Abstract: Agro-industry is one of major industries that have
strong impacts on national economic incomes, growth, stability, and
sustainable development. Moreover, this industry also has strong
influences on social, cultural and political issues. Furthermore, this
industry, as producing primary and secondary products, is facing
challenges from such diverse factors such as demand inconsistency,
intense international competition, technological advancements and
new competitors. In order to maintain and to improve industry’s
competitiveness in both domestics and international markets, science
and technology are key factors. Besides hard sciences and
technologies, modern industrial engineering concepts such as Just in
Time (JIT) Total Quality Management (TQM), Quick Response
(QR), Supply Chain Management (SCM) and Lean can be very
effective to support to increase efficiency and effectiveness of these
agricultural products on world stage. Onion is one of Thailand’s
major export products which bring back national incomes. But, it is
also facing challenges in many ways. This paper focused its interests
in onion packing process and its related activities such as storage and
shipment from one of major packing plant and storage in Mae Wang
District, Chiang Mai, Thailand, by applying Toyota Production
System (TPS) or Lean concepts, to improve process capability
throughout the entire packing and distribution process which will be
profitable for the whole onion supply chain. And it will be beneficial
to other related agricultural products in Thailand and other ASEAN
countries.
Abstract: Nanofibers are effective materials which have
frequently been investigated to produce high quality air filters. As an
environmental approach our aim is to achieve nanofibers by melting.
In spun-bond systems extruder, spin-pump, nozzle package and
attenuator are used. Molten polymer which flows from extruder is
made steady by spin-pump. Regular melt passes through nozzle holes
and forms fibers under high pressure. The fibers pulled from nozzle
are shrunk to micron size by an attenuator; after solidification, they
are collected on a conveyor. In this research different designs of
attenuator system have been studied; and also CFD analysis has been
done on these different designs. Afterwards, one of these designs
tested and finally some optimizations have been done to reduce
pressure loss and increase air velocity.
Abstract: Negative pressure phenomenon appears in many
thermodynamic, geophysical and biophysical processes in the Nature
and technological systems. For more than 100 years of the laboratory
researches beginning from F. M. Donny’s tests, the great values of
negative pressure have been achieved. But this phenomenon has not
been practically applied, being only a nice lab toy due to the special
demands for the purity and homogeneity of the liquids for its
appearance. The possibility of creation of direct wave of negative
pressure in real heterogeneous liquid systems was confirmed
experimentally under the certain kinetic and hydraulic conditions.
The negative pressure can be considered as the factor of both useful
and destroying energies. The new approach to generation of the
negative pressure waves in impure, unclean fluids has allowed the
creation of principally new energy saving technologies and
installations to increase the effectiveness and efficiency of different
production processes. It was proved that the negative pressure is one
of the main factors causing hard troubles in some technological and
natural processes. Received results emphasize the necessity to take
into account the role of the negative pressure as an energy factor in
evaluation of many transient thermohydrodynamic processes in the
Nature and production systems.
Abstract: The paper deals with communication standards for
control and production system. The authors formulate the
requirements for communication security protection. The paper is
focused on application protocols of the industrial networks and their
basic classification. The typical attacks are analysed and the safety
protection, based on requirements for specific industrial network is
suggested and defined in this paper.
Abstract: For years now, it has been recognized that logistic performance capability contributes enormously to a production enterprise’s competitiveness and as such is a critical control lever. In doing so, the orientation on customer wishes (e.g. delivery dates) represents a key parameter not only in the value-adding production but also in product regeneration. Since production and regeneration processes have different characteristics, production planning and control measures cannot be directly transferred to regeneration processes. As part of a special research project, the Institute of Production Systems and Logistics Hannover is focused on increasing the logistic performance capability of regeneration processes for complex capital goods. The aim is to ensure logistic targets are met by implementing a model specifically designed to align the capacities and load in regeneration processes.
Abstract: Just-In-Time (JIT) is a lean manufacturing tool, which provides the benefits of efficiency, and of minimizing unnecessary costs for many organisations. However, the risks arising from these benefits have been disregarded. These risks impact on system processes disrupting the whole supply chain. This paper proposes an inventory model that can 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. Some results that will be illustrated in the second part of this paper are presented.
