"The Shift from Belt Conveyor Line to Work-cell Based Assembly Systems to Cope with Increasing Demand Variation and Fluctuation in The Japanese Electronics Industries"

As consumption patterns become increasingly sophisticated and manufacturers strive to improve their competitiveness, not only offering higher quality at competitive costs, but also by providing broader mix of products, and keeping it attractive by launching successively new products, the turbulence in the markets has intensified. This has impelled leading manufacturers to search the development of alternative production systems supposed to enable them operate more responsively. This paper discusses the trend of abandoning the strategy of relying on factory automation technologies and conveyor-based assembly lines, and shifting towards more human-centered production systems based on autonomous work-cells, observed in some industries in Japan (e.g. consumer electronics, computers, printers) since mid-1990s. The purpose of this study is to investigate this trend which is seemingly uneconomic to manufacturers established in a country where labor costs are among the highest in the world, so as to contribute in the elucidation of its background and rationality. This work starts with a theoretical review linking the need to cope with nowadays' market turbulence with the issue of nurturing more agile organizations. Then, a general view of the diffusion trend of work-cell based assembly systems in Japanese electronics industries is presented, and some empirical facts gathered in field studies conducted in Japan are discussed. It is worthy mentioning that the abandonment of short cycle-time tasks performed along conveyor lines and the organization of workforce around work-cells do not imply a rejection of the lean production paradigm and its distinctive process improvement approach. High man-hour productivity is realized as a key goal to justify the implementation of work-cells usually devised to run in longer cycle-time, and the moves towards this direction has been strikingly influenced by the kaizen philosophy and techniques that underline typical initiatives of lean production system implementation. Finally, it speculates that even though the subject trend is finding wide diffusion in the considered industries, it should not be regarded as a panacea. In industries such as manufacturing of autoparts, despite the notable product diversification observed in the automobile market, its circumstances have still allowed the firms to rely on capital-intensive process, and this has sustained the development of advanced manufacturing technologies that enable the agile implementation and re-configuration of highly automated assembly lines.

Reconfiguration model using knowledge based engineering systems

Globalization has forced enterprises to adapt their products and services to remain competitive in the free market. Manufacture plays an important role in the competitive aspect; it is where an innovation in the production system could lead to business advantage. These innovations usually involve the key elements in manufacturing systems: machines, tools and resources administration. A reconfigurable manufacturing system (RMS) is one designed for rapid change in its structure and components, to quickly adjust its production capacity and functionality in response to sudden market or intrinsic system changes. However, reconfiguration alone is not enough since it will provide information to produce a certain item but it won t provide the components that will automate the machine tool for mass production. The process of automation of machine tools is known as retrofit, process being developed and researched in emergent economies. The current retrofit kits are expensive and are not tailor made, thus, they are not attractive for small and medium enterprises. This article describes a solution for fast reconfiguration of machine tools using the Knowledge Based-Engineering System methodology (KBES) that allows to obtain, structure and manage the knowledge generated in a determined engineering process, in this case, the reconfiguration processHincapié Montoya, M.; Güemes-Castorena, D.; Contero, M.; Ramírez-Cadena, M.; Diaz, C. (2015). Reconfiguration model using knowledge based engineering systems. Journal of Manufacturing Technology Research. 6(1):63-81. http://hdl.handle.net/10251/77893S63816

Development of a software application for machine tool reconfiguration using a knowledge-based engineering system approach

The automation processes industry has become increasingly expensive, which is why some small and medium sized enterprises are incapable of buying machine tools with automatic systems. This means that their processes are manual in many cases, and as a result they often have to rework their developed products due to the lack of precision and efficiency in their production processes. Considering that current manufacturing systems with variable machining and turning centers are gradually replacing dedicated systems for medium lot size production, the production systems' basic element, the machine tool, must be capable of working at high speeds with precision, and it must be reconfigurable. These systems must also be compatible and convertible in order to create economic benefits for customers. This article describes a specific software architecture designed to record all the data, information and knowledge concerning manufacturing systems. The software allows for the creation of a new knowledge database and works with it in the reconfiguration of machine tools depending on the rules, requirements and parameters needed to effectively modify production processes or products.Hincapie, M.; Guemes, D.; Contero González, MR.; Ramirez, M.; Diaz, C. (2016). Development of a software application for machine tool reconfiguration using a knowledge-based engineering system approach. International Journal of Knowledge-Based and Intelligent Engineering Systems. 20(1):49-63. doi:10.3233/KES-160334S496320

