Design methodology for production systems retrofit in SMEs

Investment in the productive systems of small and medium-sized enterprises (SMEs) in the manufacturing sector is usually quite limited. For this reason, normal practice is to apply minor developments internally or upgrade equipment as it becomes obsolete to increase their productive capacity and competitiveness at a lower cost. However, the work team, mostly made up of engineers, does not usually have experience in the use of design methodologies but also they are often familiar with the functioning of various design and quality-management tools. This paper presents a clear and simple design methodology that facilitates the development of adaptations to items of equipment that might be considered one-off products. It includes a selection of design tools that are, according to the literature on the subject, the most common and best-known among engineers, and which are also best-suited to the environment of an SME. The design methodology was validated experimentally with the upgrading of a gear-rolling tester installed on the premises of an SME in the sector. The recommended techniques and tools were satisfactory applied opening the possibilities for further application of the methodology in similar machine’s upgrades in the future.     

Improving the productivity of service businesses

Service organizations account for over 60 percent of the GNP, yet management tools are less developed for this sector than for the manufacturing sector. This article describes a new approach to help evaluate and improve the productivity of many types of service organizations, identifies inefficiencies and ways to improve productivity, and provides examples of applications to hospitals and bank branches. These insights are not available from commonly used performance measures. The article presents procedures required to use this technique and discusses ways managers can assess its potential costs and benefits.     

An approach to accidents modeling based on compounds road environments

The most common approach to study the influence of certain road features on accidents has been the consideration of uniform road segments characterized by a unique feature. However, when an accident is related to the road infrastructure, its cause is usually not a single characteristic but rather a complex combination of several characteristics. The main objective of this paper is to describe a methodology developed in order to consider the road as a complete environment by using compound road environments, overcoming the limitations inherented in considering only uniform road segments. The methodology consists of: dividing a sample of roads into segments; grouping them into quite homogeneous road environments using cluster analysis; and identifying the influence of skid resistance and texture depth on road accidents in each environment by using generalized linear models. The application of this methodology is demonstrated for eight roads. Based on real data from accidents and road characteristics, three compound road environments were established where the pavement surface properties significantly influence the occurrence of accidents. Results have showed clearly that road environments where braking maneuvers are more common or those with small radii of curvature and high speeds require higher skid resistance and texture depth as an important contribution to the accident prevention.     

场景可视化在VTM系统体验设计中的应用

目的为了把满足"用户真正需求"的用户体验切实可行地落实到产品操作以及服务流程中去,寻求银行环境、VTM(可视柜台)机器、用户体验之间的关系,以此总结出VTM系统体验设计的原则。方法通过实地考察和角色扮演结合场景可视化技术,处理生成在同一新型银行网点下不同用户需求的历程图。结论场景可视化能够充分反映用户的真实需求,并且能够将网点用户活动与网点环境相结合,从而提出更加适宜的VTM用户体验设计原则,最终为用户打造一个优化、高效、互联、整合、友善、安全的VTM系统,为用户提供更为友好的业务办理体验。     

Validating CSCW strategies and applications for rapid product development in the investment casting process

The aim of this study is to apply and validate a general-purpose working methodology, derived from the analysis of processes which come from two different domains (the field of medicine and the preservation of cultural heritage), in the investment casting process. CSCW methods and tools have proven to be the best ‘gluing tool’ to bond the different activities, and thus heavily exploited during the customization of the general-purpose working methodology. This paper describes a case study performed in an industrial sector and related to the investment casting application field. It was chosen to test methodology and to demonstrate its wide applicability. The case study involved the realization of a centrifugal pump impeller, where the application of this CSCW-based methodology has delivered important results such as the reduction of product development time and the drastic reduction of production costs.     

Evaluation of the contract reliability for alternative infrastructure project delivery: a contract engineering method

Governments at all levels are increasingly motivating the private sector to participate in infrastructure development using alternative project delivery methods to relieve financial burden. When designing contracts, governments usually offer incentives while requiring cost or time guarantee to balance project attractiveness to the private sector and fair protection of public interest. However, a practical and critical problem is how to properly design these provisions. Although previous studies have investigated the value of these provisions, a knowledge gap still exists with respect to methods of fairly and effectively designing such provisions. This study fills this gap by developing a methodology that analyzes the appropriateness of guarantee or warranty provisions for contracts. In this study, a contract reliability index is constructed, and a process of evaluating contract reliability is proposed. The New Mexico Highway 44 project, in which three warranty provision arrangements are investigated, is used as a case study to illustrate the analysis process. Results show that although a ceiling clause can effectively motivate the private sector to participate in the project, it sacrifices a significant amount of public benefits. By contrast, although a warranty option can protect public benefits, it cannot effectively incentivize the private sector. A combination of the ceiling clause and the warranty option will therefore result in improved contract provision design. The proposed methodology in this study is especially useful for governments in properly determining contract clauses in infrastructure development.     

