Intelligent systems in manufacturing: current developments and future prospects

Global competition and rapidly changing customer requirements are demanding increasing changes in manufacturing environments. Enterprises are required to constantly redesign their products and continuously reconfigure their manufacturing systems. Traditional approaches to manufacturing systems do not fully satisfy this new situation. Many authors have proposed that artificial intelligence will bring the flexibility and efficiency needed by manufacturing systems. This paper is a review of artificial intelligence techniques used in manufacturing systems. The paper first defines the components of a simplified intelligent manufacturing systems (IMS), the different Artificial Intelligence (AI) techniques to be considered and then shows how these AI techniques are used for the components of IMS

Complex low volume electronics simulation tool to improve yield and reliability

Assembly of Printed Circuit Boards (PCB) in low volumes and a high-mix requires a level of manual intervention during product manufacture, which leads to poor first time yield and increased production costs. Failures at the component-level and failures that stem from non-component causes (i.e. system-level), such as defects in design and manufacturing, can account for this poor yield. These factors have not been incorporated in prediction models due to the fact that systemfailure causes are not driven by well-characterised deterministic processes. A simulation and analysis support tool being developed that is based on a suite of interacting modular components with well defined functionalities and interfaces is presented in this paper. The CLOVES (Complex Low Volume Electronics Simulation) tool enables the characterisation and dynamic simulation of complete design; manufacturing and business processes (throughout the entire product life cycle) in terms of their propensity to create defects that could cause product failure. Details of this system and how it is being developed to fulfill changing business needs is presented in this paper. Using historical data and knowledge of previous printed circuit assemblies (PCA) design specifications and manufacturing experiences, defect and yield results can be effectively stored and re-applied for future problem solving. For example, past PCA design specifications can be used at design stage to amend designs or define process options to optimise the product yield and service reliability

TAO Conceptual Design Report: A Precision Measurement of the Reactor Antineutrino Spectrum with Sub-percent Energy Resolution

The Taishan Antineutrino Observatory (TAO, also known as JUNO-TAO) is a satellite experiment of the Jiangmen Underground Neutrino Observatory (JUNO). A ton-level liquid scintillator detector will be placed at about 30 m from a core of the Taishan Nuclear Power Plant. The reactor antineutrino spectrum will be measured with sub-percent energy resolution, to provide a reference spectrum for future reactor neutrino experiments, and to provide a benchmark measurement to test nuclear databases. A spherical acrylic vessel containing 2.8 ton gadolinium-doped liquid scintillator will be viewed by 10 m^2 Silicon Photomultipliers (SiPMs) of >50% photon detection efficiency with almost full coverage. The photoelectron yield is about 4500 per MeV, an order higher than any existing large-scale liquid scintillator detectors. The detector operates at -50 degree C to lower the dark noise of SiPMs to an acceptable level. The detector will measure about 2000 reactor antineutrinos per day, and is designed to be well shielded from cosmogenic backgrounds and ambient radioactivities to have about 10% background-to-signal ratio. The experiment is expected to start operation in 2022

Relationship between significant construction safety parameters and on site safety performance of high rise building in Karachi, Sindh Province, Pakistan

Pakistan is a developing country that is currently enjoying relatively substantial growth in construction activities. Unfortunately, Pakistan’s construction industry suffers from poor occupational safety and health (OSH) conditions. The framework of the existing OSH conditions is fragmented and inadequately enforced, making construction sites more hazardous. Therefore, it is essential to improve OSH conditions in order to improve safety performance in building construction. Thus, this research aims to find those significant safety parameters which can significantly enhance the onsite safety performance of high-rise building construction. Based on an extensive literature review, sixty (60) safety parameters for enhancing onsite safety performance have been identified and classified into fourteen (14) groups. In addition, this study also adopted a quantitative approach, whereby a questionnaire survey was carried out on two hundred and ten (210) respondents working in high-rise construction projects in Karachi city of Sindh Province, in order to determine the most significant safety parameters out of all the identified safety parameters. Initially, data analysis using SPSS version 26 found that 38 out of 60 safety parameters were the most significant safety parameters for enhancing onsite safety performance. Furthermore, the results from principal component factor analysis provided evidence for the eight (08) groups, consisting of 56 significant safety parameters accounting for 74.686% of the shared variance. Finally, correlation analysis results revealed that the 08 groups comprising 56 significant safety parameters exhibit small and medium (range from rs=0.247 to rs=0.334) correlation with onsite safety performance of high-rise building construction. This empirical analysis has provided a new framework of significant safety parameters for enhancing onsite safety performance of high-rise building construction. Therefore, focusing on these safety parameters would improve the employees’ safety, which will then enhance the overall safety performance on highrise construction projects. It is hoped that this research can positively benefit the Pakistani construction industry in enhancing the onsite safety performance of highrise buildings construction

