Computer integrated manufacturing in the chemical industry: Theory & practice

This paper addresses the possibilities of implementing Computer Integrated Manufacturing in the process industry, and the chemical industry in particular. After presenting some distinct differences of the process industry in relation to discrete manufacturing, a number of focal points are discussed. They identify the adaptations to be made to a conventional CIM system, so that it will be applicable to the process industry. Interviews with managers of six chemical firms indicate that the process industry may benefit from a new CIM approach to management thinking.Chemical Industry;Manufacturing;CIM;production

Modelling activity times by hybrid synthetic method

Uncertain (manual) activity times impact a number of manufacturing system modules: plant and layout design, capacity analysis, operator assignment, process planning, scheduling and simulation. Direct observation cannot be used for non-existent production lines. A hybrid direct observation/synthetic method derived from Method Time Measurement available in industry is proposed. To determine accurate activity times required by heuristics and metaheuristics optimisation, manufacturing system modules are modelled by MILP and operator efficiency parameters are used for time standardisation. Among human factors considered are skill and ergonomics. Application to the sterilisation of reusable medical devices is extensively described. Experimental data taken from observation on the field and a worst-case date have shown the model direct applicability for professionals also to non-manufacturing cases

Shop floor planning and control in integrated manufacturing systems

The implementation of a shop floor planning and control system is a prerequisite in establishing an effective computer integrated manufacturing system. A shop floor control system integrates management production goals with the capabilities and limitations of the manufacturing plant. Shop floor planning begins with a long term rough cut capacity plan and evolves into near term, capacity requirements and input/output plans. Shop floor control provides a status of in-process operations and a measure of the plants success in executing the plan. Effective use of technology on shop floor increases the efficiency of the manufacturing plant. Simulation is an important tools in accomplishing this. The use of simulation for planning and control of shop floor activities is a natural out growth of its application for the design of systems. Simulation, when used for production planning and control, is a useful vehicle for providing the discipline necessary for effective shop floor control in integrated manufacturing systems

Development of a container transportable baghouse filter

The purpose of this study, as commissioned by the Environmental Systems department of Valmet Technologies, was to create a concept of utilizing freight containers for transportation of baghouse filter subassemblies. The goal was to get an insight of required modifications to the design of the baghouse filter and their effects on fabrication and assembly. An estimation of efforts required for adopting the concept was done by first evaluating the scope of needed modifications to meet the size restrictions set by the dimensions of the containers. Based on the evaluation, modifications were planned to the original design of the baghouse filter and their effects on fabrication were assessed. The planning resulted in new design solutions for the subassemblies that needed to be modified. For the casing subassembly, a redivision of the original panel design was created to meet the requirements for its size. For the module of the nozzle house, two solutions were evaluated, a panel design and a division of the module into sections, of which the section design was considered more advantageous. Finally, an evaluation of the effects on manufacturing was done, that also included feedback from the fabricating shop. A conclusion of the process is that the container concept can be utilized within the scope of the thesis. The required modifications may affect the manufacturing costs, but the container concept may result in lower transport costs. Adopting the concept would still require more efforts, that would include further planning, production of drawings and evaluation of the rest of the bag house filter from the viewpoint of the concept. The thesis can be used for further evaluation and estimations regarding the concept.Valmet Technologies:n ympäristöjärjestelmät-osastolle tehdyssä opinnäytetyössä tarkasteltiin konttien hyödyntämistä letkusuotimen alikokoonpanojen kuljettamisessa työmaalle. Tavoitteena oli muodostaa käsitys tarvittavien alikokoonpanoihin tehtävien muokkausten suuruudesta ja niiden vaikutuksista alikokoonpanojen valmistukseen ja kokoonpanoon. Jotta konttien kokoon perustuvat rajoitukset pystyttiin saavuttamaan, täytyi muokkaukset määrittää. Määrityksen jälkeen alikokoonpanoihin tehtäviä muokkauksia suunniteltiin ja niiden vaikutusta valmistukseen arvioitiin. Suunnittelun tuloksena alikokoonpanoille, joiden kokoa piti muokata, saatiin uusia suunnitteluratkaisuja. Kammioiden osalta ratkaisu oli paneelirakenteen uudelleen jako ja paneelien korkeuksien muuttaminen. Suutinkammiolle arvioitiin kahta ratkaisua, jakoa paneeleihin tai osastoihin, joista osastoihin jako havaittiin paremmaksi ratkaisuksi. Lopuksi valmistajalta saatujen kommenttien tukemana selvitettiin suunniteltujen muokkausten vaikutusta alikokoonpanojen valmistukseen. Konseptin hyödyntäminen on mahdollista opinnäytetyöhön sisältyvän laajuuden osalta. Konseptin myötä valmistuskustannukset voivat nousta, mutta kuljetuskustannukset voivat laskea. Konseptin käyttöönotto vaatii vielä lisää työtä, kuten suunnittelua, piirustusten valmistamista ja letkusuotimen muiden alikokoonpanojen läpi käymistä konseptin näkökulmasta. Opinnäytetyön tuloksia voidaan jatkossa käyttää konseptin jatkokehityksessä