Design and construction of a novel reconfigurable micro manufacturing cell

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Demands for producing small components are increasing. Such components are usually produced using large-size conventional machining tools. This results in the inadequate usage of resources, including energy, space and time. In the 1990s, the concept of a microfactory was introduced in order to achieve better usage of these resources by scaling down the size of the machine tool itself. Several industries can benefit from implementing such a concept, such as the medical, automotive and electronics industries. A novel architecture for a reconfigurable micro-manufacturing cell (RMC) is presented in this research, aiming at delivering certain manufacturing strategies such as point of use (POU) and cellular manufacturing (CM) as well as several capabilities, including modularity, reconfigurability, mobility and upgradability. Unlike conventional machine tools, the proposed design is capable of providing several machining processes within a small footprint (500 mm2), yet processing parts within a volume up to 100 mm3. In addition, it delivers a rapid structure and process reconfiguration while achieving a micromachining level of accuracy. The approach followed in developing the system is highly iterative with several feedback loops. It was deemed necessary to adopt such an approach to ensure that not only was the design relevant, but also that it progresses the state-of-the-art and takes into account the many considerations in machine design. Following this approach, several design iterations have been developed before reaching a final design that is capable of delivering the required manufacturing qualities and operational performance. A prototype has been built based on the specifications of the selected design iteration, followed by providing a detailed material and components selection process and assembly method before running a performance assessment analysis of the prototype. At this stage, a correlation between the Finite Element Analysis (FEA) model and prototype has been considered, aiming at studying the level of performance of the RMC when optimising the design in the future. Then, based on the data collected during each stage of the design process, an optimisation process was suggested to improve the overall performance of the system, using computer aided design and modelling (CAD/CAM) tools to generate, analyse and optimise the design

SIMULATION-BASED DECISION MODEL TO CONTROL DYNAMIC MANUFACTURING REQUIREMENTS: APPLICATION OF GREY FORECASTING - DQFD

Manufacturing systems have to adapt to changing requirements of their internal and external customers. In fact, new requirements may appear unexpectedly and may change multiple times. Change is a straightforward reality of production, and the engineer has to deal with the dynamic work environment. In this perspective, this paper proposes a decision model in order to fit actual and future processes’ needs. The proposed model is based on the dynamic quality function deployment (DQFD), grey forecasting model GM (1,1) and the technique for order preference by similarity to ideal solution (TOPSIS). The cascading QFD-based model is used to show the applicability of the proposed methodology. The simulation results illustrate the effect of the manufacturing needs changes on the strategic, operational and technical improvements

RMS capacity utilisation: product family and supply chain

yesThe paper contributes to development of RMS through linkage with external stakeholders such as customers and suppliers of parts/raw materials to handle demand fluctuations that necessitate information sharing across the supply chain tiers. RMS is developed as an integrated supply chain hub for adjusting production capacity using a hybrid methodology of decision trees and Markov analysis. The proposed Markov Chain model contributes to evaluate and monitor system reconfigurations required due to changes of product families with consideration of the product life cycles. The simulation findings indicate that system productivity and financial performance in terms of the profit contribution of product-process allocation will vary over configuration stages. The capacity of an RMS with limited product families and/or limited model variants becomes gradually inoperative whilst approaching upcoming configuration stages due to the end of product life cycles. As a result, reconfiguration preparation is suggested quite before ending life cycle of an existing product in process, for switching from a product family to a new/another product family in the production range, subject to its present demand. The proposed model is illustrated through a simplified case study with given product families and transition probabilities

Cellular manufacturing system evolution from group technology to a reconfigurable manufacturing system: A case study of a dynamic cellular manufacturing system (DCMS) in an electromechanical assembly industry

