The economic valuation of improved process plant decision support technology

How can investments that would potentially improve a manufacturing plant's decision process be economically justified? What is the value of "better information," "more flexibility," or "improved integration" and the technologies that provide these effects? Technology investments such as improved process modelling, new real time historians and other databases, "smart" instrumentation, better data analysis and visualization software, and/or improved user interfaces often include these benefits as part of their valuation. How are these "soft" benefits to be converted to a quantitative economic return? Quantification is important if rational management decisions are to be made about the correct amount of money to invest in the technologies, and which technologies to choose among the many available ones. Modelling the plant operational decision cycle-detect, analyse, forecast, choose and implement--provides a basis for this economic quantification. In this paper a new economic model is proposed for estimation of the value of decision support investments based on their effect upon the uncertainty in forecasting plant financial performance. This model leads to quantitative benefit estimates that have a realistic financial basis. An example is presented demonstrating the application of the method.     

基于创新的机械产品快速响应设计/制造的关键技术及其应用研究

针对机械产品，首先介绍新产品开发中计算机辅助创新技术；而后阐述针对用户需求的快速响应关键技术，包括计算机辅助模块化技术，基于FEM的变量化结构快速优化技术，基于知识工程（KBE）的特定产品快速开发系统构建，基于CAX的快速设计／制造系统的集成，以及特定机械产品快速设计／制造软件系统的开发工具研究。最后以实例来介绍此技术的应用状况，以此来阐述产品快速设计／制造技术开发的可行性、必要性及其模式。     

Intelligent Data Acquisition Technology Based on Agents

Nowadays, information is the most important factor for any manufacturing enterprise. Information helps a manufacturer to make decisions about management, production, operation, maintenance, and repair. Information technology is a key for enterprises who are realising integrated manufacturing all over the world. Data acquisition is the backbone of information technology. Data acquisition technology is the product of the fusion and interaction of many technologies. It is necessary to develop new data acquisition technology and methods by using the recently produced research results. It is also important for realising manufacturing automation, promoting product quality, and enhancing the competitive ability of an enterprise. In this paper, we first analyse three common kinds of data acquisition mode and their features used in manufacturing systems. Then, based on the background of manufacturing automation, agents and distributed artificial intelligent technology, which form a new data acquisition model framework suitable for an advanced manufacturing system, is proposed, and some details about this new model are discussed. Two examples of this model used in manufacturing systems are then given to show the availability and correctness of this model framework. We conclude with current research results in this area and give an outline of future work.     

探究汽车模具制造中数控加工的应用

社会发展水平显著提升,人们对各项技术的应用提出了严格要求,特别是在生产产品零部件过程中,在模具制造方面提出的要求更加苛刻,其与产品质量密度的高低状况具有直接关联。在汽车模具制造中应用数控加工技术,在弥补传统技术不足的同时,能够提升产品质量。     

数字化制造中的建模和仿真技术

论述了面向数字化制造的三类建模和仿真技术,即产品建模和仿真技术、工艺过程建模和仿真技术以及制造系统建模和仿真技术,并结合具体研究项目,重点介绍了面向制造的产品数字化建模、导管数控弯曲过程建模与仿真、虚拟装配与装配过程仿真、生产线建模与仿真技术的应用和发展。指出为提高制造系统的快速响应特性、运行效率及可靠性,应在产品数字化建模研究的基础上,重视对工艺过程,即产品加工过程、装配过程及生产系统规划、重组和仿真等技术的研究,以实现生产资源和加工过程的优化以及从传统制造向可预测制造模式的转变。最后指出了推动数字化建模和仿真技术朝实用化方向发展的几项关键技术。     

Manufacturing and technology strategy: a survey of planning for AMT

Planning for investments in advanced manufacturing technology (AMT) is one of the most difficult areas for manufacturing managers. A balancing of the need to create competitive advantage and the ability to fund the investment is required. This paper explores the challenges associated with planning new AMT investments and reports the experiences of 61 manufacturing firms. The paper describes the planning process adopted by the manufacturers regarding their investments in AMT. The differences existing between companies, industries and technologies are established. Finally the paper compares actual practice with a conceptual model of AMT decision-making, identifying key implications for practice.     

范围经济下的生产能力扩充和技术选择模型

当前多数企业，基本上是刚性技术和柔性技术并存，因此，企业经常会面临这两种技术之间的选择决策。研究表明，范围经济体现了柔性技术生产的特点，在该前提下引入范围经济的一些假设，在操作成本上对刚性技术和柔性技术加以区分，考虑资金预算，将得到企业生产能力扩充和技术选择的一个简化模型。基于所提出模型的仿真结果，分析了范围经济下生产能力规划和技术选择的一些特性。     

国内外精密加工技术最新进展

介绍了精密和超精密加工技术各主要领域国内外的最新进展。提出应重视精密加工的研究和加大投入,加速提高我国的精密和超精密加工技术水平。     

虚拟产品制造规划中仿真优化技术的研究与应用

论述了制造系统的仿真与优化技术在规划中所起的巨大作用,提出了将工艺计划和生产计划的集成规划置于制造系统仿真的多级优化环境框架,并对仿真优化的目标进行层次分类,最后通过生产线系统设计实例,验证了本文的部分核心思想,为工程师进行产品制造规划提供了有力的前瞻性预测工具。     

