Modular production systems: a new manufacturing paradigm

It is well recognized that manufacturers of consumer goods throughout the world are facing major new demands, including shorter product life-cycles and increasing competition. In response, companies are restructuring and moving away from traditional process-centred work practices in favour of concurrent engineering methods. In particular, design for manufacture has gained widespread recognition as a means of reducing production costs and lead times. However, optimal design for manufacture is difficult to achieve using current-day work organization and business structures. An underlying problem is the lack of a scientific framework for production. To address this need, this paper proposes a radical and far-reaching new manufacturing paradigm based upon on building production systems from standardized modular machines. The manufacturing concept, termed modular production systems (MPS), is aimed specifically at hard low- to medium-technology consumer products, as typified by goods such as childrens toys and kitchen appliances. The rationale for MPS as a means of enabling concurrent product and production system design is put forward, and the long-term implications and work required to establish the concept are discussed.     

装备制造企业如何选择柔性制造策略——基于制造合格率视角

柔性制造是装备制造企业应对制造稳定性干扰、提升竞争优势的重要手段.注意到现有文献较少关注制造稳定性与制造柔性量化这一不足,分别用制造合格率和制造冗余量刻画制造稳定性和制造柔性,并在此基础上构建一个关于装备制造企业制造合格率、制造柔性以及制造利润的统一分析框架,用以考察并揭示装备制造企业柔性制造策略对其应对制造稳定性的影响.研究结果表明:柔性制造策略的开展,有助于装备制造企业提高应对环境变化的能力,保证产品质量与数量,进而促进制造利润增长;当单位制造成本较小时,制造柔性水平与制造合格率呈倒U型变化趋势;当单位制造成本较大时,制造柔性水平与制造合格率呈正相关关系;单位质检成本的提高会迫使装备制造企业降低制造柔性水平,并影响企业应对制造稳定性的能力,最终导致制造利润受损.     

基于制造流程和制造特征的零件工时估算

为了解决以往相似零件工时估算方法的精度和效率之间的矛盾,提出一种精度高且易于编程实现进而提高效率的工时估算方法。研究加工工艺对制造特征工时的影响机理,提出制造特征组合的概念,并在此基础上实现生产准备、上下料、换刀、粗加工、精加工五个工时数据库的开发。提出制造流程图的概念并描述其绘制方法。通过对历史零件制造流程图的修改及工时数据库中数据的调取计算实现对相似零件的工时估算。以某企业生产的一个零件族中相似零件的工时估算为例,验证所提出的估算方法的有效性。     

A dynamic scheduling holon for manufacturing orders

This paper deals with a new architecture and negotiation protocol for the dynamic scheduling of manufacturing systems. The architecture is based on two paradigms: multi-agent systems and holonic systems. The main contribution in the architecture is the existence of holons representing tasks together with holons representing resources. The well-known contract net protocol has been adapted to handle temporal constraints and to deal with conflicts. It also deals with conflict situations, namely with the case of the indecision problem. This approach assumes that deadlines are the most important constraints to consider.     

Holon技术在敏捷制造系统中的应用研究

面对日益多样化的客户需求和市场能够快速响应的生产状况，制造业领域的生产模式也朝着客户化、敏捷化、柔性化的方向发展，敏捷制造模式有望成为21世纪的发展趋势。讨论了将全能体Holon作为实施敏捷制造的现实技术问题，分析比较了目前国内外在此领域的研究现状。通过简单归纳Holon的定义，并对Holon的内部逻辑结构加以分析说明。提出了基于Holon的面向订单生产敏捷制造企业参考模型。     

Agent-based distributed manufacturing control: A state-of-the-art survey

Manufacturing has faced significant changes during the last years, namely the move from a local economy towards a global and competitive economy, with markets demanding for highly customized products of high quality at lower costs, and with short life cycles. In this environment, manufacturing enterprises, to remain competitive, must respond closely to customer demands by improving their flexibility and agility, while maintaining their productivity and quality. Dynamic response to emergence is becoming a key issue in manufacturing field because traditional manufacturing control systems are built upon rigid control architectures, which cannot respond efficiently and effectively to dynamic change. In these circumstances, the current challenge is to develop manufacturing control systems that exhibit intelligence, robustness and adaptation to the environment changes and disturbances. The introduction of multi-agent systems and holonic manufacturing systems paradigms addresses these requirements, bringing the advantages of modularity, decentralization, autonomy, scalability and re-usability. This paper surveys the literature in manufacturing control systems using distributed artificial intelligence techniques, namely multi-agent systems and holonic manufacturing systems principles. The paper also discusses the reasons for the weak adoption of these approaches by industry and points out the challenges and research opportunities for the future.     

