Manufacturing responsiveness through integrated process planning and scheduling

This paper describes a novel approach to improve manufacturing responsiveness, defined as the ability of a manufacturing system to make a rapid and balanced response to the predictable and unpredictable changes characterizing today's manufacturing environments. The approach aims at creating a dynamic environment that is capable of reacting to factory conditions and which has a significant impact on the reduction of cost, lead time and inventory. The concurrent engineering concept of information sharing to support all the product development phases is employed here. Techniques such as design for manufacture have been applied to the design-process planning interface. Efforts have been made towards eliminating the divisions between process and scheduling activities using the concept of resource elements, which are the exclusive and shared capability boundaries between processing elements in the manufacturing facility. A prototype integration system has been implemented consisting of a knowledge base with facility modelling functions, an intelligent feature-based design system, a featurebased process planning system and a simulation-based scheduling module.     

Optimal process parameter determination for computer‐aided manufacturing

Producing high‐quality products at low cost is one of the key factors to survival for manufacturing sectors in today's intense global competition environment. One way to gain competitiveness is to integrate product design and process planning into one activity. This study attempts to determine optimal process parameters for a manufacturing process under given design parameters. The process parameters to be determined in this study include process means and process tolerances for particular manufacturing process sequences. The problem is formulated in constrained non‐linear optimization, considering both quality‐ and manufacturing‐related costs. The proposed application evaluates alternative product designs and process sequences so that the best associated process parameters can be determined during the early stages of design and planning. This makes the link between CAD and CAM systems more useful and effective. As a result, optimal integration of product design and process planning with minimal production costs and maximal product quality is possible. Copyright © 1999 John Wiley & Sons, Ltd.     

Facility layout design in a changing environment

Increasing global competition, rapid changes in technology and the necessity to respond quickly to a cost and quality conscious customer have changed the dynamics of facilities planning. Today's manufacturing facility needs to be responsive to the frequent changes in product mix and demand while minimizing material handling and machine relocation costs. In this paper, we present a framework for the design of a dynamic facility which can respond effectively to the changes in product design, mix and volume in a continuously evolving work environment. A genetic algorithm-based heuristic is used for solving the design problem and two test cases are presented to illustrate the use of the methodology.     

生产系统的集成规划及案例分析

在分析以往制造系统设计存在不足的基础之上,论述面向生产工程的虚拟制造内涵、提出了虚拟制造环境下大批量生产的制造系统集成规划的解决方案,它包括系统布局规划、仿真规划和虚拟漫游规划3个阶段,各个阶段解决系统规划的不同优化问题,并以来自企业的应用案例进行分析,为企业设计优化的生产系统,减少投资风险。     

Supervisory control and data acquisition for virtual enterprise

The new manufacturing paradigms, such as agile manufacture and lean production, are leading industrial countries towards the new generation of concurrent enterprises involving virtual enterprise architecture and concurrent engineering extended methodology. Continuing adaptation to the market can only be achieved efficiently if the planning and control processes are both optimized horizontally (Automatic Control Systems) and vertically (Management Control Systems). The desired improvement in performance and the realization of global enterprise objectives require a tight integration of the units of the enterprise. The close monitoring of the operational performance of various plants, manufacturing shop-floors/cells/machines, as well as their associated instrumentation and control is of increasing strategic importance. Failures can lead to increased costs and reduced product quality, consistency and production, and to plant shutdowns and increased environmental impact. There is a real need for advanced monitoring technologies to be applied, and their potential demonstrated, on complex industrial plants. The planning and scheduling of manufacturing systems integrated into virtual enterprise architectures requires the implementation of new General Master Production Planning and Scheduling techniques and Supervisory Control and Data Acquisition (SCADA) functions. This paper discusses some key issues on the SCADA-oriented open system for virtual enterprise architecture.     

Product end-of-life options selection: grey relational analysis approach

Management of the product end-of-life (EOL) for a manufacturing enterprise is important. An improper EOL strategy can negatively affect the productivity and profitability and undermines the reputation of an enterprise because of the growing demands for extended producer responsibility. Producers need tools and methods to evaluate each EOL option since it is a complicated but must-be-accomplished task to achieve in order to solve the multiple-criteria problem that combines aspects such as eco-system quality, environmental impacts, human health issues, and economic factors etc. This paper presents an alternative decision-making process to generate an optimal solution from a list of EOL options under the uncertainty condition of incomplete information. Using Grey Relational Analysis, the multi-criteria weighted average is proposed to rank the product EOL options with respect to several criteria at the material level. It will guide the selection process and help a decision-maker solve the selection problem. The method is demonstrated with an example. Various EOL options are evaluated using the developed multicriteria methodology that takes account the environmental, economical and social factors.     

