Disassembly Planning and Costing Through Petri Net Approach

In the current consumer oriented environment, many new products appear in the market almost on a daily basis. Lured by advertisements and tempted by new product features, customers are constantly purchasing newer products. Acquiring newer products for often leads to throwing out older ones, but it is a totally different story for manufacturers. They need to consider the best way to reuse a product both for economic purposes and for environmental protection. Considerations for them often include: how to minimize total disassembly cost, how to achieve the lowest total disassembly time at each processing step, and how to sort valuable parts from hazardous parts as early as possible during the disassembly procedure. In this paper, we use a Disassembly Petri-Net (DPN) to generate the Disassembly Process Plan (DPP). This plan is a sequence of disassembly tasks from the initial stage of the whole product to the final stage where each part is separated from the other parts. This disassembly plan is very valuable for product recycling or remanufacturing. Prior to having the DPN, we apply an algorithm to generate a Disassembly Precedence Matrix (DPM) helped by the construction steps involved in SolidWorks™, a solid model software used to create the part in the first place. From the DPN, we find all feasible paths and generate the corresponding costs of disassembly based upon tool changes, changes in direction of the movement and individual part characteristics (e.g. hazardous components and recycle component). Cost data was extracted from previously published studies by Boothroyd et al. to obtain the handling time and disassembly time. Afterwards, we developed the optimal or near-optimal DPP for the best time and cost based disassembly options. In summary, this paper presents a systematic method to disassemble a part into its individual components and provides a cost figure for doing so. This is in contrast with many studies reported in the literature in that they concentrate either on a measure of disassembly complexity, or even if cost is presumably the driving force, their costs are arbitrary costs based on pre-selected values for such things as tool change penalty, disassembly direction change penalty or penalty for delaying removal of hazardous materials. In this paper, we are using disassembly times based on experimental work and/or industrial experience. Given the correct labor rate, our cost evaluation indeed yields a realistic cost value

Disassembly process planning using Bayesian network

The management of end-of-life systems becomes more and more important due to the awareness of their environmental impact. In this context, the disassembly process requires more attention with the ultimate goal to make profit. In this paper, we propose a new approach to determine optimal disassembly plan of an end-of-life system by using bayesian network. To take advantage of some existing approaches that use Petri Net to model such process, a Petri Net model is first established and then translated to Bayesian Network in order to take into account inevitable uncertainties associated to such process

Integration of warranty as a decision variable in the process of recertification of parts resulting from end-of-life system dismantling

In this paper, a new approach to determine optimal disassembly plan of an end-of-life system by using Bayesian network is introduced. The best solution is called the optimal trajectory. A trajectory model is proposed which allows handling the different key factors and also makes it possible to manage uncertainties specific to system deconstruction. After having presented the disassembly planning issue, Bayesian networks instantiated to dismantling problem are introduced together with the influence diagram which allow the decision maker to proceed to the economic assessment of the different possible strategies. Among the various cost factors is the cost related to warranty of the recycled products. A warranty program management is described. Eventually, the global trajectory model, including the implementation of the warranty cost has a decision variable, is presented

Modeling, design and scheduling of computer integrated manufacturing and demanufacturing systems

This doctoral dissertation work aims to provide a discrete-event system-based methodology for design, implementation, and operation of flexible and agile manufacturing and demanufacturing systems. After a review of the current academic and industrial activities in these fields, a Virtual Production Lines (VPLs) design methodology is proposed to facilitate a Manufacturing Execution System integrated with a shop floor system. A case study on a back-end semiconductor line is performed to demonstrate that the proposed methodology is effective to increase system throughput and decrease tardiness. An adaptive algorithm is proposed to deal with the machine failure and maintenance. To minimize the environmental impacts caused by end-of-life or faulty products, this research addresses the fundamental design and implementation issues of an integrated flexible demanufacturing system (IFDS). In virtue of the success of the VPL design and differences between disassembly and assembly, a systematic approach is developed for disassembly line design. This thesis presents a novel disassembly planning and demanufacturing scheduling method for such a system. Case studies on the disassembly of personal computers are performed illustrating how the proposed approaches work

Optimal and intelligent decision making in sustainable development of electronic products

Increasing global population and consumption are causing declining natural and social systems. Multi-lifecycle engineering and sustainable development address these issues by integrating strategies for economic successes, environmental quality, and social equity. Based on multi-lifecycle engineering and sustainable development concepts, this doctoral dissertation aims to provide decision making approaches to growing a strong industrial economy while maintaining a clean, healthy environment. The research develops a methodology to complete both the disassembly leveling and bin assignment decisions in demanufacturing through balancing the disassembly efforts, value returns, and environmental impacts. The proposed method is successfully implemented into a demanufacturing module of a Multi-LifeCycle Assessment and Analysis tool. The methodology is illustrated by a computer product example. Since products during the use stage may experience very different conditions, their external and internal status can vary significantly. These products, when coming to a demanufacturing facility, are often associated with incomplete/imprecise information, which complicates demanufacturing process decision making. In order to deal with uncertain information, this research proposes Fuzzy Reasoning Petri nets to model and reason knowledge-based systems and successfully applies them to demanufacturing process decision making to obtain the maximal End-of-Life (BOL) value from discarded products. Besides the BOL management of products by means of product/material recovery to decrease environmental impacts, the concepts of design for environment and sustainable development are investigated. Based on Sustainability Target Method, a sensitivity analysis decision-making method is proposed. It provides a company with suggestions to improve its product\u27s sustainability in the most cost-effective manner