Exploring lean implementation success factors in job shop, batch shop, and assembly line manufacturing settings

This study was motivated by the differences in manufacturing settings, which provide challenges for those organizations undertaking a lean implementation. The levels of applicability of sixteen lean tools were examined in three different manufacturing settings: a job shop, a batch shop, and an assembly line. Specifically, this study explored the perceptions of managers familiar with lean regarding which lean tools were associated with better operational performance. The level of satisfaction with the lean programs in each of the three manufacturing settings was explored as well. The data were collected through a survey that was emailed to one thousand managers working in manufacturing companies located in the US. The results revealed that different lean tools are used at different levels in the three manufacturing settings, and the lean tools contributing most to the group differences were Heijunka (HEIJ), Just in Time (JIT) and Kaizen (KAIZ). The analysis revealed statistically significant positive relationships between the perceived operational performance of firms in job shop and batch shop settings and the implementation of Workers Involvement (WINV) and Muda Elimination (MUDA) lean tools. Assembly line settings had statistically significant positive relationships with the implementation of Standardized Work (STANDW) and Value Stream Mapping (VSM). The results highlighted the importance of Workers Involvement(WINV), which is consistent with prior work. The managers’ satisfaction with the lean program was most associated with the implementation of Heijunka (HEIJ) in a job shop setting, Workers Involvement (WINV) in a batch shop setting, and Continuous Flow (CONTFL) in an assembly line setting. This study presents a decision-making mode l which can be helpful in the successful implementation of the lean paradigm in each of the three manufacturing settings. A number of recommendations for future research are proposed

Scheduling Algorithms: Challenges Towards Smart Manufacturing

Collecting, processing, analyzing, and driving knowledge from large-scale real-time data is now realized with the emergence of Artificial Intelligence (AI) and Deep Learning (DL). The breakthrough of Industry 4.0 lays a foundation for intelligent manufacturing. However, implementation challenges of scheduling algorithms in the context of smart manufacturing are not yet comprehensively studied. The purpose of this study is to show the scheduling No.s that need to be considered in the smart manufacturing paradigm. To attain this objective, the literature review is conducted in five stages using publish or perish tools from different sources such as Scopus, Pubmed, Crossref, and Google Scholar. As a result, the first contribution of this study is a critical analysis of existing production scheduling algorithms\u27 characteristics and limitations from the viewpoint of smart manufacturing. The other contribution is to suggest the best strategies for selecting scheduling algorithms in a real-world scenario

PRODUCTION PLANNING AND CONTROL SYSTEM WITH JUST IN TIME AND LEAN PRODUCTION : A REVIEW

Manufacturing can be defined as applying physical and/or chemical processes to modify the structure, properties and/or appearance of a given starting material to produce parts or products. Manufacturing often entails combining multiple parts for the creation of assembled products. This study aimed to establish a general understanding of development production planning and control and typical production such as just in time and lean production. Method of this study through literature review. This study described activities related to production planning and production control, the difference between lean production and traditional production (push system), and the structure of lean production as known as Toyota system manufacturing

Impact of the contemporary manufacturing environment on cost accounting information systems "an Egyptian case study"

This thesis examines the relevance of current cost accounting systems to the manufacturing environment. Egyptian manufacturing companies in the ex-public industrial sector have suffered from relatively various obstacles, with problems in production planning and control in particular. These impediments were responsible for negative effects on costs and caused low profitability for these companies in most years. Cost accounting systems were basically established for the purpose of preparing financial statements not for operational control.The literature was reviewed to explore changes in the manufacturing environment with emphasis on the developments in production planning and control systems and also to investigate the developments in cost accounting systems.To examine this research phenomenon empirically, a case study was conducted in an Egyptian EI-Nasr automotive manufacturing company. Data was collected from published and unpublished reports and by semi-structured interviews within the case company.The thesis is divided into two main parts: Part I to cover the literature review in this area. Part II for the case study analysis. The study covered three major areas of analysis. First is an overview of all factors which shape the old and new manufacturing environments and the developments in the systems of production planning and control. Second is a detailed investigation of the traditional and new cost accounting systems. Third is the main findings and conclusion including exposing the relationship between the different planning and control systems and the various cost accounting systems. It also includes a wide range of suggestions for improving the cost accounting systems of the studied case company.The major findings of this study were that manufacturing environment played a significant role in designing cost accounting systems. It concluded that planning capabilities of the company and suppliers play a significant role in the process of cost reduction and improve the competitive position