The specification of a consumer design toolkit to support personalised production via additive manufacturing

This thesis stems from the future scenario that as additive manufacturing (AM) technologies become cheaper and more readily available, consumers without formal design training will begin to customise, design and manufacture their own products. Much of this activity is likely to infringe on brands' intellectual property. The research explores the feasibility of a situation in which, rather than attempting to prohibit such activity, manufacturers engage with consumers to facilitate it, thus retaining control (albeit reduced) over their brand's image and the quality of products offered. The research begins with a literature review encompassing AM technologies and their adoption by consumers; mass customisation (MC) and the management of variation in product offering; and traditional models of industrial design (ID), including user-centred design and co-design. It finds that conventional definitions of MC and ID are unable to provide for the possibility of consumer intervention in the shape and non-modular configuration of products. Further research was then conducted in the areas of Open Design (including crowdsourcing, open sourcing and 'hardware hacking') as well as bespoke customisation, which were found to be much more accommodating of the scenario proposed. A new term, 'consumer design', is introduced and defined, together with the hypothesis that in future, the role of the industrial designer may be to design 'unfinished' products. An original classification of consumer involvement in ID is presented. Empirical research, undertaken with consumers using an iterative design software package (Genoform), demonstrated a preference for designing within pre-determined boundaries. Action research was conducted to assess consumer-oriented 3D CAD software, and compare its capabilities with that of MC toolkits. A survey of senior designers and brand managers revealed strategies for implementing and managing a brand's product design language, and a guide was created to show the relative importance of designed features. Using these findings, a prototype toolkit was created to demonstrate how a brand might facilitate consumer interaction with the shape design of a complex consumer electronics product (in this case a mobile phone). The toolkit was tested with both consumers and experienced designers to assess its viability. The research finds that it is possible to create a consumer-design toolkit which enables untrained users to change the form of a product, whilst maintaining brand equity and ensuring the product's functionality and manufacturability

Productivity and flexibility improvement of assembly lines for high-mix low-volume production. A white goods industry case

