Enhancing total agility level through assessment and product mapping: A case study in the manufacturing of refrigeration air dryer

The world’s manufacturing community has been questing for ways to face the onslaught of competition. One of those ways is the adoption of agile manufacturing (AM) paradigm. AM paradigm enables a company to quickly respond to the customers’ dynamic demands. In order to implement AM paradigm, a model named “model for enhancing total agility level” (METAL) is proposed in this paper. METAL enunciates the assessing of the total agility level (TAL), identifying the weak AM criteria and subsequently strengthening them. The practicality of METAL has been explored in an air dryer manufacturing company. During this case study, refrigeration air dryer was considered as AM capable product. After assessment, three weak AM criteria were identified. Proposals were drawn to strengthen these three weak AM criteria. These proposals envisage the strengthening of the weak AM criteria through the removal of nonvalue adding activities, utilization of mathematical models, and creation of web portal. The reassessment has indicated the possibility of enhancing the TAL value in the above company through the implementation of these proposals. The experience of carrying out this research has revealed that the deployment of METAL would facilitate the contemporary companies to systematically infuse AM paradigm and enhance their TAL values.     

Failure mechanism-based reliability assessment framework: a case study in an automotive component

This paper presents a framework for failure mechanism-based reliability assessment, starting from collecting failed field samples. The framework includes failure analysis for identifying the failure mechanism and accelerated life tests (ALTs) for reproducing the failure mechanism. We consider that relevant information, such as warranty data and qualification test results, enables to be utilized in the framework. The proposed framework is validated by using it to identify the failure mechanism and estimate the lifetime of an automotive component under normal use conditions. The case study shows that the framework enables to quantitatively assess reliability based on the failure mechanism.

     

Implementing lean manufacturing with cellular layout: a case study

Lean manufacturing is an applied methodology of scientific, objective techniques that cause work tasks in a process to be performed with a minimum of non-value adding activities resulting in greatly reduced wait time, queue time, move time, administrative time, and other delays. In a cellular manufacturing system (CMS), machines are grouped into several cells, where each cell is dedicated to a particular part family and the objective is to maximize cell independence. CMS helps in reducing the material handling, work-in-process, setup time, and manufacturing lead time and improve productivity, operation control, etc. The facility layout used during lean implementation can be either be a line layout or in the form of cells. After grouping parts in to various part families, machine cells can be formed to produce those parts well inside the cells. As some of the lean manufacturing concepts are different from that of cellular manufacturing, e.g., establishment of Takt time, Takt-based resource balancing, etc., some new cell design methodology is required to be explored that is compatible with lean manufacturing. The rate at which work progresses through the factory is called flow rate or Takt. In the present work, a design methodology for cellular layout is proposed for implementing lean concepts and is exemplified in a manufacturing industry dealing with ammunition components for defense applications. Based on Takt time for various parts, the production flow among cells was optimized thus minimizing several non-value added activities/times such as bottlenecking time, waiting time, material handling time, etc. This case study can be useful in developing a more generic approach to design cellular layouts in lean environment.     

Scheduling wafer slicing by multi-wire saw manufacturing in photovoltaic industry: a case study

Wafer slicing in photovoltaic industry is mainly done using multi-wire saw machines. The selection of set of bricks (parallelepiped block of crystalline silicon) to be sawn together poses difficult production scheduling decisions. The objective is to maximize the utilization of the available cutting length to improve the process throughput. We address the problem presenting a mathematical formulation and an algorithm that aims to solve it in very short running times while delivering superior solutions. The algorithm employs a reactive greedy randomized adaptive search procedure with some enhancements. Computational experiments proved its effectiveness and efficiency to solve real-world based problems and randomly generated instances. Implementation of an on-line decision system based on this algorithm can help photovoltaic industry to reduce slicing costs making a contribution for its competitiveness against other sources of energy.     

Rapid manufacturing techniques in the development of an axial blood pump impeller

This paper presents a comparison of manufacturing techniques used in the development of an axial blood pump impeller. In this development process the impeller was designed and its performance was evaluated with the aid of computational fluid dynamics (CFD). Prototypes of those designs where the CFD results show promise were needed in sufficient quantities at a low cost for experimental validation of the CFD results. As the impeller is less than 16 mm in diameter with a maximum blade thickness of about 1.5 mm, innovative manufacturing techniques are explored in this paper to determine the best process for quick fabrication of prototypes that are dimensionally accurate, structurally robust and low in cost. Four rapid prototyping techniques were explored. The completed parts were compared on the basis of manufacturing time, quality and strength of parts obtained, manufacturing cost and also in vitro performances. Based on these studies, it was concluded that selective laser sintering (SLS) is the most appropriate method for the quick production of prototype parts for evaluation of pump performance.     

