Energy efficiency in discrete-manufacturing systems: insights, trends, and control strategies

Since the depletion of fossil energy sources, rising energy prices, and governmental regulation restrictions, the current manufacturing industry is shifting towards more efficient and sustainable systems. This transformation has promoted the identification of energy saving opportunities and the development of new technologies and strategies oriented to improve the energy efficiency of such systems. This paper outlines and discusses most of the research reported during the last decade regarding energy efficiency in manufacturing systems, the current technologies and strategies to improve that efficiency, identifying and remarking those related to the design of management/control strategies. Based on this fact, this paper aims to provide a review of strategies for reducing energy consumption and optimizing the use of resources within a plant into the context of discrete manufacturing. The review performed concerning the current context of manufacturing systems, control systems implemented, and their transformation towards Industry 4.0 might be useful in both the academic and industrial dimension to identify trends and critical points and suggest further research lines.Peer ReviewedPreprin

Factory modelling: data guidance for analysing production, utility and building architecture systems

Work on energy and resource reduction in factories is dependent on the availability of data. Typically, available sources are incomplete or inappropriate for direct use and manipulation is required. Identifying new improvement opportunities through simulation across factory production, utility and building architecture domains requires analysis of model feasibility, particularly in terms of system data composition, input resolution and simulation result fidelity. This paper reviews literature on developing appropriate model data for assessing energy and material flows at factory level. Gaps are found in guidance for analysis and integration of resource-flows across system boundaries. The process for how data was prepared, input and iteratively developed alongside conceptual and simulation models is described. The case of a large-scale UK manufacturer is presented alongside discussions on challenges associated with factory level modelling, and the insights gained from understanding the effect of data clarity on system performance

Thermophysical Phenomena in Metal Additive Manufacturing by Selective Laser Melting: Fundamentals, Modeling, Simulation and Experimentation

Among the many additive manufacturing (AM) processes for metallic materials, selective laser melting (SLM) is arguably the most versatile in terms of its potential to realize complex geometries along with tailored microstructure. However, the complexity of the SLM process, and the need for predictive relation of powder and process parameters to the part properties, demands further development of computational and experimental methods. This review addresses the fundamental physical phenomena of SLM, with a special emphasis on the associated thermal behavior. Simulation and experimental methods are discussed according to three primary categories. First, macroscopic approaches aim to answer questions at the component level and consider for example the determination of residual stresses or dimensional distortion effects prevalent in SLM. Second, mesoscopic approaches focus on the detection of defects such as excessive surface roughness, residual porosity or inclusions that occur at the mesoscopic length scale of individual powder particles. Third, microscopic approaches investigate the metallurgical microstructure evolution resulting from the high temperature gradients and extreme heating and cooling rates induced by the SLM process. Consideration of physical phenomena on all of these three length scales is mandatory to establish the understanding needed to realize high part quality in many applications, and to fully exploit the potential of SLM and related metal AM processes

Therblig-embedded value stream mapping method for lean energy machining

To improve energy efficiency, extensive studies have focused on the cutting parameters optimization in the machining process. Actually, non-cutting activities (NCA) occur frequently during machining and this is a promising way to save energy through optimizing NCA without changing the cutting parameters. However, it is difficult for the existing methods to accurately determine and reduce the energy wastes (EW) in NCA. To fill this gap, a novel Therblig-embedded Value Stream Mapping (TVSM) method is proposed to improve the energy transparency and clearly show and reduce the EW in NCA. The Future-State-Map (FSM) of TVSM can be built by minimizing non-cutting activities and Therbligs. By implementing the FSM, time and energy efficiencies can be improved without decreasing the machining quality, which is consistent with the goal of lean energy machining. The method is validated by a machining case study, the results show that the total energy is reduced by 7.65%, and the time efficiency of the value-added activities is improved by 8.12% , and the energy efficiency of value-added activities and Therbligs are raised by 4.95% and 1.58%, respectively. This approach can be applied to reduce the EW of NCA, to support designers to design high energy efficiency machining processes during process planning

Kompetensi pembimbing syarikat bertauliah Sistem Latihan Dual Nasional (SLDN)