Computerised manufacturing and empirical knowledge

What skills are required for working with computer-controlled machines in the manufacturing area? Taking the developments in the machine building sector in Germany as an example, it becomes apparent that a human-centred approach (skill-based manufacturing) offers the companies many advantages over Tayloristic forms of work organisation and automation. Closer observations reveal that skills and qualifications based on empirical knowledge and individual capabilities, such as a feeling for machines and materials, continue to play an important part in the work with computer-controlled machines. So far, however, skills of this kind have received neither practical nor systematic consideration and are regarded as tacit skills in most cases. Therefore it is particularly the use of computer technology which is likely — in most cases unintentionally — to restrict and undermine the essential preconditions necessary for the development and application of such skills.     

Deadlock avoidance in flexible flow shops with loops

This paper presents a deadlock-avoidance scheme that was developed during the MASCADA Project—Esprit LTR Project 22728. The deadlock problem occurs in a car body painting shop. From this application, an abstract problem was derived for which a deadlock-avoidance method was developed. The paper presents the deadlock-avoidance scheme and its correctness proof. In addition, implementation issues are introduced and solutions are discussed.     

A multiagent-based control system applied to an educational shop floor

This paper addresses the design and implementation of a multiagent-based control architecture to support modular reconfigurable production systems. The requirements for plugability of modules (manufacturing components) and product changes were considered and tested against an educational platform based on Fischertechnik, which resembles a production system composed of several workstations connected by a crane and conveyors.     

An implementation framework for seru production

Seru production, which merges the flexibility of job shops, efficiency of mass production, and environment friendly characteristics of sustainable manufacturing, largely for electronics assembly, is the latest manufacturing mode developed in Japan. It is receiving attention from Japanese practitioners and researchers. However, some attempts to implement seru production are unsuccessful, especially outside Japan. This is because of lack of knowledge of the specific means to implement seru production. The purpose of this paper is to provide a general framework and some basic principles that should be followed while implementing seru production for practitioners from a practical perspective. This work is based on a systematic analysis of many implementation experiences of seru production in Japanese manufacturing factories as well as a broad investigation of the popular literature information. The proposed framework can serve as a concise guide to help implement seru production in the manufacturing industry. In addition, constructive information is provided for researchers who would like to know and study the advanced manufacturing mode of seru production but do not understand the Japanese language.     

自动化制造系统的产生与发展

探讨了自动化与制造业的产生和互促发展过程 ,论述了自动化制造系统的形成和不同发展阶段的内涵及重大作用,指出自动化技术与制造 技术是驱动自动化制造系统发展的两个轮子,不能忽视任何一个侧面,自动化研究与制造技 术研究相结合是发展先进制造技术的必由之路．     

Toward a cloud-based manufacturing execution system for distributed manufacturing

This paper illustrates the needs and challenges for the management of distributed manufacturing in a multi-company supply chain and processes these further as features of new IT systems. Requirements are collected from manufacturing companies and combined with insights from literature in the field of current ERP/MES system drawbacks, advantages, needs and challenges. The findings show that the needs and challenges in data integration inside SME networks are closely related to the limitations of current supply chain solutions. Current ERP-solutions lack extended enterprise support and a shared cloud-based approach. On the other hand, current MES solutions can operate the manufacturing process, but not for distributed manufacturing. As an answer to the requirements, we made a proposal for the core of architecture for next generation of MES solution in this position paper. Moreover, a pilot software tool has been developed to support the needs related to real time, cloud-based, light weight operation.     

Fuzzy logic based method to measure degree of lean activity in manufacturing industry

Lean manufacturing is gaining popularity as an approach that can achieve significant performance improvement in the industry. However, the application of lean manufacturing is not an easy process. To reach the level of full implementation of lean manufacturing takes a long time and during that time the continuous improvement must be made. In the process of continuous improvement, lean manufacturing assessment is required. One form of assessment is to measure the degree of lean implementation. However, it is the complexity involved in the measure of degree of leanness. This complexity arises due to (a) the inherent multi-dimensional concept of leanness (b) unavailability manufacturing practice database that can be used as a benchmark in assessing the degree of leanness and (c) the necessity for the application of subjective human judgement on lean practices which involve vagueness and bias due to variation of evaluator's knowledge and experience. In this paper a method to deal with the multi-dimensional concept, unavailability benchmark and uncertainty, which arises from the subjective and vague human judgement for the measurement of degree of leanness, is proposed. The multi-dimensional concept involving a variety of components of lean practices is measured in order to arrive at a measure for the lean activity of a given organization. It is constructed from primary and secondary data involving a comprehensive literature review and validated with interviews with a set of sample organizations representing the entire spectrum of the industry. The vagueness of subjective human judgement on degree of application of lean practices is modelled by fuzzy number in conjunction with an additional consideration related to the length of lean practice implementation and the use of multi-evaluators. Value stream mapping is used in scoring the degree of implementation of lean so the use of benchmark is not necessary. Some results from an initial survey from a sample of respondents from the manufacturing industry in Indonesia are presented to illustrate the applicability and potential strength of the proposed method.     

