Combining Structural Optimization and Process Assurance in Implicit Modelling for Casting Parts

The structural optimization of manufacturable casting parts is still a challenging and time-consuming task. Today, topology optimization is followed by a manual reconstruction of the design proposal and a process assurance simulation to endorse the design proposal. Consequently, this process is iteratively repeated until it reaches a satisfying compromise. This article shows a method to combine structural optimization and process assurance results to generate automatically structure- and process-optimized die casting parts using implicit geometry modeling. Therefore, evaluation criteria are developed to evaluate the current design proposal and qualitatively measure the improvement of manufacturability between two iterations. For testing the proposed method, we use a cantilever beam as an example of proof. The combined iterative method is compared to manual designed parts and a direct optimization approach and evaluated for mechanical performance and manufacturability. The combination of topology optimization (TO) and process assurance (PA) results is automated and shows a significant enhancement to the manual reconstruction of the design proposals. Further, the improvement of manufacturability is better or equivalent to previous work in the field while using less computational effort, which emphasizes the need for suitable metamodels to significantly reduce the effort for process assurance and enable much shorter iteration times

Backlog control in optoelectronic production using a digital twin

Digital twins are becoming increasingly popular in industry and are being used in various areas, such as production planning and control. Logistics performance still needs to be improved, especially in highly complex and automated production processes such as optoelectronics. The significant challenges faced by industrial companies today, such as stricter quality standards, smaller quantities and shorter product life cycles, exacerbate this phenomenon. In this context, digital twins offer a point of reference for improvement by providing an additional database that can be used to make more informed decisions in realtime. The novel contribution of this paper is the design of a simulation as a digital twin in the context of optoelectronic production. It is used to simulate a variety of backlog scenarios in production planning and to provide an additional source of data for backlog control. We also present an application example of how the digital twin can reduce backlogs in the production process. The simulation indicates that the designed model can effectively support the improvement of logistics performance by addressing the significant challenges in modern production

The interaction of lean and building information modeling in construction

Lean construction and Building Information Modeling are quite different initiatives, but both are having profound impacts on the construction industry. A rigorous analysis of the myriad specific interactions between them indicates that a synergy exists which, if properly understood in theoretical terms, can be exploited to improve construction processes beyond the degree to which it might be improved by application of either of these paradigms independently. Using a matrix that juxtaposes BIM functionalities with prescriptive lean construction principles, fifty-six interactions have been identified, all but four of which represent constructive interaction. Although evidence for the majority of these has been found, the matrix is not considered complete, but rather a framework for research to explore the degree of validity of the interactions. Construction executives, managers, designers and developers of IT systems for construction can also benefit from the framework as an aid to recognizing the potential synergies when planning their lean and BIM adoption strategies

Analysis framework for the interaction between lean construction and building information modelling

Building with Building Information Modelling (BIM) changes design and production processes. But can BIM be used to support process changes designed according to lean production and lean construction principles? To begin to answer this question we provide a conceptual analysis of the interaction of lean construction and BIM for improving construction. This was investigated by compiling a detailed listing of lean construction principles and BIM functionalities which are relevant from this perspective. These were drawn from a detailed literature survey. A research framework for analysis of the interaction between lean and BIM was then compiled. The goal of the framework is to both guide and stimulate research; as such, the approach adopted up to this point is constructive. Ongoing research has identified 55 such interactions, the majority of which show positive synergy between the two

Capturing, classification and concept generation for automated maintenance tasks

Maintenance is an efficient and cost effective way to keep the function of the product available during the product lifecycle. Automating maintenance may drive down costs and improve performance time; however capturing the necessary information required to perform certain maintenance tasks and later building automated platforms to undertake them is very difficult. This paper looks at the creation of a novel methodology tasked with firstly the capture and classification of maintenance tasks and finally conceptual design of platforms for automating maintenance

An Empirical Study of Cohesion and Coupling: Balancing Optimisation and Disruption

Search based software engineering has been extensively applied to the problem of finding improved modular structures that maximise cohesion and minimise coupling. However, there has, hitherto, been no longitudinal study of developers’ implementations, over a series of sequential releases. Moreover, results validating whether developers respect the fitness functions are scarce, and the potentially disruptive effect of search-based remodularisation is usually overlooked. We present an empirical study of 233 sequential releases of 10 different systems; the largest empirical study reported in the literature so far, and the first longitudinal study. Our results provide evidence that developers do, indeed, respect the fitness functions used to optimise cohesion/coupling (they are statistically significantly better than arbitrary choices with p << 0.01), yet they also leave considerable room for further improvement (cohesion/coupling can be improved by 25% on average). However, we also report that optimising the structure is highly disruptive (on average more than 57% of the structure must change), while our results reveal that developers tend to avoid such disruption. Therefore, we introduce and evaluate a multi-objective evolutionary approach that minimises disruption while maximising cohesion/coupling improvement. This allows developers to balance reticence to disrupt existing modular structure, against their competing need to improve cohesion and coupling. The multi-objective approach is able to find modular structures that improve the cohesion of developers’ implementations by 22.52%, while causing an acceptably low level of disruption (within that already tolerated by developers)