Abstract: Due to the volatile global economy, enterprises are increasingly focusing on logistics. By investing in suitable measures a company can increase their logistic performance and assert themselves over the competition. However, enterprises are also faced with the challenge of investing available capital for maximum profits. In order to be able to create an informed and quantifiably comprehensible basis for a decision, enterprises need a suitable model for logistically and monetarily evaluating measures in production. Previously, within the frame of Collaborate Research Centre 489 (SFB 489) at the Institute for Production Systems and Logistics, (IFA) a Logistic Information System was developed specifically for providing enterprises in the forging industry with support when making decisions. Based on this research, a new initiative referred to as ‘Transfer Project T7’, aims to develop a universal approach for logistically and monetarily evaluating production measures. This paper focuses on the structural measure echelon storage and their impact on the entire production system.
Abstract: The increasing interconnectedness and complexity of production processes raise the susceptibility of production systems to failure. Therefore, the ability to respond quickly to failures is increasingly becoming a competitive factor. The research project
"Sustainable failure management in manufacturing SMEs" is developing a methodology to identify failures in the production and select preventive and reactive measures in order to correct failures and to establish sustainable failure management systems.
Abstract: The paper gives the results of the project that was oriented on the usage of knowledge discoveries from production systems for needs of the hierarchical process control. One of the main project goals was the proposal of knowledge discovery model for process control. Specifics data mining methods and techniques was used for defined problems of the process control. The gained knowledge was used on the real production system thus the proposed solution has been verified. The paper documents how is possible to apply the new discovery knowledge to use in the real hierarchical process control. There are specified the opportunities for application of the proposed knowledge discovery model for hierarchical process control.
Abstract: In times when product life cycles are decreasing, while market demands are increasing, manufacturing enterprises are confronted with the challenge of more frequent and more complex ramp-ups. Thus it becomes obvious that ramp-up management is going to be a topic enterprises have to focus on in the future. Since each ramp-up is unique concerning the product, the process, the technology, the circumstances and the coaction of these four factors, the knowledge of the ramp-up situation and the current ramp-up capability of the enterprise are fundamental requirements for the subsequent improvement of the ramp-up capability of the production system.
In this article a methodology is going to be presented which can be used to define typical production ramp-up situations, to identify the current ramp-up capability of a production system and to improve it with respect to a specific situation. Additionally there will be a description of the functionality of a software-tool developed based on this methodology.
Abstract: In the past decades, the environment of production companies showed a permanent increase in dynamic and volatility in the form of demand fluctuations, new technologies or global crises. As a reaction to these new requirements, changeability of production systems came into attention. A changeable production system can adapt to these changes quickly and with little effort. Even though demand for changeable production exists for some time, the practical application is still insufficient.
To overcome this deficit, a three year research project at the Department of Production Systems and Logistics at the Leibniz University of Hanover/ Germany was initiated. As a result of this project, different concepts have been developed to design production changeable. An excerpt of the results will be presented in this paper. An eight step procedure will be presented to design the changeability of production logistics. This procedure has been applied at a German manufacturer of high demanding weighing machines. The developed procedure, their application in industry, as well as the major results of the application will be presented.
Abstract: Nowadays companies are facing an increasing turbulent environment. It is more and more important to react fast on changes to stay competitive. But not only the technology has to be adaptable; also the frame conditions for the production have to adapt as fast as the other elements of a manufacturing company. Therefore, the Institute of Production Systems and Logistics of the Leibniz University of Hanover has implemented a research project to describe and develop changeable organizational structures. The results of the analysis, which design principles can be used to evolve an organizational structure of a factory regarding their changeability will be presented in this paper.
Abstract: In production processes, assembly conceals a considerable potential for increased efficiency in terms of lowering production costs. Due to the individualisation of customer requirements, product variants have increased in recent years. Simultaneously, the portion of automated production systems has increased. A challenge is to adapt the flexibility and adaptability of automated systems to these changes. The Institute for Production Systems and Logistics developed an aerodynamic orientation system for feeding technology. When changing to other components, only four parameters must be adjusted. The expenditure of time for setting parameters is high. An objective therefore is developing an optimisation algorithm for automatic parameter configuration. Know how regarding the interaction of the four parameters and their effect on the sizes to be optimised is required in order to be able to develop a more efficient algorithm. This article introduces an analysis of the interactions between parameters and their influence on the quality of feeding.
Abstract: In order to remain competitive in what is a turbulent
environment; businesses must be able to react rapidly to change. The
past response to volatile market conditions was to introduce an
element of flexibility to production. Nowadays, what is often
required is a redesign of factory structures in order to cope with the
state of constant flux. The Institute of Production Systems and
Logistics is currently developing a descriptive and causal model for
the redesign of plant structures as part of an ongoing research project.