Cloud-based design and manufacturing: A new paradigm in digital manufacturing and design innovation

Cloud-based design manufacturing (CBDM) refers to a service-oriented networked product development model in which service consumers are enabled to configure, select, and utilize customized product realization resources and services ranging from computer-aided engineering software to reconfigurable manufacturing systems. An ongoing debate on CBDM in the research community revolves around several aspects such as definitions, key characteristics, computing architectures, communication and collaboration processes, crowdsourcing processes, information and communication infrastructure, programming models, data storage, and new business models pertaining to CBDM. One question, in particular, has often been raised: is cloud-based design and manufacturing actually a new paradigm, or is it just “old wine in new bottles”? To answer this question, we discuss and compare the existing definitions for CBDM, identify the essential characteristics of CBDM, define a systematic requirements checklist that an idealized CBDM system should satisfy, and compare CBDM to other relevant but more traditional collaborative design and distributed manufacturing systems such as web- and agent-based design and manufacturing systems. To justify the conclusion that CBDM can be considered as a new paradigm that is anticipated to drive digital manufacturing and design innovation, we present the development of a smart delivery drone as an idealized CBDM example scenario and propose a corresponding CBDM system architecture that incorporates CBDM-based design processes, integrated manufacturing services, information and supply chain management in a holistic sense.     

Virtual factory approach for implementation of holonic control in industrial applications: A case study in die-casting industry

Design and implementation of holonic manufacturing control systems for the real industrial applications require risky, careful decisions to ensure that the manufacturing system will successfully satisfy the demands of an ever-changing market. This paper suggests a virtual reality (VR)-based methodology for enhancing the design and implementation process of holonic control systems in manufacturing practice. The major focus has been given to the implementation of holonic control into the small to medium size manufacturing enterprises (SMEs).     

Adaptive-intelligent control of robots and technological equipment of intelligent manufacturing

Methods of adaptive-intelligent control of robots and technological equipment of intelligent manufacturing (IM) with incomplete information on the plant conditions are discussed. Flexible algorithms are proposed for programming and sensor correction of movements which provide adaption to obstacles and uncertainly factors. Robust and adaptive control algorithms which compensate the uncontrollable disturbances and ensure the wanted character of transient process are synthesized. The conversational means and computeraided design technology for multi-microprocessor adaptive control systems of robots and technological equipment are described. The results of using the proposed methods in adaptive-intelligent control systems of robots and flexible manufacturing systems (FMS) for powder metallurgy, laser processing are presented.     

基于敏捷制造模式的数字化生产车间的研究

着眼于敏捷制造的特点,分析了敏捷型数字化生产车间的内涵及特点。在此基础之上讨论了敏捷型生产的体系结构和运行逻辑,并更深入地阐述了敏捷型数字化生产车间的信息通讯以及与之相对应的制造资源业务管理流程。     

基于Web的客户化分布式网络制造技术

面对经济全球化的趋势,制造业传统的制造模式已不相适应,文中提出了面向21世纪制造业的基于Web的客户化分布式网络制造概念。首先对这一制造模式的特征、系统结构、主要组成和功能及运作流程作了详细的描述。然后,对系统实现的关键技术面向分布式网络制造的合弄控制体系结构和分布式计算技术进行了讨论。通过原型系统的开发和部分技术、原理的实际应用,证明该技术对提高制造系统的敏捷性是可行的、有效的。     

Sequencing and Scheduling in Robotic Cells: Recent Developments

A great deal of work has been done to analyze the problem of robot move sequencing and part scheduling in robotic flowshop cells. We examine the recent developments in this literature. A robotic flowshop cell consists of a number of processing stages served by one or more robots. Each stage has one or more machines that perform that stage’s processing. Types of robotic cells are differentiated from one another by certain characteristics, including robot type, robot travel-time, number of robots, types of parts processed, and use of parallel machines within stages. We focus on cyclic production of parts. A cycle is specified by a repeatable sequence of robot moves designed to transfer a set of parts between the machines for their processing.We start by providing a classification scheme for robotic cell scheduling problems that is based on three characteristics: machine environment, processing restrictions, and objective function, and discuss the influence of these characteristics on the methods of analysis employed. In addition to reporting recent results on classical robotic cell scheduling problems, we include results on robotic cells with advanced features such as dual gripper robots, parallel machines, and multiple robots. Next, we examine implementation issues that have been addressed in the practice-oriented literature and detail the optimal policies to use under various combinations of conditions. We conclude by describing some important open problems in the field.     

An object-oriented framework for developing distributed manufacturing architectures

Management of complexity, changes and disturbances is one of the key issues of production today. Distributed, agent-based structures represent viable alternatives to hierarchical systems provided with reactive/proactive capabilities. In the paper, approaches to distributed manufacturing architectures are surveyed, and their fundamental features are highlighted, together with the main questions to be answered while designing new structures. Moreover, an object-oriented simulation framework for development and evaluation of multi-agent manufacturing architectures is introduced.