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1.
Effect of reconfiguration costs on planning for capacity scalability in reconfigurable manufacturing systems 总被引:1,自引:1,他引:1
Ahmed M. Deif Waguih ElMaraghy 《International Journal of Flexible Manufacturing Systems》2006,18(3):225-238
In a globally competitive market for products, manufacturers are faced with an increasing need to improve their flexibility,
reliability, and responsiveness to meet the demands of their customers. Reconfigurable manufacturing systems (RMS) have become
an important manufacturing paradigm, because they broadly encompass the ability to react efficiently to this environment by
providing the exact capacity and functionality needed when needed. This paper studies how such new systems can manage their
capacity scalability planning in a cost effective manner. An approach for modeling capacity scalability planning is proposed.
The development of the model is based on set theory and the regeneration point theorem which is mapped to the reconfigurable
manufacturing paradigm as the capacity scalability points of that system. The cost function of the model incorporates both
the physical capacity cost based on capacity size and costs associated with the reconfiguration process which referred to
as the scalability penalty cost and scalability effort cost. A dynamic programming (DP) approach is manipulated for the development
of optimal capacity scalability plans. The effect of the reconfiguration costs on the capacity scalability planning horizon
and overall cost is investigated. The results showed the relation between deciding on the optimal capacity scalability planning
horizon and the different reconfiguration costs. Results also highlighted the fact that decreasing costs of reconfiguration
will lead to cost effective implementation of reconfigurable manufacturing systems. 相似文献
2.
Reconfigurable manufacturing systems (RMSs), which possess the advantages of both dedicated serial lines and flexible manufacturing systems, were introduced in the mid-1990s to address the challenges initiated by globalization. The principal goal of an RMS is to enhance the responsiveness of manufacturing systems to unforeseen changes in product demand. RMSs are costeffective because they boost productivity, and increase the lifetime of the manufacturing system. Because of the many streams in which a product may be produced on an RMS, maintaining product precision in an RMS is a challenge. But the experience with RMS in the last 20 years indicates that product quality can be definitely maintained by inserting in-line inspection stations. In this paper, we formulate the design and operational principles for RMSs, and provide a state-of-the-art review of the design and operations methodologies of RMSs according to these principles. Finally, we propose future research directions, and deliberate on how recent intelligent manufacturing technologies may advance the design and operations of RMSs. 相似文献
3.
Ahmed M. Deif Hoda A. ElMaraghy 《International Journal of Flexible Manufacturing Systems》2007,19(3):128-150
This paper presents a model for assessing different capacity scalability policies in Reconfigurable Manufacturing System (RMS)
for different changing demand scenarios. The novelty of this approach is two fold: (1) it is the first attempt to explore
different capacity scalability policies in RMS based on multiple performance measures, mainly scaling rate, Work In Process
level, inventory level and backlog level; and (2) the dynamic scalability process in RMS is modeled for the first time using
System Dynamics. Different policies for capacity scalability for various demand scenarios were assessed. Numerical simulation
results obtained using the developed capacity scalability model showed that the best capacity scalability policy to be adopted
for RMS is dependent on the anticipated demand pattern as well as the various manufacturing objectives. The presented assessment
results will help the capacity scalability planners better decide the different tradeoffs between the competing strategic
and operational objectives of the manufacturing enterprise, before setting the suitable capacity scalability plan parameters.
相似文献
Hoda A. ElMaraghy (Corresponding author)Email: |
4.
Flexible and reconfigurable manufacturing systems paradigms 总被引:5,自引:1,他引:5
Hoda A. ElMaraghy 《International Journal of Flexible Manufacturing Systems》2005,17(4):261-276
Reconfigurable Manufacturing System (RMS) is a new manufacturing systems paradigm that aims at achieving cost-effective and
rapid system changes, as needed and when needed, by incorporating principles of modularity, integrability, flexibility, scalability,
convertibility, and diagnosability. RMS promises customized flexibility on demand in a short time, while Flexible Manufacturing
Systems (FMSs) provides generalized flexibility designed for the anticipated variations and built-in a priori. The characteristics
of the two paradigms are outlined and compared. The concept of manufacturing system life cycle is presented. The main types
of flexibility in manufacturing systems are discussed and contrasted with the various reconfiguration aspects including hard
(physical) and soft (logical) reconfiguration. The types of changeability and transformability of manufacturing systems, their
components as well as factories, are presented along with their enablers and compared with flexibility and reconfigurability.
The importance of having harmonized human-machine manufacturing systems is highlighted and the role of people in the various
manufacturing paradigms and how this varies in pursuit of productivity are illustrated. Finally, the industrial and research
challenges presented by these manufacturing paradigms are discussed. 相似文献
5.