This chapter defines some characteristics of the Cellular Manufacturing System (CMS), and explores the most important features from the literature and the practices that can be used to develop a Dynamic Cellular Manufacturing System (DCMS). The possibility of system reconfiguration makes those new systems the most efficient in the presence of a dynamic environment. The main objective of this study is to assist decision makers and/or designers in choosing one of the most appropriate layouts using the DCMS. This task becomes more difficult because it is usually associated with many other decisions like production planning and resource allocation. By the end of this chapter, a case study related to the implementation of a DCMS in the electromechanical assembly industry will be presented. © 2018 by Nova Science Publishers, Inc. All rights reserved

Aggregate Cost Model for Scalability in Manufacturing Systems

Manufacturing continues to face escalated cost challenges on a global scale. To gain a competitive advantage among their rivals, manufacturing firms continuously strive to lower their manufacturing costs than their competitors. This dissertation introduces mathematical optimization model based on an Activity-Based Costing (ABC) method, which considers the relationship between hourly rates and annual hours on each machine/workcentre. Several constraints are considered in the proposed models, such as the cost of reconfiguration, capacity, available machining hours, a decision on facility expansion and a cost-benefit analysis on industry 4.0 implementation. The model outputs are the optimum hourly rates, deciding which jobs to accept or reject, and determining reconfiguration\u27s financial feasibility. Reconfiguration in this dissertation describes system-level reconfiguration (investing in additional equipment/machinery) and/or machine-level reconfiguration (extra module to a piece of existing equipment) as well as factory-level (in terms of expanding additional factory segments to the existing facility). The model will be applied to a real-life case study of a global original equipment manufacturer (OEM) of machinery. The mathematical models proposed in this dissertation are developed based on a multinational hydraulic-press manufacturing company. The company owns a local machine shop (one of the sister companies in North America) for building hydraulic presses meant to be delivered to companies producing engineered wood products (such as OSB (oriented Strand Board), PB (Particle Board), and MDF Board (Medium-Density Fibre) …etc.). The sister company in North America occupies a footprint of 5,000 meters squared with a number of capabilities such as machining (turning and machining centres, welding, assembly, material handling…etc.). Several aspects of the model proposed in this dissertation had been implemented in the company such as the bi-directional relationship between total hours and hourly rates which assisted the company in gaining more jobs and projects. In addition, connectivity between strategic suppliers and company branched has been established (enabler of Industry 4.0). The proposed model\u27s novelty incorporates the bi-directional relationship between hourly rates and annual hours in each workcentre. It provides a managerial decision-making tool for the investment level required to pursue new business and gaining a competitive advantage over rivals. Furthermore, a cost-benefit analysis is performed on the implementation of Industry 4.0. The primary aspect considered in industry 4.0 is Information Communication Technology (ICT) infrastructure with strategic suppliers to intensify interconnection between the manufacturing firm and the strategic suppliers. This research\u27s significance is focused on cost analysis and provides managers in manufacturing facilities with the required decision-making tools to decide on orders to accept or decline, as well as investing in additional production equipment, facility expansion, as well as Industry 4.0. In addition, this research will also help manufacturing companies achieve a competitive edge among rivals by reducing hourly rates within their facility. Furthermore, the implementation of the model reduced hourly rates for workcentres by up to 25% as a result of accepting more jobs (and accordingly, machining hours) on the available workcentres, and hence, reducing the hourly rates. This implementation has helped the company gain a competitive advantage among rivals since pricing of products submitted to customer was reduced. Additional benefits and significance are (1) providing manufacturing companies with a method to quantify the decision-making process for right-sizing their manufacturing space, (2) the ability to justify growing a scalable system (machine level, system-level and factory level) using costing (not customer demand), (3) expanding market share and, (4) reducing operational cost and allowing companies a numerical model to justify scaling the manufacturing system

Technologies to develop technology: the impact of new technologies on the organisation of the innovation process.

Companies are under increasing pressure to develop new product more effectively and efficiently. In order to meet this challenge, the organisation of the new product development process has received ample attention both in the academic literature and in the practitioner literature. As a consequence, a myriad of methods to design new products has been developed. These methods aim at facilitating concurrent product design and engineering. However, it is only recently, through the advent of families of new design technologies, that concurrency really becomes possible. In this paper, research on the impact of new design technologies on the product development process is reported and discussed. It is demonstrated that these technologies can have a significant impact on the organisation of innovation processes.Processes;