Developing and Deploying Electronics Assembly Line Optimization Tools: A Motorola Case Study

The assignment of workloads to production equipment is one category of planning decision for an electronics assembly factory. In practice, line balancing requires not only selecting machines with sufficient placement accuracy and feeder capacity, but also address- ing a host of other operational objectives and constraints. Motorola Labs led a multi-year effort to apply mathematical programming to balance a variety of production mix and vol- ume scenarios. By representing the optimization problem as a specially structured, mixed linear-integer program, we were able to incorporate a high degree of reality in the model, simultaneously optimizing fixed setups, handling custom parts, maximizing machine uptime, and mitigating secondary bottlenecks. This paper presents the story of how we developed and deployed a software solution that significantly improved assembly cycle times, setup changeovers, and overall factory productivity, saving the company tens of millions of dollars

A unified robotic kinematic simulation interface.

Robotic controller and application programming have evolved along with the application of computer technologies. A PC-based, open architecture controller, off-line programming and simulation system integrated in one-box solution presents the latest advancement in robotics. Open architecture controllers have been proven essential for all aspects of reconfiguration in future manufacturing systems. A Unified Reconfigurable Open Control Architecture (UROCA) research project is under way within the Intelligent Manufacturing Systems (IMS) Centre at the University of Windsor. Applications are for industrial robotic, CNC, and automotive control systems. The UROCA proposed architecture is a reconfigurable system that takes the advantages of different control structure types, thereby integrating them in a way to enhance the controller architecture design. This research develops a graphical robotic simulation platform by creating an optimized object-oriented design. (Abstract shortened by UMI.) Paper copy at Leddy Library: Theses & Major Papers - Basement, West Bldg. / Call Number: Thesis2005 .D56. Source: Masters Abstracts International, Volume: 44-03, page: 1474. Thesis (M.A.Sc.)--University of Windsor (Canada), 2005

Modelling and simulation of paradigms for printed circuit board assembly to support the UK's competency in high reliability electronics

The fundamental requirement of the research reported within this thesis is the provision of physical models to enable model based simulation of mainstream printed circuit assembly (PCA) process discrete events for use within to-be-developed (or under development) software tools which codify cause & effects knowledge for use in product and process design optimisation. To support a national competitive advantage in high reliability electronics UK based producers of aircraft electronic subsystems require advanced simulation tools which offer model based guidance. In turn, maximization of manufacturability and minimization of uncontrolled rework must therefore enhance inservice sustainability for ‘power-by-the-hour’ commercial aircraft operation business models. [Continues.

Development of an acoustic measurement system of the Modulus of Elasticity in trees, logs and boards