Génération des séquences de désassemblage et leur évaluation : Intégration dans un environnement de réalité virtuelle

Integration of disassembly operations during product design is an important issue today. It is estimated that at the earliest stages of product design, the cost of disassembly operations almost represents 30 % of its total cost. Nowadays, disassembly operation simulation of industrial products finds a strong interest in interactive simulations through immersive and real-time schemes. In this context, in the first place, this thesis presents a method for generating the feasible disassembly sequences for selective disassembly. The method is based on the lowest levels of a disassembly product graph. Instead of considering the geometric constraints for each pair of components, the proposed method considers the geometric contact and collision relationships among the components in order to generate the so-called Disassembly Geometry Contacting Graph (DGCG). The latter is then used for disassembly sequence generation thus allowing the number of possible sequences to be reduced by ignoring any components which are unrelated to the target. A simulation framework was developed integrated in a Virtual reality environment thus allowing generating the minimum number of possible disassembly sequences. Secondly, a method for disassembly operation evaluation by 3D geometric removability analysis in a Virtual environment is proposed. It is based on seven new criteria which are: visibility of a part, disassembly angles, number of tools' changes, path orientation changing, sub-assembly stability, neck score and bending score. All criteria are presented by dimensionless coefficients automatically calculated, thus allowing evaluating disassembly sequences complexity. For this purpose, a mixed virtual reality disassembly environment (VRDE) is developed based on Python programming language, utilizing VTK (Visualization Toolkit) and ODE (Open Dynamics Engine) libraries. The framework is based on STEP, WRL and STL exchange formats. The analysis results and findings demonstrate the feasibility of the proposed approach thus providing significant assistance for the evaluation of disassembly sequences during Product Development Process (PDP). Further consequences of the present work consist in ranking the criteria according to their importance. For this purpose, moderation coefficients may be allocated to each of them thus allowing a more comprehensive evaluating method.De nos jours, l'intégration des opérations de désassemblage lors de la conception des produits est un enjeu crucial. On estime que dans la phase initiale de la conception d'un produit, le coût des opérations de désassemblage représente environ 30% de son coût total. Ainsi, la simulation des opérations de désassemblage de produits industriels trouve un fort intérêt pour des simulations interactives grâce à des programmes d'immersion et en temps réel. Dans ce contexte, dans un premier temps, cette thèse présente une méthode de génération des séquences de désassemblage possibles pour le désassemblage sélectif. La méthode est basée sur les niveaux les plus bas du graphe de désassemblage des produits. Au lieu de considérer les contraintes géométriques pour chaque paire de composants, la méthode proposée tient compte des contacts (relations géométriques entre les composants) et des collisions afin de générer le Graphe Géométrique de Contacts et de Désassemblage (DGCG). Celui-ci est ensuite utilisé pour la génération des séquences de désassemblage permettant ainsi de réduite le nombre de séquences possibles en ignorant les composants non liés avec la cible. Une application de simulation a été développée, intégrée dans un environnement de réalité virtuelle (RV) permettant ainsi la génération du nombre minimum de séquences possibles de désassemblage.Dans un second temps, une méthode d'évaluation des opérations de désassemblage par analyse géométrique 3D de l'amovibilité dans un environnement RV est proposée. Elle est basée sur sept nouveaux critères qui sont: la visibilité d'une pièce, les angles de désassemblage, le nombre des changements d'outils, le changement d'orientation des trajectoires, la stabilité des sous-ensembles, les angles de rotation du cou et flexion du corps. Tous ces critères sont présentés par des coefficients sans dimension calculés automatiquement par l'application développée, permettant ainsi d'évaluer la complexité des séquences de désassemblage. A cet effet, un environnement mixte de réalité virtuelle pour le désassemblage (VRDE) est développé, basé sur le langage de programmation Python, en utilisant deux bibliothèques : VTK (Visualisation Toolkit) et ODE (Open Dynamics Engine), les formats d'échange étant fichiers: STEP, WRL et STL. L'analyse des résultats obtenus démontrent la fiabilité de l'approche proposée fournissant ainsi une aide non négligeable pour l'évaluation des séquences de désassemblage lors de processus de développement de produits (PDP). Les autres conséquences de ce travail consistent à classer les critères en fonction de leur importance. A cet effet, des coefficients de modération peuvent être attribués à chacun d'eux permettant ainsi une méthode d'évaluation plus complète

Equilibrado de líneas de montaje de productos voluminosos

Preprin

Intelligent Business Process Optimization for the Service Industry

The company's sustainable competitive advantage derives from its capacity to create value for customers and to adapt the operational practices to changing situations. Business processes are the heart of each company. Therefore process excellence has become a key issue. This book introduces a novel approach focusing on the autonomous optimization of business processes by applying sophisticated machine learning techniques such as Relational Reinforcement Learning and Particle Swarm Optimization