Energy efficiency in discrete-manufacturing systems: insights, trends, and control strategies

Since the depletion of fossil energy sources, rising energy prices, and governmental regulation restrictions, the current manufacturing industry is shifting towards more efficient and sustainable systems. This transformation has promoted the identification of energy saving opportunities and the development of new technologies and strategies oriented to improve the energy efficiency of such systems. This paper outlines and discusses most of the research reported during the last decade regarding energy efficiency in manufacturing systems, the current technologies and strategies to improve that efficiency, identifying and remarking those related to the design of management/control strategies. Based on this fact, this paper aims to provide a review of strategies for reducing energy consumption and optimizing the use of resources within a plant into the context of discrete manufacturing. The review performed concerning the current context of manufacturing systems, control systems implemented, and their transformation towards Industry 4.0 might be useful in both the academic and industrial dimension to identify trends and critical points and suggest further research lines.Peer ReviewedPreprin

A strategy for achieving manufacturing statistical process control within a highly complex aerospace environment

This paper presents a strategy to achieve process control and overcome the previously mentioned industry constraints by changing the company focus to the process as opposed to the product. The strategy strives to achieve process control by identifying and controlling the process parameters that influence process capability followed by the implementation of a process control framework that marries statistical methods with lean business process and change management principles. The reliability of the proposed strategy is appraised using case study methodology in a state of the art manufacturing facility on Multi-axis CNC machine tools

The challenges for energy efficient casting processes

Casting is one of the oldest, most challenging and energy intensive manufacturing processes. A typical modern casting process contains six different stages, which are classified as melting, alloying, moulding, pouring, solidification and finishing respectively. At each stage, high level and precision of process control is required. The energy efficiency of casting process can be improved by using novel alterations, such as the Constrained Rapid Induction Melting Single Shot Up-casting process. Within the present study the energy consumption of casting processes is analyzed and areas were great savings can be achieved are discussed. Lean thinking is used to identify waste and to analyse the energy saving potential for casting industry

Integrated Environmental Process Planning for the Design & Manufacture of Automotive Components

Advanced Product Quality Planning (APQP) logic is widely used by manufacturers for the design and manufacture of automotive components. Manufacturers are increasingly finding difficulties to incorporate environmental considerations in the broad range of products that they manufacture. Therefore, there is a need for a systematic method for environmental process planning to evaluate product configurations and their associated environmental impact. The framework and models discussed in this paper can deal with a variety of product characteristics and environmental impacts through a selection of Environmental Performance Indicators (EPIs) for a final product configuration. The framework and models have been applied in a real-life application and have proven that changes in product design or process selection can reduce the product's environmental impact and increase process efficiency. Hence, manufacturers can use the framework and models during the Advanced Product Quality Planning (APQP) process to benchmark each product variation that they manufacture in a standardised manner and realise cost saving opportunities