Interdisciplinary product lines to support the engineering in the machine manufacturing domain

Current market dynamics force today’s companies to manufacture smaller lot sizes up to individual products. As a consequence, companies need to react to such changes; it is hence inevitable to ensure a correct, reliable and flexible engineering process, which allows for managing the highly variant-rich machines. This article investigates the applicability of interdisciplinary product lines for the engineering in the machine manufacturing domain. Therein, four core aspects are addressed: first, the current practice of companies regarding the management of variants is analysed. Second, the requirements to be fulfilled by an interdisciplinary variant management approach are analysed. Third, an interdisciplinary product line approach is presented that aims at overcoming the challenges. Fourth, the benefits and limitations of the approach are discussed and research gaps that need to be addressed in future works are identified.     

A Petri net-based approach to incremental modelling of flow and resources in service-oriented manufacturing systems

In order to overcome the myopia problem, routing strategies must be based on formal representations of flow that automatically account for modifications in the values of parameters of interest and in the model itself. This work addresses this problem and discusses how to automatically incorporate resources (e.g. workstations/transportation devices/storage) in a Petri-net-derived model of flow that is modifiable at runtime to reflect and influence the routing in a manufacturing line. The modelling approach takes into consideration scalability needs and was experimentally validated. The applicability of the models is shown for PN-based dynamic scheduling.     

A complex network approach to environmental impact assessment

This article proposes a complex network methodology for the process of Environmental Impact Assessment (EIA) that limits subjectivity and reduces uncertainty by incorporating elements of complex systems theory in the stages of identification and assessment of the significance of environmental impacts. The proposed methodology reduces the sources of uncertainty, which emerge from the use of simplified models that analyse the environment-activity interactions in a unidirectional fashion. This proposal determines the significance of environmental impacts through multidirectional or complex causal relationships. Likewise, it limits the subjectivity of the evaluator by using these causality relationships instead of criteria based on the impacts’ attributes. The application of the proposed methodology demonstrates the advantages of (i) prioritizing the impacts according to their capacity to interact with other impacts, and (ii) the possibility to redirect the environmental management plans towards the prevention of impacts of higher complexity and to reduce the importance of derived impacts.

The application of the proposed methodology reveals that the percentage of irrelevant and moderate impacts is reduced, whereas the percentage of severe and critical impacts increase, in comparison to the conventional methodologies.     

An integrated approach to evaluating the production system in closed-loop supply chains

The increasing demands for environmental resource protection and sustainable development have been forcing enterprises to put sustainable supply chain management on their agendas in recent years. At the same time, intense global competition requires organisations to adopt practices that enable them to provide high-quality products and services. In this paper, we consider the problem of comprehensively evaluating the production system in closed-loop supply chains. We first propose an evaluation framework that consists of economic evaluation, product quality evaluation and ecological evaluation modules. Based on mathematical probability theory and the dynamic characteristics of reverse supply chain logistics, we then focus on the evolution dynamics in the quality evaluation dimension, where the concept of product quality, which builds on the reliability and the time-utility value of a product, is proposed. The basic production evaluation model is then extended to incorporate different sustainable procurement strategies, which take into consideration the trade-offs among cost, environment and quality. An outline and corresponding flow chart of corporate procurement strategy optimisation are provided which allow the proposed evaluation model to be implemented in computer-aided decision-making, further providing decision support for production system and supply chain management. Simulation and case studies are presented to promote a better understanding of the model approach and its managerial implications. Results also suggest that quality characteristics of components and sustainable procurement strategies are two important factors that determine the final production performance and should be paid special attention in closed-loop supply chain practice.     

Integration of human behavioural aspects in a dynamic model for a manufacturing system

The computational simulation of human intelligent behaviour has been one of the main research topics in the artificial intelligence (AI) domain. Therefore, a great number of behavioural models were proposed considering emotional, cognitive and psychological factors to simulate the human behaviour in different domains such as military or manufacturing systems. In addition to psychological factors, the social state of a group of workers plays a critical role in rational decision-making, perception, human interaction, and human intelligence. Thus, it is judicious to analyse the workers’ behaviour at work and to integrate their needs and requirements in manufacturing systems models in order to improve the simulation accuracy. In this context, this paper suggests a graphical and a mathematical representation model of workers’ behaviours as well as the ties that can exist among them. The model is also extended to consider inter-worker social relations that can influence the individual performance.     

