthetic device can be of great benefit to the amputee in the performance of everyday human tasks. This paper outlines a proposed mechanical design of a 12 degree-of-freedom SMA actuated artificial hand. It is proposed that the SMA wires be embedded intrinsically within the hand structure which will allow for significant flexibility for use either as a prosthetic hand solution, or as part of a complete lower arm prosthetic solution. A modular approach is taken in the design facilitating ease of manufacture and assembly, and more importantly, also allows the end user to easily replace SMA wires in the event of failure. A biomimetric approach has been taken during the design process meaning that the artificial hand should replicate that of a human hand as far as is possible with due regard to functional requirements. The proposed design has been exposed to appropriate loading through the use of finite element analysis (FEA) to ensure that it is structurally sound. Theoretical analysis of the mechanical framework was also carried out to establish the limits of the angular displacement and velocity of the finger tip as well finger tip force generation. A combination of various polymers and Titanium, which are suitably lightweight, are proposed for the manufacture of the design.
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: This paper presents a model for the characterization
and selection of beeswaxes for use as base substitute tissue for the
manufacture of objects suitable for external radiotherapy using
megavoltage photon beams. The model of characterization was
divided into three distinct stages: 1) verification of aspects related to
the origin of the beeswax, the bee species, the flora in the vicinity of
the beehives and procedures to detect adulterations; 2) evaluation of
physical and chemical properties; and 3) evaluation of beam
attenuation capacity. The chemical composition of the beeswax
evaluated in this study was similar to other simulators commonly
used in radiotherapy. The behavior of the mass attenuation coefficient
in the radiotherapy energy range was comparable to other simulators.
The proposed model is efficient and enables convenient assessment
of the use of any particular beeswax as a base substitute tissue for
radiotherapy.
Abstract: Hand gesture is one of the typical methods used in
sign language for non-verbal communication. It is most commonly
used by people who have hearing or speech problems to
communicate among themselves or with normal people. Various sign
language systems have been developed by manufacturers around the
globe but they are neither flexible nor cost-effective for the end
users. This paper presents a system prototype that is able to
automatically recognize sign language to help normal people to
communicate more effectively with the hearing or speech impaired
people. The Sign to Voice system prototype, S2V, was developed
using Feed Forward Neural Network for two-sequence signs
detection. Different sets of universal hand gestures were captured
from video camera and utilized to train the neural network for
classification purpose. The experimental results have shown that
neural network has achieved satisfactory result for sign-to-voice
translation.
Abstract: Inconel 718, a nickel based super-alloy is an
extensively used alloy, accounting for about 50% by weight of
materials used in an aerospace engine, mainly in the gas turbine
compartment. This is owing to their outstanding strength and
oxidation resistance at elevated temperatures in excess of 5500 C.
Machining is a requisite operation in the aircraft industries for the
manufacture of the components especially for gas turbines. This
paper is concerned with optimization of the surface roughness when
turning Inconel 718 with cermet inserts. Optimization of turning
operation is very useful to reduce cost and time for machining. The
approach is based on Response Surface Method (RSM). In this work,
second-order quadratic models are developed for surface roughness,
considering the cutting speed, feed rate and depth of cut as the cutting
parameters, using central composite design. The developed models
are used to determine the optimum machining parameters. These
optimized machining parameters are validated experimentally, and it
is observed that the response values are in reasonable agreement with
the predicted values.
Abstract: The effect of artificial pozzolan (waste brick) on the
physico-chemical properties of cement manufactured was
investigated. The waste brick is generated by the manufacture of
bricks. It was used in the proportions of 0%, 5%, 10%, 15% and 20%
by mass of cement to study its effect on the physico-chemical
properties of cement incorporating artificial pozzolan. The physicochemical
properties of cement at anhydrous state and the hydrated
state (chemical composition, specific weight, fineness, consistency of
the cement paste and setting times) were studied. The experimental
results obtained show that the quantity of pozzolanic admixture
(waste brick) of cement manufactured is the principal parameter who
influences on the variation of the physico-chemical properties of the
cement tested.
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].