Buffer allocation in unreliable production lines based on design of experiments, simulation, and genetic algorithm

This paper presents a multiobjective formulation of the buffer allocation problem in unreliable production lines. Majority of the solution methods for buffer allocation problems assume that the process times, time between failures, and repair times are deterministic or exponentially distributed. This paper relaxes these restrictions by proposing a simulation-based methodology which can consider general function distributions for all parameters of production lines. Factorial design has been used to build a meta-model for estimating production rate based on a detailed, discrete event simulation model. We use genetic algorithm combined to line search method to solve the multiobjective model and determining the optimal (or near optimal) size of each buffer storage.     

Phasor measurement unit based transmission line protection scheme design

This paper presents an adaptive transmission line protection scheme based on synchronized phasor measurement units. This scheme uses the positive-sequence voltage and current phasors at both ends of a transmission line to determine the parameter of the transmission line and the location of a fault on the transmission line. This scheme can be used for the protection of both single- and double-circuit transmission lines. This scheme is also robust against power swing conditions. A novel adaptive single pole auto re-closer is introduced based on the proposed scheme due to its capability of differentiating transient and permanent faults. System simulation studies show that the proposed scheme is able to operate fast and accurately for transmission line protection.     

Synthesis of mullite nanofibres by electrospinning of solutions containing different proportions of polyvinyl butyral

In this paper, the synthesis of continuous mullite (3Al₂O₃·2SiO₂) nanofibres by combination of the sol–gel and electrospinning technique is reported. To find out the optimum viscosity of the electrospinning solution for obtaining the high quality mullite nanofibers, solutions containing different amounts of polyvinyl butyral (PVB, 0–8 wt%) and the precursor sol were prepared for the electrospinning process. The precursor sol was made by using proper amounts of aluminium isopropoxide (AIP), hydrated aluminium nitrate (AN) and tetraethylorthosilicate (TEOS). Crystal phase, microstructure and thermal decomposition behaviour of the electrospun mullite nanofibres were investigated by conventional methods of analysis. The optimal amount of PVB in the electrospinning polymeric solutions was found to be between 4 and 6 wt% and the mullite nanofibres obtained as such were pure, smooth and uniform with diameter sizes of 85–130 nm after calcination at 1200 °C.     

Flame retardant polyurethane nanocomposite: Study of clay dispersion and its synergistic effect with dolomite

Polyurethane–clay nanocomposite adhesives were prepared by different synthetic routes and their microstructures were determined by X‐ray diffraction measurements and from transmission electron microscopy images. The preparation method of the polyurethane nanocomposite adhesives was systematically changed, that is, condensation either in the presence or absence of catalyst, concentration and type of nanoclay, premixing order of nanoclay (nanoclay was either premixed with the polyol or isocyanate part) and by using MDI surface treated nanoclays. Depending on the polymerization conditions cluster, intercalated, and exfoliated clay structures were obtained. The flame retardant properties of the manufactured nanocomposite adhesives and the synergistic effect of clay in combination with dolomite were investigated by cone calorimeter and UL 94 vertical burning tests. The results indicate that addition of nanoclay reduces burning time and the total heat evolved (THE) at flame out, and that the type of assembled clay structure (cluster, intercalated or exfoliated) had a significant effect on the flame retardant property. Nanocomposites with 3 wt % of clay loading gave the shortest burning time, the lowest THE and also UL 94 V‐2 ratings were reached, although the flame retardancy in terms of heat release rate and time to ignition was not improved. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

An Unreacted Shrinking Core Model for Calcination and Similar Solid-to-Gas Reactions

A variation on the unreacted shrinking core model has been developed for calcination and similar non-catalytic solid-to-gas decomposition reactions in which no gaseous reactant is involved and the reaction rate decreases with increasing product gas concentration. The numerical solution of the model has been validated against an analytical solution for the isothermal case. The model parameters have been tuned using literature data for the thermal dehydration (calcination) of gibbsite to alumina over a wide range of temperatures, from 490 to 923 K. The model results for gibbsite conversion agreed well with the published experimental data. A reaction order with respect to water vapor concentration of n = ?1 was found to give a good fit to the data and yield activation energies consistent with literature values. Predictions of the non-isothermal unreacted shrinking core model compare well with a more complex distributed model developed previously by the authors.     