Multi-Criteria Optimal Planning for Energy Policies in CLP

In the policy making process a number of disparate and diverse issues such as economic development, environmental aspects, as well as the social acceptance of the policy, need to be considered. A single person might not have all the required expertises, and decision support systems featuring optimization components can help to assess policies. Leveraging on previous work on Strategic Environmental Assessment, we developed a fully-fledged system that is able to provide optimal plans with respect to a given objective, to perform multi-objective optimization and provide sets of Pareto optimal plans, and to visually compare them. Each plan is environmentally assessed and its footprint is evaluated. The heart of the system is an application developed in a popular Constraint Logic Programming system on the Reals sort. It has been equipped with a web service module that can be queried through standard interfaces, and an intuitive graphic user interface.Comment: Accepted at ICLP2014 Conference as Technical Communication, due to appear in Theory and Practice of Logic Programming (TPLP

Design and Realization of Electronic Measurement Systems for Partial Discharge Monitoring on Electrical Equipment

The monitoring of insulations that composing high voltage apparatus and electrical machines is a crucial aspect for a predictive maintenance program. The insulation system of an electrical machine is affected by partial discharges (PDs), phenomena that can lead to the breakdown in a certain time, with a consequent and significant economic loss. Partial discharges are identified as both the symptom and the cause of a deterioration of solid-type electrical insulators. Thus, it is necessary to adopt solutions for monitoring the insulation status. To do this, different techniques and devices can be adopted. During this research activity, two different systems have been developed at the circuit and layout level, which base their operation respectively on the conducted and on the irradiated measurement, in compliance with the provisions of current standards, if foreseen. The first system is based on the use of a classic signal conditioning chain in which gain value can be set through PC control, allowing the conducted measurement of partial discharges in two frequency bands, Low Frequency (LF) and High Frequency (HF). Based on these bands, the application of the system is diversified. In this case, the information obtained from the measurement can be analysed by an expert operator or processed by an intelligent system, obtaining in both cases information on the status of the machine under test. The second makes use of a UHF antenna built on PCB, which takes care of detecting the irradiated signal generated in the presence of discharge activity, which is then appropriately conditioned and processed by analog electronics, to then be acquired through a programmable logic, which interprets it and returns information on the status of the machine, which can also be checked by an expert user. The application of this system is linked to the type of insulation and the type of power supply adopted, which differentiate its characteristics. In both systems, the analysis of the measurement of partial discharges is suitable for the prevention of failures and the planning of suitable maintenance interventions

A Fuzzy Inference System Approach for Evaluating the Feasibility of Product Remanufacture