The objective of this Bachelor’s Thesis is to develop a portable electronic device capable of quantifying the stiffness of the wood of standing trees, logs and boards using non-destructive testing (NDT) by means of acoustic wave analysis. As an indicator of stiffness, the Modulus of Elasticity (MOE) is used, a standard figure in the industry. This way, wood from forestry can be characterized and classified for different purposes. This Thesis is part of LIFE Wood For Future, a project of the University of Granada (UGR) financed by the European Union’s LIFE programme. LIFE Wood For Future aims to recover the cultivation of poplar (populus sp.) in the Vega de Granada, by proving the quality of its wood through innovative structural bioproducts. Recovering the poplar groves of Granada would have great benefits for the Metropolitan Area: creation of local and sustainable jobs, improvement of biodiversity, and increase in the absorption of carbon dioxide in the long term, helping to reduce the endemic air pollution of Granada. This Final Degree Project has been developed in collaboration with the ADIME research group of the Higher Technical School of Building Engineering (ETSIE) and the aerospace electronics group GranaSat of the UGR. The goal of the developed device, named Tree Inspection Kit (or TIK), is to be an innovative, portable and easy-to-use tool for non-destructive diagnosis and classification of wood by measuring its MOE. TIK is equipped with the necessary electronics to quantify the Time of Flight (ToF) of an acoustic wave that propagates inside a piece of wood. In order to do this, two piezoelectric probes are used, nailed in the wood and separated a given distance longitudinally. The MOE can be derived from the propagation speed of the longitudinal acoustic wave if the density of the is known. For this reason, this device has the possibility of connecting a load cell for weighing logs or boards to estimate their density. It also has an expansion port reserved for future functionality. A methodology based on the Engineering Design Process (EDP) has been followed. The scope of this project embraces all aspects of the development of an electronic product from start to finish: conceptualization, specification of requirements, design, manufacture and verification. A project of this reach requires planning, advanced knowledge of signal analysis, electronics, design and manufacture of Printed Circuit Boards (PCB) and product design, as well as the development of a firmware for the embedded system, based on a RTOS. Prior to the design of the electronics, a Reverse Engineering process of some similar products of the competition is performed; as well as an exhaustive analysis of the signals coming from the piezoelectric sensors that are going to be used, and the frequency response characterization of the piezoelectric probes themselves. This project has as its ultimate goal the demonstration of the multidisciplinary knowledge of engineering, and the capacity of analysis, design and manufacturing by the author; his skill and professionalism in CAD and EDA software required for these tasks, as well as in the documentation of the entire process.El presente Trabajo de Fin de Grado tiene como objetivo el desarrollo de un dispositivo electrónico portátil capaz de cuantificar la rigidez de la madera de árboles en pie, trozas y tablas usando ensayos no destructivos (Non-Destructive Testing, NDT) por medio del análisis de ondas acústicas. Como indicador de la rigidez se usa el Módulo de Elasticidad (MOE), una figura estándar en la industria. Este TFG forma parte de LIFE Wood For Future, un proyecto de la Universidad de Granada (UGR) financiado por el programa LIFE de la Unión Europea. LIFEWood For Future tiene como objetivo recuperar el cultivo del chopo (populus sp.) en la Vega de Granada demostrando la viabilidad de su madera a través de bioproductos estructurales innovadores. Recuperar las choperas de Granada tendría grandes beneficios para la zona del Área Metropolitana: creación de puestos de trabajo locales y sostenibles, mejora de la biodiversidad, e incremento de la tasa de absorción de dióxido de carbono a largo plazo, contribuyendo a reducir la contaminación endémica del aire en Granada. Este Trabajo de Fin de Grado se ha desarrollado con la colaboración del grupo de investigación ADIME de la Escuela Técnica Superior de Ingeniería de Edificación (ETSIE) y el grupo de electrónica aeroespacial GranaSat de la UGR. El objetivo del dispositivo, denominado Tree Inspection Kit (TIK), es ser una herramienta innovadora, portátil y fácil de usar para el diagnóstico y clasificación no destructiva de la madera por medio de su MOE. TIK está dotado de la electrónica necesaria para medir el tiempo de tránsito (ToF) de una onda acústica que se propaga en el interior de una pieza de madera. Para ello, se utilizan dos sondas piezoeléctricas clavadas en la madera y separadas longitudinalmente una distancia conocida. De la velocidad de propagación de la onda longitudinal se puede derivar el MOE, previo conocimiento de la densidad del material. Por ello, este dispositivo cuenta con la posibilidad de conectarle una célula de carga y pesar trozas o tablas para estimar su densidad. También tiene un puerto de expansión reservado para funcionalidad futura. Se ha seguido una metodología basada en el Proceso de Diseño de Ingeniería (Engineering Design Process, EDP), abarcando todos los aspectos del desarrollo de un producto electrónico de principio a fin: conceptualización, especificación de requisitos, diseño, fabricación y verificación. Un proyecto de este alcance requiere de planificación, conocimientos avanzados de análisis de señales, de electrónica, de diseño y fabricación de Placas de Circuito Impreso (PCB) y de diseño de producto, así como el desarrollo de un firmware para el sistema empotrado, basado en un RTOS. Previo al diseño de la electrónica, se realiza un proceso de Ingeniería Inversa (Reverse Engineering) de algunos productos similares de la competencia; al igual que un exhaustivo análisis de las señales provenientes de los sensores piezoeléctricos que van a utilizarse y la caracterización en frecuencia de las propias sondas piezoeléctricas. Este proyecto tiene como fin último la demostración de los conocimientos multidisciplinares propios de la ingeniería y la capacidad de análisis, diseño y fabricación por parte del autor; su habilidad y profesionalidad en el software CAD y EDA requerido para estas tareas, así como en la documentación de todo el proceso.Unión Europe

A Distributed Decision-Support System for Virtual Prototyping

Virtual Prototyping (VP) is a data-driven design process that promotes both knowledge reuse and innovation. High-profile applications in the automotive and aerospace industries have demonstrated its potential to significantly reduce prototype cycles, time to market, and total product cost. This paper addresses VP as a specialized application of Decision-Support Systems, and discusses common requirements for engineering design tools, as well as requirements specific to the design of electronic products, such as mobile phones. Motorola Labs' test bed for VP is introduced in terms of its open, agent-based architecture utilizing Java CORBA. One of the key principles of the VP System is the reuse of expert knowledge across multiple engineering domains. This is highlighted via several use cases, showing that the system can function not only as an Intranet-accessible repository of model services but also as an integral part of decision-making within the native CAD environment

IEEE/NASA Workshop on Leveraging Applications of Formal Methods, Verification, and Validation