Preparation and characterization of a temperature-sensitive nonwoven poly (propylene) with antibacterial properties

In this study, a temperature-sensitive fabric with antibacterial properties was prepared by the formation of silver nanoparticles (AgNPs) on nonwoven poly (propylene) (PP) grafted with poly (N-iso-propylacrylamide) (PNIPAAm-PP). First, PNIPAAm was grafted onto corona-treated nonwoven PP. Afterwards, silver nanoparticles were synthesized on the temperature-sensitive hydrogel layer grafted to the surface of nonwoven PP by the reduction of silver ions (Ag⁺). Fourier transform infra-red spectroscopy confirmed the presence of PNIPAAm on the nonwoven PP. scanning electron microscopy-energy dispersive X-ray spectroscopy was used to investigate surface morphology and the presence of silver particles in the samples. Inductively coupled-plasma atomic emission spectroscopy revealed that the Ag content in Ag-functionalized PNIPAAm-PP was significantly higher than Ag-functionalized corona-treated PP with the same concentration of silver solution. Moreover, the results of the swelling rate experiment confirmed that PNIPAAm-PP maintained temperature-sensitive properties after functionalizing with Ag. The results showed that the formation of AgNPs with enhancement in antibacterial property was possible onto PNIPAAm-PP.     

Effect of Fiber Acid Treatment on the Dynamic Mechanical Properties of Unsaturated Polyester/Carbon Fiber Unidirectional Composites

In this study, the surface modification of carbon fiber by sulfuric acid is investigated. Atomic Force Microscopy was employed to capture the corresponding changes in the surface roughness of the carbon fiber. Moreover, using treated and untreated fibers, unsaturated polyester unidirectional composite rods were prepared and their flexural properties were determined by three-point bending and dynamic mechanical thermal analysis.

The results indicated that the carbon fiber surface roughness increases in all samples. It is also found that treating the fiber decreases the magnitude of loss modulus. Besides, the flexural strength of composites made of the treated carbon fiber significantly increased.     

Statistical monitoring of multivariate multiple linear regression profiles in phase I with calibration application

In some statistical process control applications, there are some correlated quality characteristics which can be modeled as linear functions of some explanatory variables. We refer to this structure as multivariate multiple linear regression profiles. When the correlation structure between quality characteristics is ignored and profiles are monitored separately then misleading results could be expected. Hence, developing methods to account for this multivariate structure is required. In this paper, we specifically focus on phase I monitoring of multivariate multiple linear regression profiles and develop four methods for this purpose. The performance of the developed methods is compared through simulation studies in terms of probability of a signal. In addition, a diagnostic scheme to find the out‐of‐control samples is developed. Finally, the application of the proposed methods is illustrated using a calibration application at the National Aeronautics and Space Administration (NASA) Langley Research Center. Copyright © 2009 John Wiley & Sons, Ltd.     

New Approaches in Monitoring Multivariate Categorical Processes based on Contingency Tables in Phase II

In some statistical process control (SPC) applications, quality of a process or product is characterized by contingency table. Contingency tables describe the relation between two or more categorical quality characteristics. In this paper, two new control charts based on the WALD and Stuart score test statistics are designed for monitoring of contingency table‐based processes in Phase‐II. The performances of the proposed control charts are compared with the generalized linear test (GLT) control chart proposed in the literature. The results show the better performance of the proposed control charts under small and moderate shifts. Moreover, new schemes are proposed to diagnose which cell corresponding to different levels of categorical variables is responsible for out‐of‐control signal. In addition, we propose EWMA–WALD and EWMA–Stuart score test control charts to improve the performance of Shewhart‐based control charts in detecting small and moderate shifts in contingency table parameters. Meanwhile, we compare the performances of two proposed EWMA‐based control charts with the ones of three existing control charts called EWMA–GLT, EWMA–GLRT and an EWMA‐type control chart for multivariate binomial/multinomial processes along with the ones of the corresponding Shewhart‐based control charts. A numerical example is given to show the efficiency of the proposed methods. Finally, the effect of parameter estimation in Phase I based on m historical contingency table on the performance of the Shewhart‐based control charts is studied. Copyright © 2016 John Wiley & Sons, Ltd.     

Designing a cellular manufacturing system considering decision style,skill and job security by NSGA-II and response surface methodology

Cell formation is a traditional problem in cellular manufacturing systems that concerns the allocation of parts, operators and machines to the cells. This paper presents a new mathematical programming model for cell formation in which operators’ personality and decision-making styles, skill in working with machines, and also job security are incorporated simultaneously. The model involves the following five objectives: (1) minimising costs of adding new machines to and removing machines from the cells at the beginning of each period, (2) minimising total cost of material handling, (3) maximising job security, (4) minimising inconsistency of operators’ decision styles in cells and (5) minimising cost of suitable skill. On account of the NP-hard nature of the proposed model, NSGA-II as a powerful meta-heuristic approach is used for solving large-sized problems. Furthermore, response surface methodology (RSM) is used for tuning the parameters. Lastly, MOPSO and two scalarization methods are employed for validation of the results obtained. To the best of our knowledge, this is the first study that presents a multi-objective mathematical model for cell formation problem considering operators’ personality and skill, addition and removal of machines and job security.