Survey on Additive Manufacturing, Cloud 3D Printing and Services

Cloud Manufacturing (CM) is the concept of using manufacturing resources in a service oriented way over the Internet. Recent developments in Additive Manufacturing (AM) are making it possible to utilise resources ad-hoc as replacement for traditional manufacturing resources in case of spontaneous problems in the established manufacturing processes. In order to be of use in these scenarios the AM resources must adhere to a strict principle of transparency and service composition in adherence to the Cloud Computing (CC) paradigm. With this review we provide an overview over CM, AM and relevant domains as well as present the historical development of scientific research in these fields, starting from 2002. Part of this work is also a meta-review on the domain to further detail its development and structure

Modelling for data management & exchange in Concurrent Engineering - A case study of civil aircraft assembly line

This research aims to improve the dataflow performance of the Concurrent Engineering (CE) practice in the detail design stage of the aircraft Assembly Line (AL) in the C919 aircraft project. As the final integrator of the aircraft, Shanghai Aircraft Manufacturing Company Ltd. (SAMC) is responsible for developing the AL with global suppliers. Although CE has been implemented in AL projects to shorten lead time, reduce development cost and improve design quality, the lack of experience and insufficient infrastructure may lead to many challenges in cooperation with distributed suppliers, especially regarding data management/exchange and workflow control. In this research, the particular CE environment and activities in SAMC AL projects were investigated. By assessing the CE performance and benchmarking, the improvement opportunities are identified, and then an activity-oriented workflow and dataflow model is established by decomposing the work process to detail levels. Based on this model, a Product Data Management (PDM) based support platform is proposed to facilitate data management/exchange in dynamic workflow to improve work efficiency and interoperability. This solution is mocked-up on the Siemens Teamcenter 8.1 PLM(Product Lifecycle Management) software and its feasibility is checked. The mock-up is evaluated by SAMC experts and suppliers. The feedback shows the acceptance of the model by experts and the urgency of improving data/work flow design before PLM implementing. The result of this research is useful for enterprises in similar environments transiting from pre-PLM to implementing PLM and who wanting to strengthen CE in the new product development

Internet-based solutions to support distributed manufacturing

With the globalisation and constant changes in the marketplace, enterprises are adapting themselves to face new challenges. Therefore, strategic corporate alliances to share knowledge, expertise and resources represent an advantage in an increasing competitive world. This has led the integration of companies, customers, suppliers and partners using networked environments. This thesis presents three novel solutions in the tooling area, developed for Seco tools Ltd, UK. These approaches implement a proposed distributed computing architecture using Internet technologies to assist geographically dispersed tooling engineers in process planning tasks. The systems are summarised as follows. TTS is a Web-based system to support engineers and technical staff in the task of providing technical advice to clients. Seco sales engineers access the system from remote machining sites and submit/retrieve/update the required tooling data located in databases at the company headquarters. The communication platform used for this system provides an effective mechanism to share information nationwide. This system implements efficient methods, such as data relaxation techniques, confidence score and importance levels of attributes, to help the user in finding the closest solutions when specific requirements are not fully matched In the database. Cluster-F has been developed to assist engineers and clients in the assessment of cutting parameters for the tooling process. In this approach the Internet acts as a vehicle to transport the data between users and the database. Cluster-F is a KD approach that makes use of clustering and fuzzy set techniques. The novel proposal In this system is the implementation of fuzzy set concepts to obtain the proximity matrix that will lead the classification of the data. Then hierarchical clustering methods are applied on these data to link the closest objects. A general KD methodology applying rough set concepts Is proposed In this research. This covers aspects of data redundancy, Identification of relevant attributes, detection of data inconsistency, and generation of knowledge rules. R-sets, the third proposed solution, has been developed using this KD methodology. This system evaluates the variables of the tooling database to analyse known and unknown relationships in the data generated after the execution of technical trials. The aim is to discover cause-effect patterns from selected attributes contained In the database. A fourth system was also developed. It is called DBManager and was conceived to administrate the systems users accounts, sales engineers’ accounts and tool trial monitoring process of the data. This supports the implementation of the proposed distributed architecture and the maintenance of the users' accounts for the access restrictions to the system running under this architecture

Data-driven through-life costing to support product lifecycle management solutions in innovative product development

Innovative product usually refers to product that comprises of creativity and new ideas. In the development of such a new product, there is often a lack of historical knowledge and data available to be used to perform cost estimation accurately. This is due to the fact that traditional cost estimation methods are used to predict costs only after a product model has been built, and not at an early design stage when there is little data and information available. In light of this, original equipment manufacturers are also facing critical challenges of becoming globally competitive and increasing demands from customer for continuous innovation. To alleviate these situations this research has identified a new approach to cost modelling with the inclusion of product lifecycle management solutions to address innovative product development.The aim of this paper, therefore, is to discuss methods of developing an extended-enterprise data-driven through-life cost estimating method for innovative product development

PLM-based approach for collaborative design between OEM and suppliers : case study of aeronautic industry.