In the recent past, efforts have been made in enhancing sustainable manufacturing aimed at protecting the environment and saving natural resources. Among the efforts that have been explored include strategies to ensure responsible end-of-life product management so as reduce the impact on the environment and achieve effective use of resources. Towards this end, reduce, reuse and recycle product disposal strategies have found a lot of consideration in manufacturing. Of the product reuse strategies, remanufacturing has been widely applied owing to its unique feature of rendering the remanufactured product as good as new. For remanufacturers, this strategy leads to provision of quality products comparable to new their new counterparts at a reduced cost. Remanufacturing also leads to a sustainable environment through energy and material savings, as well as minimized solid wastes. Remanufacturing however, poses challenges related to collection of the returns or cores, manufacturing process planning, resource allocation, warranty estimation and redistribution. These challenges are due to product and process complexities, customer requirements, and uncertainties associated with product take back and the remanufactured products’ market-base. Key among these challenges is the remanufacturing process which is complicated, labor intensive with varying process times. In most cases the routing of these processes is stochastic in nature, based on the condition of the returned product. There is also the negative perception among consumers that remanufactured products are less superior to new ones, which calls for the need to allocate preferably longer warranty periods for the remanufactured product to induce confidence in the consumer while at the same time keeping the warranty costs low. The objectives of this study were informed by challenges faced by a local remanufacturing firm. They include: (1) a detailed study of the current remanufacturing process of the firm’s products; (2) identification of bottlenecks in the process to make recommendations for improvement; (3) develop a decision support system for assessing product remanufacture; (4) assess warranty allocation options for remanufactured product reuse. The study revealed that there are bottlenecks in the current remanufacturing process and suggested an improvement to enhance efficiency. This bottlenecks include overutilization of some of the process centers such as the diagnostic testing and the after-repair testing centers which lead to the product spending more time in the system than necessary. To improve the system performance the capacities of the bottleneck centers were increased which yielded significant reduction in the time the product spends in the system. The key contribution of this dissertation is the development of a decision support system based on a bi-level fuzzy linguistic computing approach. This model integrates qualitative and quantitative product attributes in determining the remanufacturability of a product. The fuzzy-based model established remanufacturability metric, herein referred to as an index, is applied to assess the feasibility of remanufacturing two products that were used as a case study. A number of warranty scenarios are considered to ascertain the impact of different warranty periods on the cost of warranty. The results show that the additional warranty cost for product reuse is a function of the period of first use and the residual life of the produc

A modular hybrid simulation framework for complex manufacturing system design

For complex manufacturing systems, the current hybrid Agent-Based Modelling and Discrete Event Simulation (ABM–DES) frameworks are limited to component and system levels of representation and present a degree of static complexity to study optimal resource planning. To address these limitations, a modular hybrid simulation framework for complex manufacturing system design is presented. A manufacturing system with highly regulated and manual handling processes, composed of multiple repeating modules, is considered. In this framework, the concept of modular hybrid ABM–DES technique is introduced to demonstrate a novel simulation method using a dynamic system of parallel multi-agent discrete events. In this context, to create a modular model, the stochastic finite dynamical system is extended to allow the description of discrete event states inside the agent for manufacturing repeating modules (meso level). Moreover, dynamic complexity regarding uncertain processing time and resources is considered. This framework guides the user step-by-step through the system design and modular hybrid model. A real case study in the cell and gene therapy industry is conducted to test the validity of the framework. The simulation results are compared against the data from the studied case; excellent agreement with 1.038% error margin is found in terms of the company performance. The optimal resource planning and the uncertainty of the processing time for manufacturing phases (exo level), in the presence of dynamic complexity is calculated

Advancement in robot programming with specific reference to graphical methods

This research study is concerned with the derivation of advanced robot programming methods. The methods include the use of proprietary simulation modelling and design software tools for the off-line programming of industrial robots. The study has involved the generation of integration software to facilitate the co-operative operation of these software tools. The three major researcli'themes7of "ease of usage", calibration and the integration of product design data have been followed to advance robot programming. The "ease of usage" is concerned with enhancements in the man-machine interface for robo t simulation systems in terms of computer assisted solid modelling and computer assisted task generation. Robot simulation models represent an idealised situation, and any off-line robot programs generated from'them may contain'discrepancies which could seriously effect thq programs' performance; Calibration techniques have therefore been investigated as 'a method of overcoming discrepancies between the simulation model and the real world. At the present time, most computer aided design systems operate as isolated islands of computer technology, whereas their product databases should be used to support decision making processes and ultimately facilitate the generation of machine programs. Thus the integration of product design data has been studied as an important step towards truly computer integrated manufacturing. The functionality of the three areas of study have been generalised and form the basis for recommended enhancements to future robot programming systems

Product life cycle information management in the electronics supply chain

Information availability and data transparency are key requirements from manufacturers when supporting products throughout the life cycle, for example when implementing product service systems. The application of embedded wireless technologies into printed circuit boards (PCBs) can help bridging current knowledge gaps and to minimise both technical and financial risk through reduced product downtime, improved quality of tracking and enhanced end-of-life decision making. The application of embedded RFID into PCBs for life cycle monitoring of electronic products to support Product Service Systems is discussed in this paper