基于三维轻模型的装配MES系统关键技术

针对现阶段产品设计已经实现三维数字化,但在航空等典型离散行业的制造现场仍以二维工程图为产品制造依据的现实,提出了基于三维轻模型的装配MES系统,将产品设计数据向制造过程延伸,并结合MBD( ModelBased Definition,基于模型的定义)技术实现基于三维轻模型的装配工艺定义,以三维轻模型为车间现场装配生产的...     

Integration of occupational health and safety in the facility layout planning,part II: design of the kitchen of a hospital

Facility layout design has an important effect on the performance of manufacturing systems. It intends to determine relative location of departments and machines within a plant. A good layout design must ensure that a set of criteria and objectives are met and optimised, e.g. area requirements, cost, communication and safety. The most common objective used in facility planning methods is to minimise the transportation cost. However, factors such as the plant safety, flexibility for future design changes, noise and aesthetics must be considered as well. In this paper, a case study is carried out to investigate the safety concerns in facility layout design. In this regard, a facility layout planning methodology, integrating occupational health and safety (OHS) is presented. This methodology considers transportation cost as well as safety in the facility design. By this means, OHS issues are considered at the design stage of the facility. In other words, this research demonstrates the improvements in the layout design by integrating safety aspects.     

Strategic configuration of flexible electronics assembly facilities facing stochastic requirements

Flexible configuration of manufacturing facilities is a key strategy for efficiently improving market responsiveness and market share in the face of uncertain future product demand. Flexible facility configurations can produce an efficient production system that allows higher capacity utilization given uncertainty in product demand and mix. The aim of this paper is to consider the alternative choices of flexible equipment available at the strategic planning level and to make decisions about the facility design and configuration that best suits the specific needs of the manufacturing system under consideration. A chance constrained mixed integer programming model for strategic configuration and capacity planning of flexible multiple-stage production facilities under time-varying production requirements is introduced in this paper. It is an integrated model that determines the number of assembly lines required, the flexible automation levels required in each line, capacity levels, and product assignments/reassignments for a multiple-stage production system, considering the stochastic nature of the demand. A two-step heuristic based on genetic algorithms is proposed and tested. Experimental results indicate that the two-step heuristic performs well in terms of both computation speed and solution accuracy.     

Development of an automated process planning and production activity control system for the manufacturing of engineered work surfaces

This paper describes the design and implementation of an Automated Process Planning and Production Activity Control system for a make-to-order business and presents a formal methodology for the development of integrated manufacturing systems. The research is based on concepts developed in a project undertaken in a job shop Case Study facility, producing precision-engineered work surfaces. Industry today is facing numerous challenges on many fronts demanding improved availability and dissemination of processing information. On the demand side there is increased pressure on the manufacturer to meet deadlines and provide the customer with a prompt, efficient service, with accurate lead-time information, and a product of the utmost quality, on time. On the supply side there is increasing competition, variety in the market, a diverse product range, varying processing times and extremely short lead times. The nature of today's business world means that real-time information is a requirement and not an extra. This paper documents the design, structure and implementation of an Automated Process Planning system, which completely automates and integrates Order Entry stages from order receipt to order release. The developed system, namely the Manufacturing Optimization Information System, or MOIS, relays information to and from shop floor operators via a Production Activity Control system at each of the manufacturing stations. The MOIS is part of ongoing research endeavouring to integrate order processing, Process Planning and production control activities with a combined dynamic scheduling and material optimization module in a holistic manufacturing optimization system. The two specific aims of this paper are very clear; first, to bridge the theory-practice gap between theoretical concepts and real industrial issues surrounding Process Planning and Production Control. Secondly, to outline the design, structure and evolution of an integrated Automatic Process Planning and Production Activity Control system, installed in a make-to-order enterprise.     