To achieve different assembly operations on the aircraft structure, the aeronautic OEM needs to create and manage various fixture tools. To cope with these needs, the OEM begun to adopt the supplier integration into the tooling development process. This paper presents a conceptual PLM-based approach to support new business partnership of different suppliers. The new business partnership aims to improve the role of supplier in the different tasks of design, configuration and fabrication of the tooling. The use of the PLM concepts is proposed to enhance the collaboration between OEM and the equipment's suppliers. UML models are proposed to specify the structure of the PLM solution. These models describe the relation between the aircraft assembly project, and the tooling design process

Web-based strategies in the manufacturing industry

The explosive growth of Internet-based architectures is allowing an efficient access to information resources over geographically dispersed areas. This fact is exerting a major influence on current manufacturing practices. Business activities involving customers, partners, employees and suppliers are being rapidly and efficiently integrated through networked information management environments. Therefore, efforts are required to take advantage of distributed infrastructures that can satisfy information integration and collaborative work strategies in corporate environments. In this research, Internet-based distributed solutions focused on the manufacturing industry are proposed. Three different systems have been developed for the tooling sector, specifically for the company Seco Tools UK Ltd (industrial collaborator). They are summarised as follows. SELTOOL is a Web-based open tool selection system involving the analysis of technical criteria to establish appropriate selection of inserts, toolholders and cutting data for turning, threading and grooving operations. It has been oriented to world-wide Seco customers. SELTOOL provides an interactive and crossed-way of searching for tooling parameters, rather than conventional representation schemes provided by catalogues. Mechanisms were developed to filter, convert and migrate data from different formats to the database (SQL-based) used by SELTOOL.TTS (Tool Trials System) is a Web-based system developed by the author and two other researchers to support Seco sales engineers and technical staff, who would perform tooling trials in geographically dispersed machining centres and benefit from sharing data and results generated by these tests. Through TTS tooling engineers (authorised users) can submit and retrieve highly specific technical tooling data for both milling and turning operations. Moreover, it is possible for tooling engineers to avoid the execution of new tool trials knowing the results of trials carried out in physically distant places, when another engineer had previously executed these trials. The system incorporates encrypted security features suitable for restricted use on the World Wide Web. An urgent need exists for tools to make sense of raw data, extracting useful knowledge from increasingly large collections of data now being constructed and made available from networked information environments. This explosive growth in the availability of information is overwhelming the capabilities of traditional information management systems, to provide efficient ways of detecting anomalies and significant patterns in large sets of data. Inexorably, the tooling industry is generating valuable experimental data. It is a potential and unexplored sector regarding the application of knowledge capturing systems. Hence, to address this issue, a knowledge discovery system called DISKOVER was developed. DISKOVER is an integrated Java-application consisting of five data mining modules, able to be operated through the Internet. Kluster and Q-Fast are two of these modules, entirely developed by the author. Fuzzy-K has been developed by the author in collaboration with another research student in the group at Durham. The final two modules (R-Set and MQG) have been developed by another member of the Durham group. To develop Kluster, a complete clustering methodology was proposed. Kluster is a clustering application able to combine the analysis of quantitative as well as categorical data (conceptual clustering) to establish data classification processes. This module incorporates two original contributions. Specifically, consistent indicators to measure the quality of the final classification and application of optimisation methods to the final groups obtained. Kluster provides the possibility, to users, of introducing case-studies to generate cutting parameters for particular Input requirements. Fuzzy-K is an application having the advantages of hierarchical clustering, while applying fuzzy membership functions to support the generation of similarity measures. The implementation of fuzzy membership functions helped to optimise the grouping of categorical data containing missing or imprecise values. As the tooling database is accessed through the Internet, which is a relatively slow access platform, it was decided to rely on faster Information retrieval mechanisms. Q-fast is an SQL-based exploratory data analysis (EDA) application, Implemented for this purpose