Las tendencias globales de la personalización e individualización en masa impulsan la producción industrial en serie corta y variada; y por tanto una gran variedad de productos en pequeñas cantidades. Por ello, la customización en masa precisa de sistemas de ensamblaje que sean a la vez altamente productivos y flexibles, a diferencia de la tradicional oposición entre ambas características. La llamada cuarta revolución industrial trae diversas tecnologías habilitadoras que podrían ser útiles para abordar este problema. Sin embargo, las metodologías para implementar el ensamblaje 4.0 todavía no han sido resueltas. De hecho, para aprovechar todas las ventajas potenciales de la Industria 4.0, es necesario contar con un nivel previo de excelencia operacional y un análisis holístico de los sistemas productivos. Esta tesis tiene como objetivo entender y definir cómo mejorar la productividad y la flexibilidad de las operaciones de montaje en serie corta y variada.Esta meta se ha dividido en tres objetivos. El primer objetivo consiste en comprender las relaciones entre la Industria 4.0 y las operaciones de ensamblaje, así como sus implicaciones para los operarios. El segundo objetivo consiste en desarrollar una metodología y las herramientas necesarias para evaluar el rendimiento de diferentes configuraciones de cadenas de ensamblaje. El último objetivo consiste en el diseño de sistemas de ensamblaje que permitan incrementar su productividad al menos un 25 %, produciendo en serie corta y variada, mediante la combinación de puestos de montaje manual y estaciones automatizadas.Para abordar la fase de comprensión y definición del problema, se llevó a cabo una revisión bibliográfica sistemática y se desarrolló un marco conceptual para el Ensamblaje 4.0. Se desarrollaron, verificaron y validaron dos herramientas de evaluación del rendimiento: un modelo matemático analítico y varios modelos de simulación por eventos discretos. Para la verificación, y como punto de partida para los análisis, se ha utilizado un caso de estudio industrial de un fabricante global de electrodomésticos. Se han empleado múltiples escenarios de simulación y técnicas de diseño de experimentos para investigar tres cuestiones clave.En primer lugar, se identificaron los factores más críticos para el rendimiento de líneas de montaje manuales multi-modelo. En segundo lugar, se analizó el rendimiento de líneas de montaje semiautomáticas paralelas con operarios móviles en comparación con líneas semiautomáticas o manuales con operarios fijos, empleando diversos escenarios de demanda en serie corta y variada. Por último, se investigó el uso de trenes milkrun para la logística interna de líneas de ensamblaje multi-modelo bajo la influencia de perturbaciones.Los resultados de las simulaciones muestran que las líneas paralelas con operarios móviles pueden superar a las de operarios fijos en cualquier escenario de demanda, alcanzando como mínimo el objetivo de mejorar la productividad en un 25% o más. También permiten reducir cómodamente el número de operarios trabajando en la línea sin afectar negativamente al equilibrado de la misma, posibilitando la producción eficiente de bajo volumen. Los resultados de las simulaciones de logística interna indican que los milkrun pueden proteger las líneas de ensamblaje de las perturbaciones originadas en procesos aguas arriba.Futuras líneas de investigación en base a los resultados obtenidos en esta tesis podrían incluir la expansión e integración de los modelos de simulación actuales para analizar las cadenas de montaje paralelas con operarios móviles incorporando logística, averías y mantenimiento, problemas de control de calidad y políticas de gestión de los retrabajos. Otra línea podría ser el uso de diferentes herramienta para el análisis del desempeño como, por ejemplo, técnicas de programación de la producción que permitan evaluar el desempeño operacional de diferentes configuraciones de cadenas de montaje con operarios móviles, tanto en términos de automatización como de organización en planta. Podrían incorporarse tecnologías de la Industria 4.0 a los modelos de simulación para evaluar su impacto operacional global ¿como cobots para ensamblaje o para la manipulación de materiales, realidad aumentada para el apoyo cognitivo a los operarios, o AGVs para la conducciónde los trenes milkrun. Por último, el trabajo presentado en esta tesis acerca las líneas de ensamblaje semiautomáticas con operarios móviles a su implementación industrial.<br /

Decomposition of Manufacturing Processes: A Review

Manufacturing is a global activity that started during the industrial revolution in the late 19th century to cater for the large-scale production of products. Since then, manufacturing has changed tremendously through the innovations of technology, processes, materials, communication and transportation. The major challenge facing manufacturing is to produce more products using less material, less energy and less involvement of labour. To face these challenges, manufacturing companies must have a strategy and competitive priority in order for them to compete in a dynamic market. A review of the literature on the decomposition of manufacturing processes outlines three main processes, namely: high volume, medium volume and low volume. The decomposition shows that each sub process has its own characteristics and depends on the nature of the firm’s business. Two extreme processes are continuous line production (fast extreme) and project shop (slow extreme). Other processes are in between these two extremes of the manufacturing spectrum. Process flow patterns become less complex with cellular, line and continuous flow compared with jobbing and project. The review also indicates that when the product is high variety and low volume, project or functional production is applied

Decomposition of manufacturing processes: a review

YesManufacturing is a global activity that started during the industrial revolution in the late 19th century to cater for the large-scale production of products. Since then, manufacturing has changed tremendously through the innovations of technology, processes, materials, communication and transportation. The major challenge facing manufacturing is to produce more products using less material, less energy and less involvement of labour. To face these challenges, manufacturing companies must have a strategy and competitive priority in order for them to compete in a dynamic market. A review of the literature on the decomposition of manufacturing processes outlines three main processes, namely: high volume, medium volume and low volume. The decomposition shows that each sub process has its own characteristics and depends on the nature of the firm’s business. Two extreme processes are continuous line production (fast extreme) and project shop (slow extreme). Other processes are in between these two extremes of the manufacturing spectrum. Process flow patterns become less complex with cellular, line and continuous flow compared with jobbing and project. The review also indicates that when the product is high variety and low volume, project or functional production is applied.The financial support by the Malaysian Government, Universiti Malaysia Pahang and Bradford University for this research is gratefully acknowledged