Sistem Latihan Dual Nasional (SLDN) merupakan satu sistem latihan dan usahasama antara sektor awam dan sektor swasta dilaksanakan untuk melahirkan tenaga mahir k-worker selari dengan keperluan industri masa kini untuk membangunkan ekonomi negara. Pihak kerajaan dan syarikat swasta menaja pekerja pilihan mereka sebagai pelatih dalam sistem latihan ini bagi mempertingkatkan kebolehan pekerja mereka. Selain itu, pelatih juga terdiri daripada pelajar yang tidak dapat melanjutkan pelajaran ke mana-mana institusi pengajian tinggi awam mahupun swasta. Sistem ini menjalankan pendekatan day release iaitu pelatih menjalani latihan selama empat hari di industri dan satu hari di institusi latihan atau block release iaitu pelatih menjalani latihan kemahiran di industri empat bulan dan satu bulan di institusi latihan mengikut kesesuaian industri tersebut. Kajian berbentuk deskriptif dijalankan untuk melihat melihat tahap kompetensi pembimbing SLDN. Selain itu juga, kajian ini dijalankan bagi melihat perbezaan terhadap tahap pengetahuan, kemahiran dan sikap pembimbing SLDN berdasarkan jantina. Kajian ini juga dibuat bagi menentukan hubungan kompetensi pembimbing berdasarkan pengalaman bekerja. Penyelidikan tinjauan deskriptif ini menggunakan borang soal selidik sebagai instrumen kajian berskala Likert. Seramai 84 orang responden yang terdiri daripada pembimbing syarikat bertauliah SLDN terlibat di dalam kajian ini. Data dianalisis menggunakan SPSS versi 16.0. Hasil analisis mendapati pembimbing mempunyai pengetahuan yang tinggi di samping kemahiran dan sikap. Keputusan inferensi pula menunjukkan tidak terdapat perbezaan antara tahap pengetahuan, kemahiran dan sikap pembimbing berdasarkan jantina manakala analisis korelasi Pearson menunjukkan tidak terdapat hubungan antara kompetensi pembimbing berdasarkan pengalaman bekerja

Kompetensi pembimbing syarikat bertauliah Sistem Latihan Dual Nasional (SLDN)

Sistem Latihan Dual Nasional (SLDN) merupakan satu sistem latihan dan usahasama antara sektor awam dan sektor swasta dilaksanakan untuk melahirkan tenaga mahir k-worker selari dengan keperluan industri masa kini untuk membangunkan ekonomi negara. Pihak kerajaan dan syarikat swasta menaja pekerja pilihan mereka sebagai pelatih dalam sistem latihan ini bagi mempertingkatkan kebolehan pekerja mereka. Selain itu, pelatih juga terdiri daripada pelajar yang tidak dapat melanjutkan pelajaran ke mana-mana institusi pengajian tinggi awam mahupun swasta. Sistem ini menjalankan pendekatan day release iaitu pelatih menjalani latihan selama empat hari di industri dan satu hari di institusi latihan atau block release iaitu pelatih menjalani latihan kemahiran di industri empat bulan dan satu bulan di institusi latihan mengikut kesesuaian industri tersebut. Kajian berbentuk deskriptif dijalankan untuk melihat melihat tahap kompetensi pembimbing SLDN. Selain itu juga, kajian ini dijalankan bagi melihat perbezaan terhadap tahap pengetahuan, kemahiran dan sikap pembimbing SLDN berdasarkan jantina. Kajian ini juga dibuat bagi menentukan hubungan kompetensi pembimbing berdasarkan pengalaman bekerja. Penyelidikan tinjauan deskriptif ini menggunakan borang soal selidik sebagai instrumen kajian berskala Likert. Seramai 84 orang responden yang terdiri daripada pembimbing syarikat bertauliah SLDN terlibat di dalam kajian ini. Data dianalisis menggunakan SPSS versi 16.0. Hasil analisis mendapati pembimbing mempunyai pengetahuan yang tinggi di samping kemahiran dan sikap. Keputusan inferensi pula menunjukkan tidak terdapat perbezaan antara tahap pengetahuan, kemahiran dan sikap pembimbing berdasarkan jantina manakala analisis korelasi Pearson menunjukkan tidak terdapat hubungan antara kompetensi pembimbing berdasarkan pengalaman bekerja

An optimization-based control strategy for energy efficiency of discrete manufacturing systems

In order to reduce the global energy consumption and avoid highest power peaks during operation of manufacturing systems, an optimization-based controller for selective switching on/off of peripheral devices in a test bench that emulates the energy consumption of a periodic system is proposed. First, energy consumption models for the test-bench devices are obtained based on data and subspace identification methods. Next, a control strategy is designed based on both optimization and receding horizon approach, considering the energy consumption models, operating constraints, and the real processes performed by peripheral devices. Thus, a control policy based on dynamical models of peripheral devices is proposed to reduce the energy consumption of the manufacturing systems without sacrificing the productivity. Afterward, the proposed strategy is validated in the test bench and comparing to a typical rule-based control scheme commonly used for these manufacturing systems. Based on the obtained results, reductions near 7% could be achieved allowing improvements in energy efficiency via minimization of the energy costs related to nominal power purchased.Peer ReviewedPostprint (author's final draft

A framework for smart production-logistics systems based on CPS and industrial IoT

Industrial Internet of Things (IIoT) has received increasing attention from both academia and industry. However, several challenges including excessively long waiting time and a serious waste of energy still exist in the IIoT-based integration between production and logistics in job shops. To address these challenges, a framework depicting the mechanism and methodology of smart production-logistics systems is proposed to implement intelligent modeling of key manufacturing resources and investigate self-organizing configuration mechanisms. A data-driven model based on analytical target cascading is developed to implement the self-organizing configuration. A case study based on a Chinese engine manufacturer is presented to validate the feasibility and evaluate the performance of the proposed framework and the developed method. The results show that the manufacturing time and the energy consumption are reduced and the computing time is reasonable. This paper potentially enables manufacturers to deploy IIoT-based applications and improve the efficiency of production-logistics systems