A function block based approach for increasing adaptability of assembly planning and control

Today's market turbulences cause frequent changes in manufacturing environments. Products diversity, small batch sizes and short life cycles have increased production uncertainties and created a highly dynamic shop floor environment. One essential requirement of such an environment is an adaptive planning and control system that is sufficiently agile to respond to the variety of production requirements and enable easy system reconfiguration at run-time. When developing a product, assembly is a key area that impacts the manufacturing system's responsiveness to the changes. In this research, a framework and a new methodology are introduced to increase the adaptability and autonomy of job-shop assembly process planning and control using function blocks (FBs). A function block is a reusable functional module with an explicit event-driven model, and provides for data flow and finite state automata based control. Event-driven and FB-enabled decision-making is unique in adaptive assembly planning and control. It is explained through an example of a two-robot assembly work cell, where the result of the adaptive planning is wrapped in FBs for execution. The proposed approach has been implemented and simulated using Matlab Simulink in the case study. The simulation demonstrates how this approach would increase the adaptability and responsiveness to changes that may occur regularly in dynamic job-shop assembly operations.     

Towards a generic product modelling framework

In response to the current rapidly changing manufacturing environment, product modelling technology has been widely applied to provide the essential information for product development (PD) processes. The traditional product modelling technologies are unable to support the information exchange and share in various stages of PD processes that could be taken place among departments in a company or even among companies in distributed manufacturing environment. This has caused many problems such as information loss, data format incompatibility and reduced efficiency and effectiveness of product data applications. This has consequently created bottlenecks for the integration of PD processes. In this paper, a generic product modelling framework (GPMF) is proposed to overcome the abovementioned problems in today's manufacturing environment. This framework uses the standard for the exchange product model data (STEP) as a foundation. It consists of four functional components: an EXPRESS data model namely EDM; a STEP–based modelling environment; a “five-phase” modelling method; and three EDM data exchange and sharing methods. Case studies show that the product models built based on the GPMF are capable of integrating information in product design, manufacturing and assembly. The GPMF is compatible, comprehensive, and flexible, and is able to support information exchange and sharing.     

A knowledge-based decision support system for locating a manufacturing facility

This paper examines the design and implementation of a knowledge-based decision support system (KBDSS) in the facility location domain. The KBDSS for locating a manufacturing facility is intended to support facilities planners in improving the quality of strategic decision-making in facility location. A survey of past location studies was conducted to identify the major considerations of location analysts and to develop a hierarchy of factors for locating a manufacturing facility in the USA. Location evaluation is accomplished via a location model that is formulated as a linear additive multiattribute utility model. The microcomputer-based DSS developed integrates an object-oriented expert system with other modeling tools, such as a database management system and a C-based interactive graphical user interface. The system incorporates subjective, judgemental evaluations from management with objective, factual location data to recommend the best location for a new manufacturing facility. The system also makes transparent the justification for its recommendations by providing appropriate textual and graphical explanation facilities.     

Concurrent process planning and scheduling in distributed virtual manufacturing

With the fast development of the world economy, distributed virtual manufacturing is becoming increasingly important since it can respond rapidly to market changes and make resource sharing more efficient among manufacturing partners. In this environment, partners may be located at different geographical locations, and co-operation among partners is a vital task and thus concurrent planning and scheduling has become a challenging research topic. This paper presents a computerized model that can integrate these manufacturing functions and resolve some of the critical problems in distributed virtual manufacturing, such as virtual cooperation, optimal partner selection, etc. This integration model is realized through a multi-agent approach that provides a practical approach for software integration in a distributed environment. A cost function is proposed and adopted for optimal partner selection in a virtual enterprise, which not only considers a partner's manufacturing capability and process requirements, but also the processing time, partner's location and product due date. Through establishing a virtual manufacturing model in a simulated environment, the proposal was validated with a case study. It shows that the proposed methodology can satisfy the distribution and agility requirements. This approach is able to contribute to the reduction of product cost, improving product quality and shortening lead time, compared to the sequential approach in the normal engineering and production practice.     