Production planning and performance optimization of reconfigurable manufacturing systems using genetic algorithm 总被引:1,自引:1,他引:0
Morteza Abbasi Mahmoud Houshmand 《The International Journal of Advanced Manufacturing Technology》2011,54(1-4):373-392
To stay competitive in the new dynamic market having large fluctuations in product demand, manufacturing companies must use systems that not only produce their goods with high productivity but also allow for rapid response to market changes. Reconfigurable manufacturing system (RMS) is a new paradigm that enables manufacturing systems to respond quickly and cost effectively to market demand. In other words, RMS is a system designed from the outset, for rapid changes in both hardware and software components, in order to quickly adjust its production capacity to fluctuations in market demand and adapt its functionality to new products. The effectiveness of an RMS depends on implementing its key characteristics and capabilities in the design as well as utilization stage. This paper focuses on the utilization stage of an RMS and introduces a methodology to effectively adjust scalable production capacities and the system functionalities to market demands. It is supposed that arrival orders of product families follow the Poisson distribution. The orders are lost if they are not met immediately. Considering these assumptions, a mixed integer nonlinear programming model is developed to determine optimum sequence of production tasks, corresponding configurations, and batch sizes. A genetic algorithm-based procedure is used to solve the model. The model is also applied to make decision on how to improve the performance of an RMS. Since there is no practical RMS, a numerical example is used to validate the results of the proposed model and its solution procedure. 相似文献
6.
An expert enhanced coloured fuzzy Petri net approach to reconfigurable manufacturing systems involving information delays 总被引:4,自引:1,他引:4
Rupesh Kumar Santosh Kumar M.K. Tiwari 《The International Journal of Advanced Manufacturing Technology》2005,26(7-8):922-933
In today’s competitive market, manufacturers need to quickly adapt to the changing demands of the customers. Reconfigurable
manufacturing system (RMS) is a cost-effective system that can easily absorb frequent changes in product demands. In this
article such a system is modelled using expert enhanced coloured fuzzy Petri net (EECFPN), which considers the demands of
customers as a fuzzy parameter and vividly captures the reconfigurability aspect of RMS. A fuzzy control strategy (FCS) is
proposed to deal with the information delays occurring during information transfer or decision implementation. After intensive
computational experimentation, it has been found that FCS outperforms the alternative priority (AP) heuristic and it is considered
an effective measure to deal with situations where considerable information delay is involved. 相似文献
7.
R. Galan J. Racero I. Eguia D. Canca 《The International Journal of Advanced Manufacturing Technology》2007,33(3-4):345-353
The launch of new products to the market is essential for companies in order to remain competitive. Products are constantly
being replaced for others that fulfil the changing requirements of the customers. For achieving this, companies have to adapt
their production system to the new requirements of the new products by adding or removing machines, changing the lay-out,
etc. Normally, this reconfiguration implies a high investment. Reconfigurable manufacturing systems (RMSs) arise for facilitating
the reconfiguration of the production system, being considered as the next step in manufacturing. This paper deals with the
development of a methodology based on RMSs that allows a feasible reconfiguration of production systems. This methodology
is based on the ALCA algorithm from group technology, and takes into account five requirements of products on RMSs: modularity,
commonality, compatibility, reusability and demand. The selection of the product families is obtained with a mathematical
model specifically formulated for this purpose. 相似文献
8.
Paolo Renna 《The International Journal of Advanced Manufacturing Technology》2010,46(1-4):395-404
During a manufacturing operation, exceptions may occur dynamically and unpredictably. Their occurrence may lead to the degradation of system performance or, in the worst case scenario, may interrupt the production process. The research proposes a multi-agent architecture for the capacity reconfiguration problem in a reconfigurable manufacturing system (RMS). A policy to manage capacity exchange among manufacturing lines based on due date performance is proposed. The Multi-Agent architecture was built in a simulation environment developed in ARENA® package and it is compared with a dedicated manufacturing and flexible manufacturing systems. The simulations are conducted in several demand scenarios to test the approach in a static and dynamic context. The simulation environment developed can support the planner to decide among the different manufacturing systems by the evaluation of the manufacturing performance. The simulation results, in dynamic environment, showed that the proposed approach leads to similar performance to flexible manufacturing system. 相似文献
9.