Integration of e-business strategy for multi-lifecycle production systems

Internet use has grown exponentially on the last few years becoming a global communication and business resource. Internet-based business, or e-Business will truly affect every sector of the economy in ways that today we can only imagine. The manufacturing sector will be at the forefront of this change. This doctoral dissertation provides a scientific framework and a set of novel decision support tools for evaluating, modeling, and optimizing the overall performance of e-Business integrated multi-lifecycle production systems. The characteristics of this framework include environmental lifecycle study, environmental performance metrics, hyper-network model of integrated e-supply chain networks, fuzzy multi-objective optimization method, discrete-event simulation approach, and scalable enterprise environmental management system design. The dissertation research reveals that integration of e-Business strategy into production systems can alter current industry practices along a pathway towards sustainability, enhancing resource productivity, improving cost efficiencies and reducing lifecycle environmental impacts. The following research challenges and scholarly accomplishments have been addressed in this dissertation: Identification and analysis of environmental impacts of e-Business. A pioneering environmental lifecycle study on the impact of e-Business is conducted, and fuzzy decision theory is further applied to evaluate e-Business scenarios in order to overcome data uncertainty and information gaps; Understanding, evaluation, and development of environmental performance metrics. Major environmental performance metrics are compared and evaluated. A universal target-based performance metric, developed jointly with a team of industry and university researchers, is evaluated, implemented, and utilized in the methodology framework; Generic framework of integrated e-supply chain network. The framework is based on the most recent research on large complex supply chain network model, but extended to integrate demanufacturers, recyclers, and resellers as supply chain partners. Moreover, The e-Business information network is modeled as a overlaid hypernetwork layer for the supply chain; Fuzzy multi-objective optimization theory and discrete-event simulation methods. The solution methods deal with overall system parameter trade-offs, partner selections, and sustainable decision-making; Architecture design for scalable enterprise environmental management system. This novel system is designed and deployed using knowledge-based ontology theory, and XML techniques within an agent-based structure. The implementation model and system prototype are also provided. The new methodology and framework have the potential of being widely used in system analysis, design and implementation of e-Business enabled engineering systems

Innovative configurable and collaborative approach to automation systems engineering for automotive powertrain assembly

Presently the automotive industry is facing enormous pressure due to global competition and ever changing legislative, economic and customer demands. Both, agility and reconfiguration are widely recognised as important attributes for manufacturing systems to satisfy the needs of competitive global markets. To facilitate and accommodate unforeseen business changes within the automotive industry, a new proactive methodology is urgently required for the design, build, assembly and reconfiguration of automation systems. There is also need for the promotion of new technologies and engineering methods to enable true engineering concurrency between product and process development. Virtual construction and testing of new automation systems prior to build is now identified as a crucial requirement to enable system verification and to allow the investigation of design alternatives prior to building and testing physical systems. The main focus of this research was to design and develop reconfigurable assembly systems within the powertrain sector of the automotive industry by capturing and modelling relevant business and engineering processes. This research has proposed and developed a more process-efficient and robust automation system design, build and implementation approach via new engineering services and a standard library of reusable mechanisms. Existing research at Loughborough had created the basic technology for a component based approach to automation. However, no research had been previously undertaken on the application of this approach in a user engineering and business context. The objective of this research was therefore to utilise this prototype method and associated engineering tools and to devise novel business and engineering processes to enable the component-based approach to be applied in industry. This new approach has been named Configurable and Collaborative Automation Systems (CO AS). In particular this new research has studied the implications of migration to a COAS approach in terms of I) necessary changes to the end-users business processes, 2) potential to improve the robustness of the resultant system and 3) potential for improved efficiency and greater collaboration across the supply chain... cont'

A design-for-casting integrated approach based on rapid simulation and modulus criterion

This paper presents a new approach to the design of cast components and their associated tools. The current methodology is analysed through a case study and its main disadvantages underlined. Then, in order to overcome these identified drawbacks, a new approach is proposed. Knowing that this approach is mainly based on a rapid simulation of the process, basics of a simplified physical model of solidification are presented as well as an associated modulus criterion. Finally, technical matters for a software prototype regarding the implementation of this Rapid Simulation Approach (RSA) in a CAD environment are detailed

The role of collaboration in the South African tooling industry

Published ArticleThe efficient design and manufacturing of injection moulds (and other tooling), requires collaboration between multi-disciplinary, geographically separated units and companies, including the company that orders plastic parts, the ones that design and/or produce the moulds and/or mould-components, and those that use injection moulding machines to produce components. Distributed collaborative tooling design and manufacturing, while being a great concept, is still difficult to implement in today's complex environment. This is clear as more functional groups become involved in the total product development process earlier to meet time-to-market and cost objectives. Although internal design and manufacturing groups may have experience in collaborating with different degrees of success, the global trend is towards greater outsourcing of activities and inclusion of complementary organisations. The requirement for extended collaboration - the process of securely and selectively exchanging, reviewing, and managing the change of product information with other internal participants and external groups such as customers, design partners, suppliers and distributed manufacturing companies - presents huge challenges. Delivering these capabilities in today's global product development processes requires a different approach to doing business than a few years ago. Companies must be willing to share more information, which "is hard because we are competitors." The toolmaking companies' in South Africa (of which 90% are small and medium size enterprises (SMEs)) concern for success in delivering these capabilities, can also be greatly impacted by the underlying software or information technology infrastructure required for supporting the entire product development process. This article provides a perspective for SMEs and others that might participate in collaborative tool design and manufacture in South Africa today or in the future