This volume contains the Preliminary Proceedings of the 2005 IEEE ISoLA Workshop on Leveraging Applications of Formal Methods, Verification, and Validation, with a special track on the theme of Formal Methods in Human and Robotic Space Exploration. The workshop was held on 23-24 September 2005 at the Loyola College Graduate Center, Columbia, MD, USA. The idea behind the Workshop arose from the experience and feedback of ISoLA 2004, the 1st International Symposium on Leveraging Applications of Formal Methods held in Paphos (Cyprus) last October-November. ISoLA 2004 served the need of providing a forum for developers, users, and researchers to discuss issues related to the adoption and use of rigorous tools and methods for the specification, analysis, verification, certification, construction, test, and maintenance of systems from the point of view of their different application domains

Development of VR-simulator software for manufacturing systems as a decision making and simulation tool

Modern manufacturing is characterised by high levels of automation and integration, complex interactions among system elements, and high capital costs. Simulation and Virtual Reality technologies hold tremendous promise for reducing costs, improving quality, process data management, enhancing control over operations and shortening the time-to-market for manufactured goods. Unfortunately, these technologies still remains largely underutilised by industry today due to the requirement for a high standard of skills in programming and modelling methodologies. Visualisation has become a critical component of simulation technology in manufacturing applications. It provides the simulation practitioners with an environment to discuss and get a better understanding of the simulation model’s behaviour. Graphical presentation and animation can be a significant tool to communicate the outcome of simulation models for the non-technical audience. Decision makers often do not have the technical knowledge to understand the statistical results of a simulation model. But when the outcome can be expressed using animation, a better level of understanding becomes possible. This thesis presents a VR-Simulator software developed entirely by the author to overcome some of the limitations of simulation packages to allow users (who are not specialists in simulation and virtual reality techniques, or have no programming skills) to develop simulation and virtual models of manufacturing systems automatically without any need for excessive training on modelling techniques or programming. The users can interact with the generated models using voice commands and virtual reality devices (e.g. HMD). The VR-Simulator can be used as an operational décision-support tool to enable decision makers to model and analyse manufacturing systems

Governing Through Risk: The Politics of Anticipation in the British Fire and Rescue Service

This thesis examines practices of fire risk governance in the contemporary British Fire and Rescue Service (FRS). I trace the fundamental organisational and operational transformations the Fire and Rescue Service has undergone since the early twenty-first century. I argue that these transformations are structured around a new conceptualisation of fire as an event to be secured. Rather than understood and acted upon merely by its occurrence in the here and now, fire is known and governed in the contemporary as a risk of the future. Through a case study of one of its regional headquarters, I explore what I call the digital infrastructure of the FRS. This digital infrastructure encompasses the data, analytic technologies and organisational processes by which fire is rendered as a risk. In turn, I inquire into how the risk projections made by the digital infrastructure facilitate and condition what I call anticipatory modes of governance to manage fire. Forming the strategic architecture of the contemporary FRS, these modes of governance are deployed in the present but are directed at, and justified through, visions of fire risk in the future. Through my case study, I describe overall the contemporary problematisation of fire risk governance. I call this problematisation governing through risk. I use the term governing through risk to express how risk identification has become the conditions of possibility for the Fire and Rescue Service in the present day. I show how risk identification works to organisationally shape the FRS and justify the existence of the service as a contemporary security apparatus. Furthermore, I argue that risk identification is used to mould and legitimate the forms of strategy used to govern fire risk and secure populations from fire

TIDAL STREAM DEVICES: RELIABILITY PREDICTION MODELS DURING THEIR CONCEPTUAL & DEVELOPMENT PHASES

Tidal Stream Devices (TSDs) are relatively new renewable energy converters. To date only a few prototypes, primarily horizontal-axis turbine designs, are operational; therefore, little reliability data has accumulated. Pressure to develop reliable sources of renewable electric power is encouraging investors to consider the technology for development. There are a variety of engineering solutions under consideration, including floating tethered, submerged tethered, ducted sea-bed bottom-mounted and sea-bed pile-mounted turbines, but in the absence of in-service reliability data it is difficult to critically evaluate comparative technologies. Developing reliability models for TSDs could reduce long-term risks and costs for investors and developers, encouraging more feasible and economically viable options. This research develops robust reliability models for comparison, defining TSD reliability block diagrams (RBD) in a rigorous way, using surrogate reliability data from similarly-rated wind turbines (WTs) and other relevant marine and electrical industries. The purpose of the research is not to derive individual TSD failure rates but to provide a means of comparison of the relative reliabilities of various devices. Analysis of TSD sub-assemblies from the major types of TSDs used today is performed to identify criticality, to improve controllability and maintainability. The models show that TSDs can be expected to have lower reliability than WTs of comparable size and that failure rates increase with complexity. The models also demonstrate that controls and drive train sub-assemblies, such as the gearbox, generator and converter, are critical to device reliability. The proposed developed models provide clear identification of required changes to the proposed TSD system designs, to raise availability, including duplication of critical systems, use of components developed for harsh environments and migration of equipment onshore, wherever practicable