Models for capacity acquisition decisions considering operational costs

In this article, we study a capacity acquisition problem by considering technology choice and operational factors in a stochastic environment. The motivation for our work comes from developments in modern flexible technologies and a problem encountered in a real industrial setting. We study the impact of operational factors such as setup times, demand patterns, and inventory/back order costs on the decisions of capacity acquisition and technology choice. We consider three alternatives in capacity and technology decisions: (i) a flexible system, (ii) a dedicated system, and (iii) a combination of these two systems. For each system, we develop a model that integrates investment decisions and operational decisions to determine an optimal amount of capacity to purchase and the time and the types of parts to produce. The objective is to minimize the capacity acquisition cost at the beginning of the planning horizon and the total expected operational costs over an infinite planning horizon. To solve the problem in this article, a solution procedure is proposed. Managerial insights are also derived from extensive computational results.     

Flexible versus dedicated technology: A capacity expansion model

Over the past two decades, flexible manufacturing systems have been adopted in a variety of industries. Shorter product lives have necessitated acquiring flexible facilities. Further, the economies of scope that can be derived from producing products with different seasonality have made flexible facilities attractive. At the same time, dedicated facilities (such as transfer lines) have not disappeared because they offer economies of scale beneficial in high volume manufacturing environments. Hence, when producing a wide variety of products with different seasonality and demand growth rates, firms need to consider both economies of scale and economies of scope in deciding whether to acquire capacity of flexible or dedicated technology or both. In this paper, we consider the problem of making capacity acquisition decisions, when there is a choice of flexible and dedicated technologies available in a deterministic multi-product manufacturing environment with demand assumed to be nondeclining over time. We present a novel formulation of the problem and show the equivalence of the formulation to the uncapacitated plant location formulation. This enables us to use a very efficient solution procedure (Erlenkotter 1978) to solve even large problems optimally. We then present the results of an extensive computational study performed to evaluate the impact of key problem parameters on the proportion of flexible and dedicated capacity acquired. An interesting result of the study is that the proportion of flexible capacity acquired decreases with increasing scale economies. We also find that investment in flexible technology is significant even when it is relatively more expensive than dedicated technology.     

Developing manufacturing response models to predict the manufacturability of new modular products

Product developers usually rely on their experience and knowledge during the design process to generate manufacturable products that can fulfill the required functions. Product developers make various decisions during the course of developing a modular product that affect the functional, physical, and operational structures, which either enhance or reduce the manufacturability of the products. This paper proposes constructing manufacturing response models by modeling the behavior of the manufacturability as a response to the series of decisions made during the design process. The manufacturability response models are mathematical models used to relate the product manufacturability to the different metrics used to quantify the results of the design decisions made during the development life cycle. Decisions made during the design process includes specifying the product functionalities needed to meet customer needs, the physical components capable of delivering the required functionalities, and the manufacturing processes needed to produce the physical components. Manufacturing response models can be used by product developers to predict the effect of the decisions made during the course of developing a modular product on the final modular product manufacturability. Furthermore, this paper demonstrates the construction of the manufacturing response models and their usage in new product design by using an illustrative example.     

制造技术面临的挑战及对策

针对传统制造技术所面临的挑战,讨论了现代制造技术应当采用面向订单的柔性生产、集成协同的生产形式,以及全面质量和成本控制的生产过程,以满足现代市场的需求;同时论述了信息社会中制造业的产品将有着产品信息模型和物质产品2种不同范畴的表现形式,并且由于产品生产中最具创新和价值的部分被包含在产品信息模型中,所以信息时代的制造业应当把产品信息模型的获取置于生产活动的重要地位。最后对大规模定制生产的特点和支撑技术群展开了论述。     

Aligning demand and supply flexibility in custom product co-design

Flexibility of supply and demand is essential for successful implementation of a mass customization strategy that delivers sustained competitive advantage. Supply flexibility, i.e., a choice of alternative products designed to perform the same basic function, is made possible by the range of capabilities available in flexible and agile manufacturing systems and in supply chains. Demand flexibility is derived from the degree to which a customer is willing to compromise on product features or performance levels in order to meet budgetary (reflected in price) or schedule (reflected in delivery) constraints. Flexibility of both supply and demand can have significant strategic and financial value if they are properly aligned. However, customers are mostly unaware of mapping of demand flexibility on to supply flexibility and its impact on production cost and time. Recent advances in information technology have made it possible to co-design a product that involves customer on one end and the manufacturer on the other. This creates an aura and an opportunity where a middle ground between the supply and demand flexibility can be explored and a “deal” can be struck where both parties settle for a product that is beneficial to both through a negotiated settlement. In this paper, we develop a framework for such negotiations. The customer requirements are treated as a range of negotiable options instead of a set of fixed inputs. Demand and supply for customization is then matched by aligning the flexibility of manufacturing systems with customers’ requirement options. Based on this framework, a negotiation scheme is developed to assist customers and manufacturers in exploring and utilizing demand and supply flexibility information in co-design. The negotiation scheme is formulated using goal programming. Finally, an interactive problem-solving procedure is developed and implemented with an illustrative example.

