Mathematical model for quality cost optimization

Quality engineering uses robust design in order to improve quality by reducing the effects of variability. Variability of the product can be reduced by two stages. One is parameter design which is adjustable to the nominal value so that output is less sensitive to the cause of variability. Other one is tolerance design which is to reduce the tolerance in order to control variability. All costs incurred in a product life cycle can be divided into two categories—manufacturing cost before the sale to the customer and quality loss after the shipment of the product to the customer. It is very important to find the optimum tolerances for each of the characteristics. A balance between manufacturing cost and quality loss should be arrived at in the tolerance design for quality improvement and cost reduction. For the case of Nominal-The-Best, a mathematical model is developed in order to determine the optimum product tolerance and minimize the total cost which includes the manufacturing cost and the quality loss. Since the process capability index (C_pm) shows the balance of quality responsibility between the design and the manufacturing engineers, this is taken as the basis in developing the functional relationship between the variability of the product and the tolerance. Based on these relationships, the total cost of model can be expressed as a function of product tolerance from which the optimal tolerance limits can be found out. Finally, using this model a tolerance design approach that increases the quality and reduces the cost can be achieved in the early stages of the product process design stage itself.     

Product platform configuration for product families: Module clustering based on product architecture and manufacturing process

Product family design utilizes platform-based modularity to enable product variety and efficient mass-production. While product platform issues have attracted much attention from both academia and industry, traditional product platform design for product families emphasized the platform-based modularity that focuses on product structure dimension (functional or non-functional) to realize cost reductions during the design stage. Both the design architecture and manufacturing process are objectives that define product family modularity (PFM). They should be closely coupled with each other for the planning and configuration of platforms. This paper focuses on the product platform configuration by recognizing and utilizing shared product modules for product families. Instead of clustering product modules only based on their design structure, this approach differentiates each product variant, and considers the inherent relationship between product architecture and processing activities. The advantage is that similar components can be grouped and produced on a shared platform, thus benefitting from lower cost and shorter production time. First, both the architecture and manufacturing information of the product variety are captured in matrix format. Then, hierarchical clustering is applied over the components to generate PFM. Finally, a set of platforms are constructed to efficiently process most components of variants.     

Multiple platforms design and product family process planning for combined additive and subtractive manufacturing

Industry 4.0 promotes the utilization of new exponential technologies such as additive manufacturing in responding to different manufacturing challenges. Among these, the integration of additive and subtractive manufacturing technologies can play an important role and be a game changer in manufacturing products. In addition, using product platforms improves the efficiency and responsiveness of manufacturing systems and is considered an enabler of mass customization. In this paper, a model to design multiple platforms that can be customized using additive and subtractive manufacturing to manufacture a product family cost-effectively is proposed. The developed model is used to determine the optimal number of product platforms, each platform design (i.e. its features set), the assignment of each platform to various product variants, and the macro process plans for customizing the platforms while minimizing the overall product family manufacturing cost.The multiple additive/subtractive platforms and their process plans are determined by considering not only the commonality between the product variants but also their various manufacturing cost elements and the customer demand of each variant. The design of multiple product family platforms and their process plans is NP-hard problem. A genetic algorithm-based model is developed to reduce the computational complexity and find optimal or near optimal solution. Two case studies are used to illustrate the developed multiple platform model. The model results were compared with a single platform model in literature and the results demonstrate the multiple platform model superiority in manufacturing product families in lower cost. The use of the developed model enables manufacturing product families cost efficiently and allows manufacturers to manage diversity in products and market demands.     

Manufacturing evaluation using resource-based, template-free features

This paper addresses the theory and tools that promote rapid product and process development of machined products. A foundation of this approach is the application of a new definition of manufacturing features called resource-based free-form features. Using free-form features we demonstrate how cost, time and quality predictions, based on available equipment, are computed. We also introduce the concept of intelligently clustering alternative features to achieve better process alternatives. The approach presented herein is appropriate throughout the product design life-cycle as an aid to faster product realization by evaluating the parochial manufacturability of a completed design. In particular, this approach will provide the design team with cost, time and quality predictions, based on available equipment, that can be used to guide the design process. It also provides the manufacturing team with an approach to evaluating producibility and generating a production plan for a product model using available equipment in terms of cost, time and quality.     