The Evolution of the Engineering Community: Pressures,Opportunities, and Challenges

The practice of engineering is undergoing significant changes due not only to the inexorable progress of technology but also to the changes being wrought in business practice the world over. The manufacturing sector is showing decline in numbers of engineers, and the service sector is growing. The advent of the truly global economy augers still further change. Perhaps the most pervasive changes are due to the digital revolution along with the molecular biology revolution. Inevitably the engineering disciplines will find new branches and engineering education will find new paths to follow as a result.     

Energy sector planning using multiple-index pinch analysis

Pinch analysis was initially developed as a methodology for optimizing energy efficiency in process plants. Applications of pinch analysis applications are based on common principles of using stream quantity and quality to determine optimal system targets. This initial targeting step identifies the pinch point, which then allows complex problems to be decomposed for the subsequent design of an optimal network using insights drawn from the targeting stage. One important class of pinch analysis problems is energy planning with footprint constraints, which began with the development of carbon emissions pinch analysis; in such problems, energy sources and demands are characterized by carbon footprint as the quality index. This methodology has been extended by using alternative quality indexes that measure different sustainability dimensions, such as water footprint, land footprint, emergy transformity, inoperability risk, energy return on investment and human fatalities. Pinch analysis variants still have the limitation of being able to use one quality index at a time, while previous attempts to develop pinch analysis methods using multiple indices have only been partially successful for special cases. In this work, a multiple-index pinch analysis method is developed by using an aggregate quality index, based on a weighted linear function of different quality indexes normally used in energy planning. The weights used to compute the aggregate index are determined via the analytic hierarchy process. A case study for Indian power sector is solved to illustrate how this approach allows multiple sustainability dimensions to be accounted for in energy planning.     

Setting competitiveness indicators using BSC and ANP

In this paper a new approach to assess companies' competitiveness performance in an efficient and reliable way is presented. It introduces a rigorous methodology, based on multi-criteria techniques, which seeks to assist managers of companies within a specific industrial sector in providing information about their relative position in order to define improvement action plans. The approach combines the use of the analytic network process (ANP) method with the balanced scorecard (BSC) to achieve competitiveness indicators. The ANP method allows the aggregation of experts’ judgments on each of the selected indicators used into one company competitiveness index (CCI). To demonstrate the goodness of the methodology, a case study of the plastic sector of Venezuela has been carried out. Three companies have been analysed using the CCI proposed. The participating experts agreed that the methodology is useful and an improvement from current competitiveness measurement techniques. They found the results obtained coherent and the use of resources significantly less than in other methods.     

Mass deployment of sustainable transportation: evaluation of factors that influence electric vehicle adoption

Mass penetration of electric vehicles into the market will have a number of impacts and benefits, including the ability to substantially reduce greenhouse gas emissions from the transportation sector. Therefore, it is expected that in coming years this technology will progressively penetrate the market. This research presents an analysis of factors that influence electric vehicle adoption by modeling the conditions under which an individual, particularly one with an engineering or technical background, is more or less likely to adopt an electric vehicle. This model is developed by considering demographic determinants as well as behavioral and attitudinal measures that affect individual adoption of the technology. The methodology involves applying logistic regression to provide a good fit and predict the response given explanatory variables. Analyzing these outcomes generates empirical findings that better inform electric vehicle technology and policy development. This study takes into account preferences of potential customers and analyzes how individuals with engineering and technology background differ in electric vehicle adoption considerations compared to the general population. Therefore, this research provides both engineers and policy makers with critical information for developing future electric vehicle technology. The model results show that several factors including willingness to pay for new appealing technology, distance driven, perceptions of electric vehicles as good for the environment, perception of EV speed are statistically significant in influencing willingness to purchase an electric vehicle.     

Analysis of accident inequality of the Spanish fishing fleet

There is at present a clear tendency to consider safety as a vital factor in the running of a country's fishing sector. However, the planning of the necessary resources and their adequate distribution according to the sector's needs is only possible if detailed information is available about the degree of concentration of the accidentality of that sector.