面向快速制造的特种加工技术进展

特种加工是对传统机械加工方法的有力补充和延伸。在已有的特种加工工艺不断完善和定型的同时，新的特种加工技术也不断涌现出来，正在形成面向快速制造的特种加工技术新体系。本文分析总结了特种加工技术的构成及其最新的研究进展，并介绍了面向快速制造的特种加工技术新体系。     

Information-Based Manufacturing with the Web

Manufacturing has been evolving over the years as different needs and technologies arise. This paper describes an emerging manufacturing technology driven by information systems, the global network infrastructure, and new business models driven by the availability of real-time information. Information-based manufacturing concerns using the right information to know what products to make, when to make them, and then making them the best possible. This becomes more complicated when a number of products, facilities, markets, and companies are involved. More than just information is needed. Connectivity, ability to coordinate and integrate, and implementation strategy all are important. Information systems provide the infrastructure to carry out these objectives. Because of the need for an effective information infrastructure, the Internet has the potential to further enhance information-based manufacturing. Information-based manufacturing can be efficient only when the underlying supply-chain network is run efficiently, for the supply chain provides the infrastructure for directing all the activities from receiving raw materials to the delivery of final products. This paper illustrates how the Web technology can help coordinate the supply-chain activities in manufacturing. It also illustrates the relationships between product types, supply-chain structures, information-sharing, coordination, and the Web.     

Using data envelopment analysis for evaluating flexible manufacturing systems in the presence of imprecise data

The aim of this paper is to present a comprehensive methodology for evaluation and selection of advanced manufacturing technologies, incorporating both the economic and strategic aspects and the related imprecise as well as exact data into the decision making process. Initially, a data envelopment analysis (DEA) model that can take into account crisp, ordinal, and fuzzy data is introduced. Then, the developed framework is used for flexible manufacturing system (FMS) selection. The DEA approach is performed by employing capital and operating cost, required floor space and work-in-process (WIP) as the input variables, and using product flexibility, quality improvement and lead time reduction as the output variables. The assessment of FMS alternatives versus product flexibility and quality improvement are represented via ordinal data, while WIP and lead time reduction are stated using triangular fuzzy numbers. The proposed framework is illustrated through an application and comparative results are presented.     

CAD-CAM in Australia: flexibility quality and manufacturing strategy

This paper presents a small empirical study of CAD-CAM applications in Australia, ranging from a simple PC-driven engraver to an FMS. The technology constitutes the core of the so-called ‘factory of the future’. In this context there is considerable speculation concerning manufacturing strategy, flexible automation, and the dawn of a new competitive environment. Academic opinion visualizes the major players running highly-integrated systems, making better-quality goods that are tailored to individual requirements, yet can be delivered very quickly. So far, the (push button) fusion of all stages of design and manufacture remains a dream, although we do observe ‘islands of automation’. Generally, CAD-CAM has had a bigger impact on preproduction activities, especially patternmaking and toolmaking, than on actual factory operations. These particular businesses already undertook considerable product and/or process design, and the main thrust of greater flexibility has been to provide much higher productivity in related areas. However, there are significant spin-off benefits too, for new products, quality, delivery and service. They hardly amount though, to a basic shift in manufacturing strategy.     

基于虚拟制造技术的产品设计方法研究

虚拟制造被视为增强企业竞争能力的新型产品创新设计技术,得到广泛应用.文中阐述了虚拟制造技术的内涵及特点,系统分析了虚拟制造所涉及的主要支撑技术--虚拟现实技术、建模技术、仿真技术,并对虚拟制造技术的应用现状给予了评价.     

RFID-based wireless manufacturing for real-time management of job shop WIP inventories

Modern manufacturing shop-floors suffer from a bottleneck of capturing and collection of real-time field information. Paper-based manual systems are time-consuming, prone to errors, tedious, and frequently damaged, lost or misplaced. As a result, the information does not accurately and promptly reflect the real-life situations and changes of the situations due to disturbances. Without up-to-date information, it is impossible to make accurate shop-floor decisions. This paper presents an affordable approach to shop-floor performance improvement by using wireless manufacturing (WM)—an emerging advanced manufacturing technology (AMT). WM relies substantially on wireless devices such as RFID (radio frequency identification) or auto-ID sensors and wireless information networks for the collection and synchronization of the real-time field data from manufacturing workshops. Emphasis is placed upon how to deploy WM technology for managing work-in-progress (WIP) inventories in manufacturing job shops with typical functional layouts. This approach avoids the change from functional to cellular layouts in order to retain existing operational flexibility while improving efficiency and capacity. Representative WIP logistic processes will be used to demonstrate how production and logistic operators and their supervisors accomplish their tasks in a WM shop-floor.