Process improvement through Six Sigma with Beta correction: a case study of manufacturing company

This article discusses the successful implementation of Six Sigma DMAIC (Define–Measure–Analyse–Improve–Control) methodology along with Beta correction technique in an automotive part manufacturing company. The implementation of Six Sigma approach resulted in reduction of process capability-related problems and improved the first pass yield from 94.86 % to 99.48 %. After studying the baseline performance of the process, a brainstorming session was conducted with all stakeholders of the process for identifying the potential causes of the problem. Data were collected on all the identified potential causes and various statistical analyses like regression analysis, hypothesis testing, and Taguchi methods were performed for identifying the root causes. Solutions were identified and implemented for the validated root causes, and results were observed. The Beta correction technique was introduced for monitoring the process in the control phase. Implementation of Six Sigma methodology with Beta correction technique had a significant financial impact on the profitability of the company. An approximate saving of US$87,000 per annum was reported, which is in addition to the customer-facing benefits of improved quality on returns and sales. This study contributes uniquely by elucidating the synergistic impact of Beta correction for greater effectiveness of Six Sigma programmes in the engineering industry.     

Compromise ranking approach for sustainable concept selection in an Indian modular switches manufacturing organization

The modern manufacturing organizations are forced to adopt the principles of sustainability to sustain in the competitive market scenario. Sustainability paradigm stipulates that manufacturing organizations develop eco-friendly products coupled with economic and social dimensions. Sustainability concepts include life cycle impact assessment, environmental conscious quality function deployment, environmental impact assessment, life cycle assessment, and theory of inventive problem solving. The concept selection in the context of sustainability is the typical multicriteria decision-making problem (MCDM). MCDM method can be used to find out the best alternative among the given alternatives. In our study, we have utilized the compromise ranking method namely VlseKriterijumska Optimizacija I Kompromisno Resenje. This method focuses on ranking and selecting from a set of conflicting criteria based on the measure of closeness to the ideal solution. The best concept has been selected for implementation in the organization as stated by Opricovic and Tzeng (Eur J Oper Res 156:445–455, 2004).     

绿色制造环境绩效评价模型研究

从绿色制造的广义内涵入手 ,分析绿色制造环境绩效评价的理论基础 ,讨论在众多因素影响下的绿色制造环境绩效评价指标体系 ;采用专家法确定各因素权重 ;运用多层模糊综合评价原理对绿色制造的环境绩效进行系统评价。     

The implementation and evaluation of Total Productive Maintenance (TPM)—an action case study in a Hong Kong manufacturing company

This paper records the pilot implementation and evaluation of Total Productivity Maintenance (TPM) in the advanced manufacturing environment of a Hong Kong Manufacturing company. The management of the company would like to implement TPM in the company. However, many people doubt whether the project will succeed. The main concerns are: 1) TPM is a Japanese method. 2) The method may not be suitable for people in Hong Kong. Therefore, the company decided to have a pilot test in an advanced model machine. The pilot project turned out to be very successful. The experiences from this will be useful for the company to apply to all manufacturing. It can also be a reference for other companies that would like to implement TPM.     

Development of an environmental performance assessment method for manufacturing process plans

The environmental impacts of the manufacturing stage of the product life cycle are resource consumption and waste emissions. The development of an appropriate assessment method for evaluating the environmental performance of a manufacturing process, or an entire process plan, is one of the keys to realize a successful sustainable manufacturing strategy. This paper describes a new method for the environmental evaluation of a manufacturing process plan, where actual values for various environmental measures for the different operations in the plan are used to form an impact matrix. If desired, scores for each process, each environmental measure, and for the entire plan may be obtained by applying weights obtained from the analytical hierarchy process. The method has been encoded in software (Manufacturing Environmental Performance Evaluation), which provides insights into how manufacturing decisions affect the environment. A case study is used to illustrate how the assessment method may be applied and to demonstrate its applicability.     