The impact of maintainability on the manufacturing system architecture

The rapid development of big data technologies can improve the maintainability of machines and equipment in manufacturing systems, which could impact the selection of the optimal system architecture. In this paper, two typical architectures for large manufacturing systems ? serial lines in parallel and reconfigurable manufacturing systems ? are considered, and their productivities are compared. A decision locus is calculated that divides the configuration space into two areas; in each area, one of the architectures is the preferred one. It is also investigated how the locus is affected by different parameters, such as system size, buffer capacity and machine or gantry maintainability. The analysis provides valuable managerial insights for designing the architecture of large manufacturing systems.     

The elementary flux modes of a manufacturing system: a novel approach to explore the relationship of network structure and function

Elementary flux modes (EFMs) are a concept from Systems Biology, where they serve as an indicator of component relevance in metabolic networks. An elementary flux mode is a functionally relevant, non-decomposable path through a given network. In this paper, we apply elementary flux mode analysis to manufacturing systems, with the aim of using the number of EFMs as a predictor for resource significance in the manufacturing system. For this, we formulate a network representation of a manufacturing process, which allows us to define the manufacturing equivalent of a stoichiometric matrix to draw an analogy between metabolic and manufacturing systems. This, in turn, allows the computation of EFMs, which we conduct in a case-study for a real manufacturing system. We further show that the change of EFMs under resource breakdown is a good indicator of the average order lateness in the manufacturing system. In this way, EFMs provide insight into the relationship of network structure and function in manufacturing.     

A mathematical model and a heuristic approach for design of the hybrid manufacturing systems to facilitate one-piece flow

One-piece flow is a design rule that entails production in manufacturing cells on a ‘make one, check one, and move-on one’ basis (Black, J.T., 2007. Design rules for implementing Toyota Production System. International Journal of Production Research, 45 (16), 3639–3664), which reduces manufacturing lead time significantly. This paper proposes a sequential methodology comprised of a mathematical model and a heuristic approach (HA) for the design of a hybrid cellular manufacturing system (HMS), to facilitate one-piece flow practice. The mathematical model is employed in the cases of small- and medium-sized problems, and it attempts to minimise the total number of exceptional operations, while considering machine capacities and alternative machines. The machine-part matrix achieved by the mathematical model is input into the flow line design stage of the HA, where backflow within the cells is eliminated. However, for industrial problems, the proposed HA is utilised. After the formation of the cells by clustering, the HA attempts to eliminate exceptional operations of a given cellular configuration together with a functional structure by employing alternative machines, based on the decision rules developed. Later, unidirectional flow within the cells is achieved and the capacity and budget constraints are satisfied. A medium-sized problem is solved by using both of the approaches, namely, the model integrated with the flow-line design stage of the HA and the complete HA. The results are discussed and the limitations are explained.     

Assessing the effects of manufacturing infrastructure preparation prior to enterprise information-systems implementation

Reports on the success or failure of enterprise information system (EIS) implementation have been decidedly mixed. In this study, we focus on manufacturing infrastructure preparation prior to EIS implementation and report the results of a survey of 152 US manufacturing companies that have implemented EIS. We have provided four major findings in this study: (1) the requirements from customers and trading partners are more powerful drivers motivating US manufacturing firms to implementing enterprise systems than internal business planning needs; (2) one manufacturing infrastructural issue often has implications for other infrastructural items in implementing technology, so various manufacturing infrastructural issues should be prepared simultaneously; (3) manufacturing infrastructure preparation prior to EIS implementation has significant positive effects on customer-focused performance, production/operations performance, and financial performance; and (4) better customer-focused performance contributes to better financial performance.     

An ISM approach for modelling the enablers of flexible manufacturing system: the case for India

The volatile condition of today's market is forcing the manufacturing managers to adapt the flexible manufacturing systems (FMS) to meet the challenges imposed by international competition, ever changing customer demands, rapid delivery to market and advancement in technology. There are certain enablers, which help in the implementation of FMS or in the transition process from traditional manufacturing systems to FMS. The utmost need is to analyse the behaviour of these enablers for their effective utilization in the implementation of FMS. The main objective of this paper is to understand the mutual interaction of these enablers and identify the ‘driving enablers’ (i.e. which influence the other enablers) and the ‘dependent enablers’ (i.e. which are influenced by others). In the present work, these enablers have been identified through the literature, their ranking is done by a questionnaire-based survey and interpretive structural modelling (ISM) approach has been utilized in analysing their mutual interaction. An ISM model has been prepared to identify some key enablers and their managerial implications in the implementation of FMS.     