Closed loop supply chain network design and optimisation using fuzzy mixed integer linear programming model

Owing to the revolution in sustainable and green manufacturing the production planning and network design of closed loop supply chain concept has got the attention of researchers and managers. In this paper, a multi-product, multi-facility capacitated closed-loop supply chain framework is proposed in an uncertain environment including reuse, refurbish, recycle and disposal of parts. The uncertainty related to demand, fraction of parts recovered for different product recovery processes, product acquisition cost, purchasing cost, transportation cost, processing, and set-up cost is handled with fuzzy numbers. A fuzzy mixed integer linear programming model is proposed to decide optimally the location and allocation of parts at each facility and number of parts to be purchased from external suppliers in order to maximise the profit of organisation. The proposed solution methodology is able to generate a balanced solution between the feasibility degree and degree of satisfaction of the decision maker. The proposed model has been tested with an illustrative example.     

Intelligent Manufacturing for the Process Industry Driven by Industrial Artificial Intelligence

Based on the analysis of the characteristics and operation status of the process industry, as well as the development of the global intelligent manufacturing industry, a new mode of intelligent manufacturing for the process industry, namely, deep integration of industrial artificial intelligence and the Industrial Internet with the process industry, is proposed. This paper analyzes the development status of the existing three-tier structure of the process industry, which consists of the enterprise resource planning, the manufacturing execution system, and the process control system, and examines the decision-making, control, and operation management adopted by process enterprises. Based on this analysis, it then describes the meaning of an intelligent manufacturing framework and presents a vision of an intelligent optimal decision-making system based on human–machine cooperation and an intelligent autonomous control system. Finally, this paper analyzes the scientific challenges and key technologies that are crucial for the successful deployment of intelligent manufacturing in the process industry.     

From product documentation to a ‘method prototype’ and standard times: a new technique for complex manual assembly

This paper suggests a new technique to facilitate consistent transition between planning and production stages of small lots of complex products (in quantities that do not justify full automation). Despite the usage of modern approaches such as design for assembly and design for manufacturing the typical product planning ends up before production planning begins, instead of having a unified seamless planning process. This paper presents a new three stage technique to fill the gap between product planning and production. The paper shows how to generate a rigorous production plan by: (1) extending the Bill-of-Materials to include additional required information, (2) constructing an assembly ‘method prototype’ and (3) using the ‘method prototype’ to calculate time standards for executing the assembly. A case study illustrates the proposed technique.     

Strategic evolution of eco-products: a product life cycle planning methodology

This paper presents a methodology and a software tool to establish an eco-design concept of a product and its life cycle by assigning appropriate life cycle options to the components of the product. The product life cycle planning (LCP) methodology provides the following systematic procedures. First, the medium- or long-term production and collection plan for the product family is clarified. Next, target values for the product and its life cycle are set in the process of determination of customer-oriented specification and eco-specification. Then, eco-solution ideas to realize reasonable resource circulation are generated by using various life cycle option analysis charts. Finally, an eco-design concept which involves eco-solution ideas is evaluated for decision-making at early stages of product development. A design support tool was made for efficiently planning product life cycles by using quality function deployment and life cycle assessment data. Based on case studies, it was verified that the proposed methodology and tool are useful for developing multi-generational eco-products.     

包装机快速设计系统研究

为实现快速设计制造,提高包装机企业竞争力,提出了建立可以实现企业资源和网络资源充分重用的快速设计制造系统的解决方案。 分析了包装机械快速设计制造系统的开发环境、组织结构、功能以及一些典型模型和子系统,结合系统实际开发,建立了包装机快速设计支持模块,最后开发了一个包装机产品快速设计制造集成平台的原型系统。     

Design for life-cycle profit with simultaneous consideration of initial manufacturing and end-of-life remanufacturing

Remanufacturing is emerging as a promising solution for achieving green, profitable businesses. This article considers a manufacturer that produces new products and also remanufactured versions of the new products that become available at the end of their life cycle. For such a manufacturer, design decisions at the initial design stage determine both the current profit from manufacturing and future profit from remanufacturing. To maximize the total profit, design decisions must carefully consider both ends of product life cycle, i.e. manufacturing and end-of-life stages. This article proposes a decision-support model for the life-cycle design using mixed-integer nonlinear programming. With an aim to maximize the total life-cycle profit, the proposed model searches for an (at least locally) optimal product design (i.e. design specifications and the selling price) for the new and remanufactured products. It optimizes both the initial design and design upgrades at the end-of-life stage and also provides corresponding production strategies, including production quantities and take-back rate. The model is extended to a multi-objective model that maximizes both economic profit and environmental-impact saving. To illustrate, the developed model is demonstrated with an example of a desktop computer.