Lean production system design for fishing net manufacturing using lean principles and simulation optimization

Value stream mapping (VSM) is a useful tool for describing the manufacturing state, especially for distinguishing between those activities that add value and those that do not. It can help in eliminating non-value activities and reducing the work in process (WIP) and thereby increase the service level. This research follows the guidelines for designing future state VSM. These guidelines consist of five factors which can be changed simply, without any investment. These five factors are (1) production unit; (2) pacemaker process; (3) number of batches; (4) production sequence; and (5) supermarket size. The five factors are applied to a fishing net manufacturing system. Using experimental design and a simulation optimizing tool, the five factors are optimized. The results show that the future state maps can increase service level and reduce WIP by at least 29.41% and 33.92% respectively. For the present study, the lean principles are innovatively adopted in solving a fishing net manufacturing system which is not a well-addressed problem in literature. In light of the promising empirical results, the proposed methodologies are also readily applicable to similar industries.     

Twin screw granulation – review of current progress

Twin screw granulation (TSG) is a new process of interest to the pharmaceutical community that can continuously wet granulate powders, doing so at lower liquid concentrations and with better product consistency than found by a high shear batch mixer. A considerable body of research has evolved over the short time since this process was introduced but generally with little comparison of results. A certain degree of confidence has been developed through these studies related to how process variables and many attributes of machinery configuration will affect granulation but some major challenges still lay ahead related to scalability, variations in the processing regimes related to degree of channel fill and the impact of wetting and granulation of complex powder formulations. This review examines the current literature for wet granulation processes studied in twin screw extrusion machinery, summarizing the influences of operational and system parameters affecting granule properties as well as strives to provide some practical observations to newly interested users of the technique.     

Lean philosophy: implementation in a forging company

This research addresses the implementation of lean philosophy in a forging company with a focus on radial forging production flow lines. Here, the prime motive is to evolve and test several strategies to eliminate waste on the shop floor. In this research, a systematic approach is suggested for the implementation of lean principles. This paper describes an application of value stream mapping (VSM). Consequently, the present and future states of value stream maps are constructed to improve the production process by identifying waste and its sources. Furthermore, Taguchi’s method of design of experiments is pursued here to minimize the forging defects produced due to imperfect operating conditions. A noticeable reduction in set-up time and work-in-process (WIP) inventory level is substantiated. Finally, we conclude with a discussion of managerial implications and the future scope of research.     

信息化对制造业的影响综述

信息技术是一种新型技术。信息技术和制造业相互依存、相互促进是一种发展趋势。信息技术对制造业的影响主要有:信息化在制造业的产品开发设计技术方面带来的进步,这主要包括计算机辅助技术;信息化在制造业的生产管理技术方面带来的进步,主要包括企业制造资源计划系统及产品数据管理;信息化在制造业的制造方式上带来的进步,主要包括柔性制造、计算机集成制造等先进制造技术。     

Note on ‘Construction of Double Sampling s‐Control Charts for Agile Manufacturing’

He and Grigoryan (Quality and Reliability Engineering International 2002; 18 :343–355) formulated the design of a double‐sampling (DS) s control chart as an optimization problem and solved it with a genetic algorithm. They concluded that the DS s control charts can be a more economically preferable alternative in detecting small shifts than traditional s control charts. We explain that, since they only considered the average sample size when the process is in control, their conclusion is questionable. Copyright © 2006 John Wiley & Sons, Ltd.     

制造业跟踪系统解决方案剖析

NetLinx技术的发展，使得跟踪系统发生了划时代的飞跃，在制造业上的应用更加广泛。本文以一间显像管厂为例，详细介绍了跟踪系统在制造业上的应用。     

非串行生产线的建模,分析及设计

本文利用等效工作站理论和工件流平衡原理，推导出非串行离散事件生产线可以等价于串联系统，并归结为装配和拆卸两条定理，解决了系统的建模、分析与设计问题。     

An efficient heuristic for scheduling batches of parts in a flexible flow system

Flexible manufacturing systems (FMSs) are a class of automated systems that can be used to improve productivity in batch manufacturing. Four stages of decision making have been defined for an FMS—the design, planning, scheduling, and control stages. This research focuses on the planning stage, and specifically in the area of scheduling batches of parts through the system.The literature to date on the FMS planning stage has mostly focused on the machine grouping, tool loading, and parttype selection problems. Our research carries the literature a step further by addressing the problem of scheduling batches of parts. Due to the use of serial-access material-handling systems in many FMSs, the batch-scheduling problem is modeled for a flexible flow system (FFS). This model explicitly accounts for setup times between batches that are dependent on their processing sequence.A heuristic procedure is developed for this batch-scheduling problem—the Maximum Savings (MS) heuristic. The MS heuristic is based upon the savings in time associated with a particular sequence and selecting the one with the maximum savings. It uses a two-phase method, with the savings being calculated in phase I, while a branch-and-bound procedure is employed to seek the best heuristic solution in phase II. Extensive computational results are provided for a wide variety of problems. The results show that the MS heuristic provides good-quality solutions.     

应用型机械本科专业教学体系改革研究与实践

根据当前高等教育改革与发展的指导思想，紧紧围绕国家实施制造业信息化建设工程为背景，积极配合打造浙江先进制造业基地建设，结合现代机械专业结构调整，本着交叉、复合、应用型人才的培养目标，塑造具有宽口径、厚基础和强创新意识的人才培养理念，以数字化设计制造为核心，以机械技术、电子技术、信息技术和管理学科结合为主线，突出知识综合与创新能力，强调专业实践与专业知识的有效结合，有的放矢实施机械专业教学改革与实践。     

Disassembly sequence planning in a disassembly cell context

In this paper a two-phase approach is proposed for determining the optimal disassembly sequence when the disassembly system has a cellular configuration. Operations are first grouped into cells based on the resources they require with the goal of minimizing machine acquisition costs. The aim is to group together those operations that use similar equipment in order to achieve good utilization levels of such equipment. A maximum cell size may be imposed. Once the cells have been formed and the operations have been assigned to them, a metaheuristic algorithm (namely GRASP) is used to search for the disassembly sequence for each product that leads to the minimum number of intercellular movements. To account for uncertainty regarding the condition in which the product may arrive, each disassembly task is assumed to be required with a certain probability, regardless of the other tasks. AND/OR precedence relations among the disassembly tasks are also considered. The proposed approach is illustrated on a randomly generated disassembly problem.