Using DMAIC for in-plant logistic activities improvement

Goal: In-plant logistics activities are important for increasing the performance of the supply chains, so our research aims to study the application of Six Sigma tools for in-plant logistics activities in the cement industry. Our research contributes to the literature by developing a real case study that provides insights into the practical implementation of continuous improvement programs. Design / Methodology / Approach: This study uses the Industrial Case Study in a large cement plant, a branch of a multinational business group, in Brazil’s Middle-west region. This research applies Define, Measure, Analyze, Improve, Control (DMAIC) guidelines with Statistical Process Control tools for solving a real problem for out-control processes. From this, we propose an improvement plan to correct flaws in the in-plant cement loading and unloading process (in-plant logistics). Results: The results suggest that based on the control chart, the studied in-plant logistics activities were out of control. These processes exhibit a high variability, between 3σ and 5σ, presenting 26 problems with causes related to machine, measure, and human resources. An out-control action plan was proposed aiming for improvements to solve these problems. Limitations of the investigation: On the out-control action plan, this study presents an improvement proposal. The action plan does not fully develop the control step for DMAIC. Practical implications: Managers in the cement industry can use our case for insights and learning about improvement programs, especially for the in-plant logistics activities addressing processing-based manufacturing environments. Originality / Value: Our research contributes a real case study that applies the DMAIC methodology, with a specific focus on in-plant logistics activities. By developing the application of improvement programs within the cement industry, our study offers practical insights into how processing industries can effectively implement such programs

Towards a Physical Internet: the Impact on Logistics Facilities and Material Handling Systems Design and Innovation

Aiming for a radical sustainability improvement, the Physical Internet has the potential of revolutionizing the fields of material handling, logistics, transportation and facilities design. It exploits the enabling concept of standardized, modular and smart containers as well as the universal interconnectivity of logistics networks and services. Its underlying paradigm shift creates a tremendous breakthrough innovation opportunity for the material handling and facility logistics community in terms of equipment, systems and facility design and operation. This paper provides a primer overview of a key subset of the physical elements serving as the foundation of the Physical Internet infrastructure, classified in three categories: containers, movers and nodes. Each element introduced is characterized and illustrated to enable visualization of their innovative nature. The paper helps uncover a wide variety of potent research avenues

A pneumatic conveyor robot for color detection and sorting

Despite numerous research works on conveyor robots, few works can be found on electropneumatic conveyor belt robots with two separated lines. The unique feature of this study is a combination of various systems to develop an electropneumatic robot. In this work, an automated and intelligent mechatronic conveyor system is designed and developed for transporting and positioning circular objects that can be used in the manufacturing and packaging industries. In addition to moving and positioning, timing can also be controlled on this conveyor belt robot. All control operations are handled by an electrical and programmable relay called a mini programmable logic controller (PLC), color sensor, gripper arm, and electronic switches. An electropneumatic system is used to control the robot for placing objects. The main goal of this study is to develop a novel 3D structural design which make the procedure unique for better efficiency and accuracy. The novelty of this work lies within the 3D design of two belts and assembly of all electropneumatic components which are helpful for manufacturing assembly lines. Also, TCS230 sensor and AVR microcontroller are used to identify the colors within the operation. The results show the accuracy of the developed system is reliable in terms of color and positioning detection. The system is able to work non-stop for more than 1 hour without any issues

An agent-based evolutionary approach for manufacturing system layout design

Dissertação apresentada na Faculdade de Ciências e Tecnologia da Universidade Nova de Lisboa para obtenção do grau de Mestre em Engenharia Electrotécnica e de ComputadoresIn this thesis it is presented an approach to the problem of layout design for a manufacturing system, which is an important part of its design stage, given that it has influence in the system efficiency and, therefore, in its output rate and fault handling capabilities. The presented approach is based on a Genetic Algorithm (GA) that, by using information provided by the the user through an ontology file, and by using algorithms from graph-theory, designs the layout of a manufacturing system. The instances of the ontology represent manufacturing resources and their characteristics that, when they are being used by the algorithm, are encoded in chromosomes and in their genes. The algorithm begins with a number of chromosomes with low fitness which, with the directed evolution provided by the algorithm, that is restricted by the control parameters that might be tunned by the user, improve with the passing of the new generations. It is considered that the fittest solution is the one that connects, in order, all the resources required by the manufacturing plan, described in the ontology, without the occurrence of overlaps when the layout is constructed. The configuration presented by the transport system that handles parts and materials, in the selected layout, is only dependent on the available resources and on the fitness function used by the GA, being that the last cannot be changed by the user. This approach differs from others by positioning simultaneously all the components of the manufacturing system and not only workstations or transport system. The solution is directed to evolvable assembly systems, purpose for which it was implemented inside an agent, so it can be integrated in a Multiagent System (MAS) to be used in the control of a manufacturing system with minimal changes. Keywords: layout design, manufacturing system, multiagent system, ontology, genetic algorithm