An experimental study for the selection of modules and facilities in a mass customization context

To design an efficient product family, designers have to anticipate the production process and, more generally, the supply chain costs. But this is a difficult problem, and designers often propose a solution which is subsequently evaluated in terms of logistical costs. This paper presents a design problem in which the product and the supply chain design are considered at the same time. It consists in selecting a set of modules that will be manufactured at distant facilities and then shipped to a plant close to the market for final, customized assembly under time constraints. The goal is to obtain the bill of materials for all the items in the product family, each of which is made up of a set of modules, and specifying the location where these modules will be built, in order to minimize the total production costs for the supply chain. The objective of the study is to analyze both, for small instances, the impact of the costs (fixed and variable) on the optimal solutions, and to compare an integrated approach minimizing the total cost in one model with a two-phases approach in which the decisions relating to the design of the products and the allocation of modules to distant sites are made separately.     

基于ASP技术的计算机辅助工业设计系统的设计与研究

随着计算机网络技术的迅猛发展,全球经济面临着深刻的变革。计算机技术的发展使得制造业发生了很大变化。为了更好地将计算机技术应用到工业上去,本文提出了一种基于服务提供商模式的解决方案,用于解决计算机辅助工业设计中网络化制造的问题。本文设计并开发的系统由四个工具集构成,每个工具都是利用可重用组件技术进行开发,动态加载到计算机辅助工业设计平台中。本文重点研究了工具集中的形态布局、色彩方案、人机设计等技术,开发出的系统可以为企业提供一些基本的计算机辅助工业设计应用服务。实验表明,该系统能够提高企业的工作效率,提高企业的设计能力,对网络化制造业具有重要意义。     

Integrated product line design and supplier selection: A multi-objective optimization paradigm

Product line design is commonly used to provide higher product variety for satisfying diversified customer needs. To reduce the cost and development time and improve quality of products, companies quite often consider sourcing. Conventionally, product line design and supplier selection are dealt with separately. Some previous studies have been attempted to consider product line design and supplier selection simultaneously but two shortcomings were noted. First, the previous studies considered several objectives as a single objective function in the formulation of optimization models for the integrated problem. Second, positions of product variants to be offered in a product line in competitive markets are not clearly defined that would affect the formulation of marketing strategies for the product line. In this paper, a methodology for integrated product line design and supplier selection is proposed to address the shortcomings in which a multi-objective optimization model is formulated to determine their specifications and select suppliers for maximizing the profit, quality and performance as well as minimizing the cost of the product line. In addition, joint-spacing mapping is introduced to help estimate market share of products and indicate positions of product variants. The proposed methodology can provide decision makers with a better tradeoff among various objectives of product line design, and define market positions of product variants explicitly. The results generated based on the methodology could help companies develop product lines with higher profits, better product quality and larger market share to be obtained. A case study of a product line design of notebook computers was performed to illustrate the effectiveness of the proposed methodology. The results have shown that Pareto optimal product line designs and the specifications of product variants can be determined. Suppliers of components and modules can be selected with considerations of minimum sourcing cost, and maximum performance and quality of product variants. Prices and positions of the product variants can also be determined.     

Incorporating customer personalization preferences in open product architecture design

Open product architecture is a key enabler for product personalization, as it allows the integration of personalized modules in a product architecture to satisfy individual customer needs and preference. A critical challenge for integrating personalized modules into a product architecture is determining the optimal assembly architecture when considering market expectations and manufacturing constraints. In this paper, an optimization method is proposed for determining the personalized product design architecture that incorporates individual customer preferences. First, a decision hierarchy is presented to describe the integrated design decisions of the product architecture, including product variety determination, module variant selection, and personalized module configuration. Next, a profit model is formulated as an overall performance metric that incorporates customer preferences and manufacturing cost. The systematic patterns and randomness of diverse customer preferences are modeled by combining conjoint analysis and market segmentation with a multivariate normal mixture model. Individual customer product utilities in the target market and their product purchase intent probability are estimated through Monte-Carlo simulation, which is incorporated into the profit calculation. Manufacturing limitations on processes and materials are included as they influence manufacturer’s planning on candidate module variants and production strategies of personalized modules. These models are used to determine a product family architecture that maximizes profit by optimally determining its offering of product variants, module combinations, and personalized module configuration through a genetic algorithm. The proposed method is demonstrated by a personalized bicycle architecture design example.     

A decision-making framework model for design and manufacturing of mechanical transmission system development

Knowledge-based systems are proving to be a powerful tool with great potential for developing intelligent design support environments to improve quality of products and reduce product development costs by eliminating or minimizing many of the trial-and-error iterations involved in product development. This article describes an approach towards the development of intelligent design support environments for mechanical transmission systems, along with implementation details of a distributed knowledge-based gearing design and manufacturing system that is deployed over the Internet. The system embodies the various tasks of the design process, with modules that address: performance evaluation, process optimization, manufacturability analysis, and provides reasoning and decision-making capabilities for reducing the time between gear tooth creation, detailed design and final production. This methodology is highly desirable in that it is able to simulate real working conditions, evaluate and optimize the design effectively, prevent designers from time-consuming iterations and reduce long and expensive test phases.     