Investigating the value of integrated operations planning: A case-based approach from automotive industry

During the last decade, many researchers have focused on joint consideration of various operations planning aspects like production scheduling, maintenance scheduling, inventory control, etc. Such joint considerations are becoming increasingly important from the point of view of current advancement in intelligent manufacturing, also known as Industry 4.0. Under the concept of Industry 4.0, advanced data analytics aim to remove human intervention in decision-making. Thus, the managerial level coordination of decisions taken independently by various departments will be out of trend. Therefore, developing an approach that optimises various operations planning decisions simultaneously is essential. Available literature on such joint considerations is more of the exploratory in nature and is limited to simplistic production environments. This necessitates the investigations of value of integrated operations planning for wide range of manufacturing scenarios. Present paper adopts a case-oriented approach to investigate the value of integrated operations planning. First, an integrated approach for simultaneously determining job sequencing, batch-sizing, inventory levels and preventive maintenance schedule is developed. The approach is tested in a complex production environment of an automotive plant and substantial economic improvement was realised. Second, a comprehensive evaluation is performed to study the robustness and implications of proposed approach for various production scenarios. Results of such pervasive performance investigations confirm the value of proposed approach over conventional approaches.     

Development of a financial management system in a CIMS environment

This research is based on the Anshan Project, a cool strip millwork computer integrated manufacturing system (LZ-CIMS). The study describes the design and completion of a LZ-CIMS financial management system that was developed using an Oracle database with client/server architecture and Developer/2000. During the development of the system, the study explores the use of both software engineering and database theory and Oracle RDBMS to discuss the integrating methods of financial information.     

A quantitative approach for measuring process innovation: a case study in a manufacturing company

Process management and innovation arguably remain among the concepts under focus of recent researches since there is no significantly outstanding method to measure and monitor the level of innovation in the manufacturing processes over a particular time period taking the fundamental activities of manufacturing processes into account. Although there are various studies relevant to process improvement, manufacturing processes are not focused on in the literature. This paper presents a novel performance indicator, called degree of process innovation, for monitoring and measuring innovation in manufacturing processes based on the four most important components among the fundamental activities of a manufacturing system. The components are namely Average Labour Utilisation, Cumulative Bottleneck Ratio, Unit Production Time and Unit Production Cost. The idea behind this approach has flourished on the basis of an indicator proposed in the literature to measure the general organisational improvements. The scope of that indicator has been narrowed down to manufacturing processes to accurately reflect the state of the manufacturing processes. The proposed approach has been verified with a case study in manufacturing industry, where each of the four sub-indicators was calculated based on the data provided and aggregated into the degree of process innovation. The innovation degree is successfully indicated.     

A simulative approach for evaluating alternative feeding scenarios in a kanban system

In accordance with the lean production philosophy, an assembly line may be supplied by means of a kanban system, which regulates and simplifies the flow of materials between the lines and the warehouses. This paper focuses on evaluation of feeding policies that differ from each other in term of the number of kanbans managed per feeding tour. A pure cost-based approach is thus proposed, which considers both inline inventories along with handling costs proportionate to the number of operators involved in the parts-feeding process. A multi-scenario simulative approach is applied in order to establish the number of operators required to avoid inline shortages. The scenario minimising total cost is then selected. The innovation introduced is a model for describing kanban arrivals and their requests for feeding, improving the potential of the simulation to describe real-life environments. Lastly, a case study from the automotive industry is presented in order to highlight the applicability of the proposed approach as well and the effects of alternative feeding policies on the total cost incurred.     

A mathematical model to evaluate the role of agility enablers and criteria in a manufacturing environment

Modern manufacturing arena necessitates the need for responsiveness by practicing agile manufacturing (AM) principles. AM imposes the transformation of the manufacturing organisation so as to respond to dynamic market changes. This article focuses towards the application of graph theory (GT) for conceptual modelling the agile system and to compute the dependencies among the individual agile enabler, criteria and attributes as a top-down approach. Using GT approach, digraphs were systematically constructed for agile enablers and variable permanent matrix values were computed for different scenarios and the relative importance of agility enablers were determined. The permanent values of ‘Management responsibility’ enabler and technology enabler are found to be 920 (minimum) and 3529?×?10¹⁴, respectively for the existing situation, whereas for the practically base case situation, it was found to be 1185 (minimum) and 5081.17?×?10¹⁴ (maximum), respectively. The Comprehensive Agility Index was found to be 1.3996?×?10⁴⁵, which can be even used to benchmark with other best-in-class agile organisations.     