Reconfigurability level assessment in Portuguese companies

O conceito de sistemas de produção reconfiguráveis (SPRs) surgiu como uma estratégia para alcançar sistemas de produção mais ágeis, capazes de ajustar a funcionalidade e capacidade quando necessário. Este tópico é um problema atual para empresas porque a viabilidade de SPRs foi alcançada recentemente devido às novas tecnologias promovidas pela Indústria 4.0. Em SPRs, a reconfigurabilidade é a capacidade que permite a mudança de um produto para outro, a adição ou remoção de recursos, com mínimo esforço e sem demora. Por esta razão, a avaliação do nível de reconfigurabilidade é de extrema importância para as indústrias. O objetivo desta pesquisa é descrever o desenvolvimento de um índice de reconfigu rabilidade (RI) que pode ser utilizado por empresas para definir o quão reconfiguráveis são seus sistemas de manufatura. Especificamente, este estudo pretende determinar em que medida cada característica fundamental contribui para a composição da reconfi gurabilidade e o nível atual de reconfigurabilidade presente nas empresas portuguesas. Adicionalmente, este trabalho tenta estabelecer uma relação entre as características es senciais e o desempenho operacional dos sistemas de manufatura, e a extensão em que cada característica básica é implementada em diferentes setores industriais. Para construir o IR, uma pesquisa por questionário foi usada para selecionar as va riáveis e uma análise de componentes principais (ACP) foi aplicada aos resultados da pesquisa para determinar as contribuições das características centrais. O IR foi usado para estabelecer um ranking dos setores industriais das empresas respondentes e para discutir o nível de implementação das características centrais de reconfigurabilidade. Os resultados mostram que cada característica central contribui com uma quantidade diferente para a composição da reconfigurabilidade. A adaptabilidade e a diagnostica bilidade são as que mais contribuem, com 25% cada. As empresas portuguesas têm um nível moderado de reconfigurabilidade implementado. Em relação ao desempenho ope racional, a modularidade parece contribuir para a qualidade e entrega; integrabilidade para entrega e flexibilidade; adaptabilidade para custo e qualidade e capacidade de di agnóstico para qualidade e entrega. Entre os setores industriais, a reconfigurabilidade varia de níveis baixos a moderados. A implementação das características centrais variam significativamente, mas o RI parece estar relacionado aos níveis de flutuações do mercado

How will standards facilitate new production systems in the context of EU innovation and competitiveness in 2025? ANNEXES

Standards are very important as they provide requirements, specifications, guidelines or characteristics that can be used consistently to ensure that materials, products, processes and services are fit for their purpose. They contribute to remove technical barriers to trade, leading to new markets and economic growth for industry. They also facilitate technology transfer and they contribute to ensure safety of products thereby affecting the daily life of citizens. This report ‘How will standards facilitate new production systems in the context of EU innovation and competitiveness in 2025?’ is the outcome of a foresight process looking at how standards and standardisation can become even more relevant policy tool supporting different European policies. The study has especially looked at the areas where Europe drives innovation, where the development of new products and processes could lead to new trade of goods, services and technologies. The foresight process has dealt with standardisation by using a holistic approach. It explored at how effective standards can be developed within a European industrial landscape vision able to contribute to jobs and growth in a sustainable manner. The report provides a clear overview of the evolution of the European production system and illustrates what are the drivers of change influencing the future production system. The Industrial Landscape Vision was used to identify the its implications on the European Standardisation System and it highlights priorities for the development of standards in the future.JRC.DDG.02-Foresight and Behavioural Insight