Dimensional metrology interoperability and standardization in manufacturing systems

Dimensional metrology is an important part of any manufacturing system. It consists of distinct components and requires a large, diverse, and interconnected knowledge base. How to pass information seamlessly with minimal cost and minimal data loss between different components of a dimensional metrology system is a major issue that concerns software and hardware vendors, standards developers, and customers. This paper focuses on the four main elements of a dimensional metrology system: product definition, measurement process plan definition, measurement process execution, and analysis and reporting of quality data. The activities and software modules that are involved in these elements are discussed. Key issues that cause interoperability problems are identified. These issues are discussed as they relate to the current situation in dimensional metrology standards development. The STEP (ISO 10303) standards are the product of an international effort to achieve interoperability for manufacturing systems. Extending STEP is an appropriate way to solve the interoperability problem within dimensional metrology systems. Further development of STEP standards is proposed so that Geometric Dimensioning and Tolerancing (GD&T) information already available in STEP can be linked with manufacturing feature information, measurement technology, and measurement results. The proposed STEP data model is an attempt to provide a standard that will support automatic measurement process plan generation for in-process on-machine measurement. Some case studies are under way to test the model.     

Integrated process planning using tool/process capabilities and heuristic search

CAD–CAM integration has involved either design with standard manufacturing features (feature-based design), or interpretation of a solid model based on a set of predetermined feature patterns (automatic feature recognition). Thus existing approaches are limited in application to predefined features, and also disregard the dynamic nature of the process and tool availability in the manufacturing shop floor. To overcome this problem, we develop a process oriented approach to design interpretation, and model the shape producing capabilities of the tools into tool classes. We then interpret the part by matching regions of it with the tool classes directly. In addition, there could be more than one way in which a part can be interpreted, and to obtain an optimal plan, it is necessary for an integrated computer aided process planning system to examine these alternatives. We develop a systematic search algorithm to generate the different interpretations, and a heuristic approach to sequence operations (set-ups/tools) for the features of the interpretations generated. The heuristic operation sequencing algorithm considers features and their manufacturing constraints (precedences) simultaneously, to optimally allocate set-ups and tools for the various features. The modules within the design interpretation and process planner are linked through an abstracted qualitative model of feature interactions. Such an abstract representation is convenient for geometric reasoning tasks associated with planning and design interpretation.     

基于SolidWorks的虚拟装配路径规划研究

在机械产品制造过程中,装配工作占有重要的地位,其成本可以占到制造成本的30％—50％.装配工作对产品的最终质量也有很大影响.虚拟装配可以提前模拟装配过程,对保障装配质量和最终产品质量有着重要的意义,机械手臂的应用也使得装配工作更可控.本文基于SolidWorks三维模型设计软件,利用SolidWorks提供的API接口...     

Pharmaceutical supply chain networks with outsourcing under price and quality competition

In this paper, we present a pharmaceutical supply chain network model with outsourcing under price and quality competition, in both equilibrium and dynamic versions. We consider a pharmaceutical firm that is engaged in determining the optimal pharmaceutical flows associated with its supply chain network activities in the form of manufacturing and distribution. In addition to multimarket demand satisfaction, the pharmaceutical firm seeks to minimize its total cost, with the associated function also capturing the firm's weighted disrepute cost caused by possible quality issues associated with the contractors. Simultaneously, the contractors, who compete with one another noncooperatively in prices in the manner of Bertrand, and in quality, seek to secure manufacturing and distribution of the pharmaceutical product from the pharmaceutical firm. This game theory model allows for the determination of the optimal pharmaceutical product flows associated with the supply chain in‐house and outsourcing network activities and provides the pharmaceutical firm with its optimal make‐or‐buy decisions and the optimal contractor selections. We state the governing equilibrium conditions and derive the equivalent variational inequality formulation. We then propose dynamic adjustment processes for the evolution of the product flows, the quality levels, and the prices, along with stability analysis results. The algorithm yields a discretization of the continuous‐time adjustment processes. We present convergence results and compute solutions to numerical examples to illustrate the generality and applicability of the framework.     