Jaime Mesa Heriberto Maury John Turizo Antonio Bula 《The International Journal of Advanced Manufacturing Technology》2014,70(9-12):2199-2210
Due to the unexpected, fast, and constant changes of market requirements and the hypercompetency, robust manufacturing systems are needed that adjust easily to operational variability and the customized product supply. The simply substitution of components, software, hardware, and/or their adaptation by parameters resetting are an attractive option to face this challenge. Short product life cycles are an undeniable consequence and evidence of this. For this reason, to develop products or services profitably in the product manufacturing field, it is common to use the product family concept, which involves sharing components, functional features, and manufacturing process, both to make a cheaper product development process and to obtain customized products. A new generation of manufacturing systems that deploy characteristics such as adaptability and flexibility responding to the market dynamics called reconfigurable manufacturing systems (RMS) are required by market according to manufacturing experts. The manufacturing systems with modular architecture are the best way to meet flexible and adaptable RMSs because they allow reconfiguration by a simple module substitution or by resetting module operation parameters. This paper presents a design methodology developed to obtain modular RMS. The method integrates the utilization of modular architecture principles, selection algorithms (analytical hierarchical process), clustering algorithms (average linkage clustering algorithm), family product features and functional system analysis in the classical product design process. The methodology proposed allows defining the most adequate modular system architecture and the modular definition of the reconfiguration variables that are needed to reach the flexibility required. A real study case about a heat exchanger assembly machine is presented where this methodology is applied in order to present an evidence of its usefulness. 相似文献
10.
O. Kuzgunkaya H. A. ElMaraghy 《International Journal of Flexible Manufacturing Systems》2007,19(3):217-246
The evolution of manufacturing systems, according to changing internal and external conditions, requires design and assessment
techniques that consider both strategic and financial criteria to evaluate the suitability of the Flexible and Reconfigurable
system solutions in addressing these variations. In this paper, a fuzzy multi-objective mixed integer optimization model to
evaluate RMS investments used in a multiple product demand environment is presented. The model incorporates in-house production
and outsourcing options, machine acquisition and disposal costs, operational costs, and re-configuration cost and duration
for the utilized modular machines. The resulting system configurations are optimized for lifecycle costs, responsiveness performance,
and system structural complexity simultaneously. A complexity metric that incorporates the quantity of information using an
entropy approach is used to represent the inherent structural complexity of the considered system configurations. It accounts
for the complexity of the machine modules in a manufacturing system through the use of an index derived from a newly developed
manufacturing systems classification code, which captures the effect machine types and technologies on the system’s structural
complexity. A metric is proposed to measure the responsiveness ability and efficiency as well as the overall capability of
each machine and effectiveness of machines changeover. The application of the developed planning and assessment model that
incorporates these three criteria is illustrated with a case study where FMS and RMS alternatives were compared. The suitable
conditions for investing in RMS are also discussed.
相似文献
O. KuzgunkayaEmail: |
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首先介绍了可重构制造系统和公理化设计的基本概念,然后对可重构制造系统进行了二级分解,选取了其中非耦合情况下和准耦合情况下的案例,进行了可重构制造系统公理化设计,提出了X是算子的概念,并赋予了,新的概念。创新的利用公理化设计的方法对可重构制造系统进行相应的拆分与重组:根据市场需求,将整个制造系统拆分成具有部分功能组合的制造系统;将各个功能组合,组成整个制造系统。这对于提高制造系统的利用率,快速应对市场需求具有十分重要的意义。 相似文献
14.
C. Renzi F. Leali M. Cavazzuti A. O. Andrisano 《The International Journal of Advanced Manufacturing Technology》2014,72(1-4):403-418
Reconfigurable manufacturing systems (RMS) are considered the future of manufacturing, being able to overcome both dedicated (DMS) and flexible manufacturing systems (FMS). In fact, they provide significant cost and time reductions in the launch of new products, and in the integration of new manufacturing processes into existing systems. The goals of RMS design are the extension of the production variety, the adaption to rapid changes in the market demand, and the minimization of the investment costs. Despite the interest of many authors, the debate on RMS is still open due to the lack of practical applications. This work is a review of the state-of-the-art on the design of cellular RMS, compared to DMS, by means of optimization. The problem addressed belongs to the NP-Hard family of combinatorial problem. The focus is on non-exact meta-heuristic and artificial intelligence methods, since these have been proven to be effective and robust in solving complex manufacturing design problems. A wide investigation on the most recurrent techniques in DMS and RMS literature is performed at first. A critical analysis over these techniques is given in the end. 相似文献
15.