In this context, the aim of this work is two-fold: firstly, to formalise a methodology for the fishing sector of a country which allows the inequality in the concentration of accidents to be analysed; and secondly, to apply this methodology to the Spanish fishing fleet for the period 1994–2002. Thus, indices are built by regions and by types of vessel for two variables: fishermen and vessels. Results are obtained both for the inequality in the concentration of accidents and their associated Lorenz curves and for the rates and elasticities of fishing sector accidents.     

A system dynamics model: Transition to sustainable processes

Academics, firms, governments, and society, in general, are increasingly interested in studies and actions that help mitigate the effects of climate change. Therefore, this becomes an opportunity for firms in the manufacturing sector to carry out sustainable activities across their production areas. In this paper, we propose a model that seeks to analyze through computer modeling and simulation. These dynamics occur in the implementation of eco-innovation processes across organizations in the manufacturing sector. For developing the computer simulation model, we applied the system dynamics methodology (used to model policies and strategies) to understand better the interaction between the industrial sector, the environment, and society. Among the results, we highlight the importance of investing in training employees in sustainability matters and in more efficient equipment to reduce costs and energy consumption. Thus, we propose implementing this generic model in a real case study to test and adjust it and validate our findings. The proposed model can be used to examine various strategies to identify the most efficient ones for the process and answer questions about the results of long-term decisions regarding implementing sustainable processes within organizations.     

Statistical analysis of incidents reported in the Greek Petrochemical Industry for the period 1997-2003

This paper makes an analysis of all reported accidents and incidents in the Greek Petrochemical Industry for the period spanning from 1997 to 2003. The work performed is related to the analysis of important parameters of the incidents, their inclusion in a database adequately designed for the purposes of this analysis and an importance assessment of this reporting scheme. Indeed, various stakeholders have highlighted the importance of a reporting system for industrial accidents and incidents. The European Union has established for this purpose the Major Accident Reporting System (MARS) for the reporting of major accidents in the Member States. However, major accidents are not the only measure that can characterize the safety status of an establishment; neither are the former the only events from which important lessons can be learned. Near misses, industrial incidents without major consequences, as well as occupational accidents could equally supply with important findings the interested analyst, while statistical analysis of these incidents could give significant insight in the understanding and the prevention of similar incidents or major accidents in the future. This analysis could be more significant, if each industrial sector was separately analyzed, as the authors do for the petrochemical sector in the present article.     

A heuristic for designing manufacturing focus units with resource considerations

This paper presents a model of the plant-within-a-plant (PWP) design problem and demonstrates a heuristic for analysing the problem. Although the benefits of a manufacturing focus have been articulated in the literature, methods for implementation with consideration for resource requirements have not been developed previously. In this study, we discuss the importance of including resource considerations and propose a methodology that can help managers arrive at a facility design with a high degree of focus and minimum resource needs. A heuristic is developed that incorporates the concept of order-winning criteria and volume into the focus design. The heuristic not only recognises the effects of conflicting manufacturing tasks, but also considers resource costs and material flows between PWP units. Experimental results show that the proposed methodology offers managers the opportunity to generate and assess alternative PWP designs, which are otherwise unavailable. Overall, this research provides an analytical framework for further research in focused manufacturing.     

Theoretical development of stochastic delay analysis and forecast method

Abstract

Schedule delay analysis and claim management for construction projects have received much attention recently due to an increasing number of construction disputes. Most of the available delay analysis methods employ a deterministic approach that uses deterministic activity duration in as-planned schedules for schedule comparison. However, the duration of construction projects is naturally uncertain. Based on a mathematical-model delay analysis method, this study proposes an innovative approach, the Stochastic Delay Analysis and Forecast method (the SDAF method), which combines probabilistic activity duration and systematic delay analysis procedures to predict the contribution of a single activity’s delay and its probability to cause overall project delay. This paper proposes a methodology and examines its results by means of a simulated case. Although this study has simplified practical problems, preliminary study results are valuable and form a basis for further research. Namely, these study results provide not only a stochastic delay analysis and forecast method but also a fundamental basis for developing advanced schedule delay analysis methodology to help in solving complicated schedule delay problems in construction projects.     