This article presents the first research findings attained in devising
this model.
Abstract: In today-s competitive market, most companies
develop manufacturing systems that can help in cost reduction and
maximum quality. Human issues are an important part of
manufacturing systems, yet most companies ignore their effects on
production performance. This paper aims to developing an integrated
workforce planning system that incorporates the human being.
Therefore, a multi-objective mixed integer nonlinear programming
model is developed to determine the amount of hiring, firing,
training, overtime for each worker type. This paper considers a
workforce planning model including human aspects such as skills,
training, workers- personalities, capacity, motivation, and learning
rates. This model helps to minimize the hiring, firing, training and
overtime costs, and maximize the workers- performance. The results
indicate that the workers- differences should be considered in
workforce scheduling to generate realistic plans with minimum costs.
This paper also investigates the effects of human learning rates on the
performance of the production systems.
Abstract: The problem of lot sizing, sequencing and scheduling
multiple products in flow line production systems has been studied
by several authors. Almost all of the researches in this area assumed
that setup times and costs are sequence –independent even though
sequence dependent setups are common in practice. In this paper we
present a new mixed integer non linear program (MINLP) and a
heuristic method to solve the problem in sequence dependent case.
Furthermore, a genetic algorithm has been developed which applies
this constructive heuristic to generate initial population. These two
proposed solution methods are compared on randomly generated
problems. Computational results show a clear superiority of our
proposed GA for majority of the test problems.
Abstract: 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.
Abstract: Scarcity of resources for biodiversity conservation gives rise to the need of strategic investment with priorities given to the cost of conservation. While the literature provides abundant methodological options for biodiversity conservation; estimating true cost of conservation remains abstract and simplistic, without recognising dynamic nature of the cost. Some recent works demonstrate the prominence of economic theory to inform biodiversity decisions, particularly on the costs and benefits of biodiversity however, the integration of the concept of true cost into biodiversity actions and planning are very slow to come by, and specially on a farm level. Conservation planning studies often use area as a proxy for costs neglecting different land values as well as protected areas. These literature consider only heterogeneous benefits while land costs are considered homogenous. Analysis with the assumption of cost homogeneity results in biased estimation; since not only it doesn’t address the true total cost of biodiversity actions and plans, but also it fails to screen out lands that are more (or less) expensive and/or difficult (or more suitable) for biodiversity conservation purposes, hindering validity and comparability of the results. Economies of scope” is one of the other most neglected aspects in conservation literature. The concept of economies of scope introduces the existence of cost complementarities within a multiple output production system and it suggests a lower cost during the concurrent production of multiple outputs by a given farm. If there are, indeed, economies of scope then simplistic representation of costs will tend to overestimate the true cost of conservation leading to suboptimal outcomes. The aim of this paper, therefore, is to provide first road review of the various theoretical ways in which economies of scope are likely to occur of how they might occur in conservation. Consequently, the paper addresses gaps that have to be filled in future analysis.
Abstract: A dead leg is a typical subsea production system
component. CFD is required to model heat transfer within the dead
leg. Unfortunately its solution is time demanding and thus not
suitable for fast prediction or repeated simulations. Therefore there is
a need to create a thermal FEA model, mimicking the heat flows and
temperatures seen in CFD cool down simulations.
This paper describes the conventional way of tuning and a new
automated way using parametric model order reduction (PMOR)
together with an optimization algorithm. The tuned FE analyses
replicate the steady state CFD parameters within a maximum error in
heat flow of 6 % and 3 % using manual and PMOR method
respectively. During cool down, the relative error of the tuned FEA
models with respect to temperature is below 5% comparing to the
CFD. In addition, the PMOR method obtained the correct FEA setup
five times faster than the manually tuned FEA.
Abstract: Assembly line balancing is a very important issue in
mass production systems due to production cost. Although many
studies have been done on this topic, but because assembly line
balancing problems are so complex they are categorized as NP-hard
problems and researchers strongly recommend using heuristic
methods. This paper presents a new heuristic approach called the
critical task method (CTM) for solving U-shape assembly line
balancing problems. The performance of the proposed heuristic
method is tested by solving a number of test problems and comparing
them with 12 other heuristics available in the literature to confirm the
superior performance of the proposed heuristic. Furthermore, to
prove the efficiency of the proposed CTM, the objectives are
increased to minimize the number of workstation (or equivalently
maximize line efficiency), and minimizing the smoothness index.
Finally, it is proven that the proposed heuristic is more efficient than
the others to solve the U-shape assembly line balancing problem.