M. Selim Akturk H. Muge Yayla 《International Journal of Flexible Manufacturing Systems》2005,17(2):93-117
In today’s markets, non-uniform, customized products complicate the manufacturing processes significantly. In this paper,
we propose a cellular manufacturing system design model to manage product variety by integrating with the technology selection
decision. The proposed model determines the product families and machine groups while deciding the technology of each cell
individually. Hedging against changing market dynamics leads us to the use of flexible machining systems and dedicated manufacturing
systems at the same facility. In order to integrate the market characteristics in our model, we proposed a new cost function.
Further, we modified a well known similarity measure in order to handle the operational capability of the available technology.
In the paper, our hybrid technology approach is presented via a multi-objective mathematical model. A filtered-beam based
local search heuristic is proposed to solve the problem efficiently. We compare the proposed approach with a dedicated technology
model and showed that the improvement with the proposed hybrid technology approach is greater than 100% in unstable markets
requiring high product varieties, regardless of the volumes of the products. 相似文献
16.
Onur Kuzgunkaya Hoda A. ElMaraghy 《International Journal of Flexible Manufacturing Systems》2006,18(2):145-171
Modern manufacturing systems are increasingly required to be flexible and adaptable to changing market demands, which adds
to their structural and operational complexity. One of the major challenges at the early design stages is to select a manufacturing
system configuration that both satisfies the production functional requirements and is easy to operate and manage. A new metric
for assessing the structural complexity of manufacturing system configurations is presented in this paper. The proposed complexity
metric incorporates the quantity of information using an entropy approach. It accounts for the complexity inherent in the
various modules in the manufacturing system through the use of an index derived from a newly developed manufacturing systems
classification code. The code captures the effect of various component types and technologies used in a manufacturing system
on the system’s structural complexity. The presented metric would be helpful in selecting the least complex manufacturing
system configuration that meets the requirements. An engine cylinder head production system is used to illustrate the application
of the proposed methodology in comparing feasible but different manufacturing system configurations capable of producing the
cylinder head based on their structurally inherent complexity. 相似文献
17.
H.S. Ong C.K. Chua C.M. Cheah 《The International Journal of Advanced Manufacturing Technology》2002,20(5):368-374
Rapid prototyping (RP) is fast becoming a standard tool in today’s product design and manufacturing environment. Significant
benefits in terms of lead time and cost savings have been reported with the use of RP technology. However, these benefits
can be derived only during the design and planning stages of a new product where RP parts are produced in small quantities
for design evaluation, form fitting, and marketing analysis. The high cost of raw material stock used in current RP systems
makes them economically unsuitable even for small-batch production during the product evaluation and manufacturing stages.
Further to this, the difference between the mechanical and physical properties of RP and traditional manufacturing materials
limits the functionality of RP end products. Rapid tooling (RT) technology has opened up new cost-effective solutions for
small-batch production. In this paper, a technique using a rapid soft-tooling approach, namely, aluminium filled epoxy resin
tooling for injection mould preparation is successfully explored. An aluminium filled epoxy resin mould is evaluated and the
characteristics of the injection-moulded end products are presented. 相似文献
18.
The policy of Land Rover Limited towards new technology in manufacturing has always been one of forward thinking, but based
on a ‘step-by-step’ approach to ensure successful implementation. This is the approach being taken with CADCAM in general.
A development programme has been established to ensure that as the quantity of CAD equipment increased in manufacturing, the
systems are at a level where significant benefits are achievable. Land Rover Limited has undertaken a major rationalisation
project which involved relocating 15 external sites onto one main location. A large amount of plant layout work was necessary
to carry out the project and this paper describes the development work on CADCAM in order to achieve a working system in time
for implementing the project with the assistance of a CAD system and the subsequent use of the system by the facilities engineers. 相似文献
19.
全球市场的激烈竞争,给制造业带来了新的工业革命。如何应对不可预测的市场和用户个性化的需求,成为全球制造业的核心问题。本文研究了可重构制造系统的起源、核心特征、基本原理,分析了可重构制造系统与专用制造生产线和柔性制造系统的区别,介绍了可重构制造系统在工业领域的应用及其商业化目标。 相似文献
20.
L. Cronjäger K. Bergmann W. Michel 《The International Journal of Advanced Manufacturing Technology》1987,2(2):89-96
The current situation on the market concerning industrial products has a great influence on production techniques, i.e. the
development is concerned more with smaller batches than mass production of similar items. The reason for this is that competition
requires the satisfaction of growing customer requirements. In addition, the life of product lines is getting shorter with
an expanding field of products. Therefore the trends in machine tool design are directed towards flexible automated production.
For the manufacturing of axially symmetrical parts ‘flexible manufacturing cells’ consisting of lathes and robots have been
created. For prismatic workpieces, stations with automated clamping and pallet changers now exist which also improve the prospects
for flexible production systems. 相似文献