Disassembly sequence structure graphs: An optimal approach for multiple-target selective disassembly sequence planning

Modern green products must be easy to disassemble. Specific target components must be accessed and removed for repair, reuse, recycling, or remanufacturing. Prior studies describe various methods for removing selective targets from a product. However, solution quality, model complexity, and searching time have not been considered thoroughly. The goal of this study is to improve solution quality, minimize model complexity, and reduce searching time. To achieve the goal, this study introduces a new ‘disassembly sequence structure graph’ (DSSG) model for multiple-target selective disassembly sequence planning, an approach for creating DSSGs, and methods for searching DSSGs. The DSSG model contains a minimum set of parts that must be removed to remove selected targets, with an order and direction for removing each part. The approach uses expert rules to choose parts, part order, and part disassembly directions, based upon physical constraints. The searching methods use rules to remove all parts, in order, from the DSSG. The DSSG approach is an optimal approach. The approach creates a high quality minimum-size model, in minimum time. The approach finds high quality, practical, realistic, physically feasible solutions, in minimum time. The solutions are optimized for number of removed parts, part order, part disassembly directions, and reorientations. The solutions remove parts in practical order. The solutions remove parts in realistic directions. The solutions consider contact, motion, and fastener constraints. The study also presents eight new design rules. The study results can be used to improve the product design process, increase product life-cycle quality, and reduce product environmental impact.     

产品族设计与延迟制造过程决策的主从关联优化

在市场全球化的进程中,延迟仍然是当今企业降低供应链风险的一种有效策略.然而,当前对延迟的研究往往是基于预先已固定好的产品族架构,较少关注到产品族设计与延迟制造过程决策间存在的内在固有耦合关系.鉴于此,提出对这二者的一种主从关联优化方法.首先,通过构建二者间的主从交互评价机制,建立以产品族设计为上层优化、延迟制造过程决策为下层优化的非线性双层规划模型:模型上层为设计产品族架构和决策延迟产品模块类型,从而最大化单位成本的顾客效用;下层分别为非延迟和延迟产品模块决策最优的制造方式以及为终端产品决策最优的组装方式,从而最小化工程成本.然后,设计一种嵌套式遗传算法对模型进行求解,以智能冰箱产品族延迟制造案例验证所提出模型和算法的可行性.最后,通过设计一种嵌套GAPSO算法对嵌套式遗传算法进行改进,并对比分析两种算法的计算过程和结果.     

Accessibility and ergonomic analysis of assembly product and jig designs

In the aircraft industry, the design of floor assembly jigs (FAJs) is an important activity that directly affects productivity. It involves tool frame generation and locator and clamp placement to ensure that the assembly components are held properly with respect to each other to meet the required tolerances. The tool designer also has to analyze the design to ensure that the assembly process does not pose accessibility and ergonomics related problems. The current approach is dependent on the experience of the tool designer and the limited visualization possible on commercial CAD systems. This leads to extensive redesign when accessibility and ergonomic related problems are detected on the physical prototype. In this research, an integrated Virtual Reality-based environment is being developed for the analysis of assembly product and jig designs. CAD models of the assembly product and jig are imported into a Virtual Reality (VR)-based visualization system for accessibility analysis. A motion tracking system is integrated to allow ergonomic posture analysis. The combined VR and motion tracking system allows evaluation of alternate assembly sequences and the jig design. In this paper, the theoretical basis for the analysis environment is presented along with details of the prototype implementation of this system.

Relevance to industry

Floor assembly jigs are used extensively by the aircraft industry. Improvement of their design process will lead to savings in better design and reduced development time and cost. Better designs will require fewer changes after the jigs have been fabricated. The overall result will be a reduction in product realization time and cost and improved product quality.     

An imperfect production process for time varying demand with inflation and time value of money – An EMQ model

The paper deals with an economic manufacturing quantity (EMQ) model for time-dependent (quadratic) demand pattern. Every manufacturing sector wants to produce perfect quality items. But in long run process, there may arise different types of difficulties like labor problem, machinery capabilities problems, etc., due to that the machinery systems shift from in-control state to out-of-control state as a result the manufacturing systems produce imperfect quality items. The imperfect items are reworked at a cost to become the perfect one. The rework cost may be reduced by improvements in product reliability i.e., the production process depend on time and also the reliability parameter. We want to determine the optimal product reliability and production rate that achieves the biggest total integrated profit for an imperfect manufacturing process using Euler–Lagrange theory to build up the necessary and sufficient conditions for optimality of the dynamic variables. Finally, a numerical example is discussed to test the model which is illustrated graphically also.     

Integrated product and process design: a multi-objective modeling framework

In this paper we present an analytical multi-objective framework for the concurrent design of product and processes. The objective is to simultaneously consider the tolerance specification on the product or the component dimensions along with the selection of the manufacturing processes. For this purpose we consider three objectives: to minimize unit cost, to minimize quality loss and to minimize manufacturing lead time. We characterize the properties of the non-dominated solutions. These solutions provide flexibility needed in an agile manufacturing environment. The min–max approach is used to obtain trade-off solutions.