Hazard assessment of substances produced from the accidental heating of chemical compounds

Accidental events concerning process industries can affect not only the staff working in, but also the environment and people living next to the factory. For this reason a regulation is imposed by the European Community to prevent accidents that could represent a risk for the population and the environment. In particular, Directive 96/82/CE, the so-called 'Seveso II directive', requests a risk analysis involving also the hazardous materials generated in accidental events. Therefore, it is necessary to develop simple and economic procedure to foresee the hazardous materials that can be produced in the case of major accidents, among which the accidental heating of a chemical due to a fire or a runaway reaction is one of the most frequent. The procedure proposed in this work is based on evolved gas analysis methodology that consists in coupling two instruments: a thermogravimetric analyzer or a flash pyrolyzer, that are employed to simulate accident conditions, and a FTIR spectrometer that can be used to detect the evolved gas composition. More than 40 materials have been examined in various accident scenarios and the obtained data have been statistically analyzed in order to identify meaningful correlations between the presence of a chemical group in the molecule of a chemical and the presence of a given hazardous species in the fume produced.     

A practical approach for predicting fatigue reliability under random cyclic loading

The purpose of this paper is to provide a simple approach for reliability analysis based on fatigue or overstress failure modes of mechanical components, and explain how this integrated method carries out spectral fatigue damage and failure reliability analysis. In exploring the ability to predict spectral fatigue life and assess the reliability under a specified dynamics environment, a methodology for reliability assessment and its corresponding fatigue life prediction of mechanical components using a supply-demand interference approach is developed in this paper. Since the methodology couples dynamics analysis and stochastic analysis for fatigue damage and reliability prediction, the conversion of the duty cycle history for the reliability study of an individual component is also presented. Using the proposed methodology, mechanical component reliability can be predicted according to different mission requirements. For an explanation of this methodology, a probabilistic method of deciding the relationship between the allowable stress or fatigue endurance limit and reliability is also presented.     

Optimal Control of Oxygen Concentration in a Magnetic Czochralski Crystal Growth by Response Surface Methodology

Concepts and techniques of response surface methodology have been widely applied in many branches of engineering, especially in the chemical and manufacturing areas. This paper presents an application of the methodology in a magnetic crystal Czochralski growth system for single crystal silicon to optimize the oxygen concentration at the crystal growth interface in a cusp magnetic field. The simulation demonstrates that the response surface methodology is a feasible algorithm for the optimization of the Czochralski crystal growth process.     

MMALE—A Methodology for Malware Analysis in Linux Environments

In a computer environment, an operating system is prone to malware, and even the Linux operating system is not an exception. In recent years, malware has evolved, and attackers have become more qualified compared to a few years ago. Furthermore, Linux-based systems have become more attractive to cybercriminals because of the increasing use of the Linux operating system in web servers and Internet of Things (IoT) devices. Windows is the most employed OS, so most of the research efforts have been focused on its malware protection rather than on other operating systems. As a result, hundreds of research articles, documents, and methodologies dedicated to malware analysis have been reported. However, there has not been much literature concerning Linux security and protection from malware. To address all these new challenges, it is necessary to develop a methodology that can standardize the required steps to perform the malware analysis in depth. A systematic analysis process makes the difference between good and ordinary malware analyses. Additionally, a deep malware comprehension can yield a faster and much more efficient malware eradication. In order to address all mentioned challenges, this article proposed a methodology for malware analysis in the Linux operating system, which is a traditionally overlooked field compared to the other operating systems. The proposed methodology is tested by a specific Linux malware, and the obtained test results have high effectiveness in malware detection.     

Application of Bayesian Methods for Age‐Dependent Reliability Analysis

In this article, the authors present a general methodology for age‐dependent reliability analysis of degrading or ageing components, structures and systems. The methodology is based on Bayesian methods and inference—its ability to incorporate prior information and on ideas that ageing can be thought of as age‐dependent change of beliefs about reliability parameters (mainly failure rate), when change of belief occurs not only because new failure data or other information becomes available with time but also because it continuously changes due to the flow of time and the evolution of beliefs. The main objective of this article is to present a clear way of how practitioners can apply Bayesian methods to deal with risk and reliability analysis considering ageing phenomena. The methodology describes step‐by‐step failure rate analysis of ageing components: from the Bayesian model building to its verification and generalization with Bayesian model averaging, which as the authors suggest in this article, could serve as an alternative for various goodness‐of‐fit assessment tools and as a universal tool to cope with various sources of uncertainty. The proposed methodology is able to deal with sparse and rare failure events, as is the case in electrical components, piping systems and various other systems with high reliability. In a case study of electrical instrumentation and control components, the proposed methodology was applied to analyse age‐dependent failure rates together with the treatment of uncertainty due to age‐dependent model selection. Copyright © 2013 John Wiley & Sons, Ltd.