砂带磨削在齿轮泵生产中的应用

齿轮泵在液压系统中作为能量转换元件，将机械能变成液压能，是系统的能量提供元件。随着科学技术的日益进步，要求提高液压系统压力，降低液压系统的噪声，于是对齿轮泵的制造精度也就提出了更高的要求，如齿轮轴轴径的表面粗糙度由0．4μm降为0.2μm，甚至于0．1μm。这样一来，对零件的加工工艺也提出了更高的要求。     

Optimization and implementation of cellular manufacturing system in a pump industry using three cell formation algorithms

In recent years cellular manufacturing has become an effective tool for improving productivity. Attainment of full benefits of cellular manufacturing depends firstly on the design of the machine cells and part families and secondly on the method of operation which take full advantages of cell properties. Inappropriate methods of loading and scheduling can even lead to the failure of cellular manufacturing systems (CMS), however efficiently the cell is designed. This paper examines three array-based clustering algorithms, namely rank order clustering (ROC), rank order clustering-2 (ROC2) and direct clustering analysis (DCA) for manufacturing cell formation, with a real-life example to demonstrate the effectiveness of various clustering algorithms. The machine cell formation methods considered in this comparative and evaluative study belongs to the cluster formation approach of solving the MCF problem. The most effective method is selected and used to build the cellular manufacturing system. The comparison and evaluation are performed using four published performance measures and compares the improvements with the existing conventional system and the cellular manufacturing system. The above algorithms were written in the C++ language on an Intel/Pentium III-PC-compatible system.     

Performance evaluation of manufacturing systems based on dependability management indicators—case study: chemical industry

Dependability is a key decision factor in today’s global business environment affecting product cost and process. Dependability reflects user confidence in fitness for use by attaining satisfaction in product performance capability, delivery, service availability upon demand, and minimizing cost. The main objective of this study is to develop an integrated approach for evaluation of manufacturing systems based on dependability indicators for conducting a better dependability management system (DMS) through integration of the principal component analysis (PCA) and the data envelopment analysis (DEA). To achieve the objective of this study, an industrial sector—chemicals and chemical products in Iran—is selected as the case of this study in accordance with the International Standard for Industrial Classification of all economic activities (ISIC). Firstly, we define dependability indicators, for both inputs and outputs, based on IEC 60300. Due to the extra amount of indicators, we utilize a hierarchical structure to cluster the indicators for an easier analysis. Secondly, for reducing the number of some variables, we apply pair-wise comparison to assign weights and to unify the related sub-criteria to one main criterion. Finally, an integrated DEA–PCA approach is employed to assess the most and the least dependable units and to find critical indicators in macro and micro levels in order to make policy for implementation of DMS in manufacturing systems.     

云制造——面向服务的网络化制造新模式

为求解更加复杂的制造问题和开展更大规模的协同制造,分析了目前应用服务提供商、制造网格等现有网络化制造模式在应用推广等方面遇到的问题,阐述了云计算服务模式、云安全、高性能计算、物联网等理念和新技术对解决网络化制造中运营、安全等问题的契机。在此基础上提出了一种面向服务的网络化制造新模式——云制造。给出了云制造的定义,分析了云制造与应用服务提供商、制造网格等的区别。提出了一种云制造的体系结构,讨论了实施云制造所需攻克的关键技术和所取得的成果。最后,给出了一个云制造的典型应用案例——基于云仿真原型平台的云设计。     

泵叶轮熔模铸造的关键技术探索

将熔模铸造技术应用在叶片制造上,可以解决传统砂型铸造工艺的诸多弊端。从二维水力模型图出发,采用Pro/E软件就叶片三维造型、叶片与前、后盖板蜡模定位结构的设计以及叶片压型设计、制造等关键问题进行了分析和探讨。     

Thermal AFM: a thermopile case study

In this work, an atomic force microscope (AFM) with an integrated thermal sensor has been used to obtain the local spatial distribution of temperatures in a micromachined thermopile with submicron resolution. In this communication, we will show how the dimensional, structural and functional characteristics of a thermopile suits well with the requirements for AFM thermal imaging, and how a deeper insight of the thermopile operation can be gained with the aid of these advanced scanning probe-based tools.     

Impact of integrating knowledge-based technologies in manufacturing: an evaluation

Knowledge-based technologies offer significant benefits in innovating manufacturing systems. However, evaluation of the actual impact, including cost, effort and limitations as well as advantages of these technologies is required before their wide applications can be justified. An impact evaluation approach is discussed, and specific impacts on the quality of results and efficiency are evaluated in two specific areas: knowledge-based facility planning using FADES and QLAARP, and knowledge-based production scheduling using TDKA.