A quantitative investigation of the role of information and communication technologies in the implementation of a product-service system

This paper reports evidence from a survey, aimed at testing whether and how Information and Communication Technologies (ICTs), which enable the adoption of product-service systems, can contribute to value creation. This analysis builds on previous contributions, according to which companies that are enriching their product offering through value-added services (the so-called servitisation strategy) often report lower levels of profitability, owing to the poor performance of their operating process. A wide stream of research claims that companies that invest in ICTs can enjoy valuable outcomes, since the adoption of such technologies results in processes that are more efficient and more responsive. Our hypothesis concerns the possibility of leveraging ICTs at operating process level so as to pursue a servitisation strategy. The in-field analysis presented in this paper concerns a sample of 109 companies located in Italy; data collected through the survey have been analysed using the structural equation modelling approach. The evidence presented demonstrates that ICTs can have a relevant impact on value creation because they lead to superior responsiveness of operating processes and to sound improvements in the product offering. In particular, companies that are able to embed such superior responsiveness into their product offering can further boost value creation.     

A systematic approach to determine the optimal maintenance policy for an automated manufacturing system

We propose a systematic approach to determine the optimal maintenance policy for an automated manufacturing system which includes a flexible manufacturing cell (FMC) and several automated machine shops. The systematic approach combines simulation, fractional factorial design, noise or outer array of Taguchi design, regression metamodelling, and classical queueing analysis. A useful expression of the fractional utilization of the manufacturing system is derived and incorporated into formulating and solving the corresponding decision problem. The systematic approach provides an effective implementation procedure to handle practical maintenance problems found in a complex manufacturing environment. © 1997 John Wiley & Sons, Ltd.     

A multiscale micromechanical approach to model the deteriorating impact of alkali-silica reaction on concrete

The alkali-silica reaction (ASR) in concrete is one of the most harmful deterioration processes, which leads to expansion and cracking of the material. To understand the evolution of ASR in concrete and its deteriorating impact on the material, a multiscale material model, from aggregate to concrete level, is proposed. The concrete, which at macro scale is considered a homogeneous material, is micromechanically modelled by a matrix-cracks system, in which each phase is uniform and behaves elastically. The damage criterion, associated to the cracks, is formulated on the basis of linear fracture mechanics theory. The model, which is analytically solved, is based on a limited numbers of input parameters, to be determined via micro and macro experimental investigations. The model is able to predict the non-linear behaviour of concrete subject to uniaxial loading in good agreement with code formulations, which are usually input for numerical analyses of structures. For the case of ASR-affected material, the model overestimates the degradation rate of mechanical properties as a function of the expansion. On the contrary, the relationship between stiffness and strength deterioration is correctly approximated. Various model modifications are explored suggesting that the assumption of elastic behaviour of each phase should be reconsidered.     

A comprehensive approach to operation sequence similarity based part family formation in the reconfigurable manufacturing system

The industrial sector of the twenty-first century faces a highly volatile market in which manufacturing systems must be capable of responding rapidly to the market changes, while fully exploiting resources. The reconfigurable manufacturing system (RMS) is a state of the art technology offering the exact functionality and capacity needed, which is built around a part family. The configuration of an RMS evolves over a period to justify the needs of upcoming part families. The foundation for the success of an RMS, therefore, lies in the recognition of appropriate sets of part families. In the present work the authors have developed a novel operation sequence based BMIM (bypassing moves and idle machines) similarity coefficient using longest common subsequence (LCS) and the minimum number of bypassing moves and the quantity of idle machines. The effectiveness of the developed similarity coefficient has been compared with the existing best similarity/dissimilarity coefficients available in the existing literature. An example set of parts has been classified using the developed similarity coefficient and average linkage hierarchical clustering algorithm. The developed approach can also be used very effectively for part family formation in the cellular manufacturing system.     

Graph-neural network approach in cellular manufacturing on the basis of a binary system

In the past several years, many studies have been carried out on cellular manufacturing. Group technology is a manufacturing philosophy in which similar parts are identified and grouped together to take advantage of their similarities in manufacturing and design. The main problem in the development of cellular manufacturing is that of cell formation. In this paper, a graph-neural network approach is given for cell formation problems in group technology. Effort has been made to develop an algorithm that is more reliable than conventional methods. A graph-neural network has the advantages of fast computation and the ability to handle large scale industrial problems without the assumption of any parameter and the least exceptional elements in the presence of bottleneck machines and/or bottleneck parts. Two examples from the literature have been solved to demonstrate the advantages of the algorithm.