Advanced Numerical Modeling in Manufacturing Processes

In manufacturing applications, a large number of data can be collected by experimental studies and/or sensors. This collected data is vital to improving process efficiency, scheduling maintenance activities, and predicting target variables. This dissertation explores a wide range of numerical modeling techniques that use data for manufacturing applications. Ignorance of uncertainty and the physical principle of a system are shortcomings of the existing methods. Besides, different methods are proposed to overcome the shortcomings by incorporating uncertainty and physics-based knowledge. In the first part of this dissertation, artificial neural networks (ANNs) are applied to develop a functional relationship between input and target variables and process parameter optimization. The second part evaluates the robust response surface optimization (RRSO) to quantify different sources of uncertainty in numerical analysis. Additionally, a framework based on the Bayesian network (BN) approach is proposed to support decision-making. Due to various uncertainties, estimating interval and probability distribution are often more helpful than deterministic point value estimation. Thus, the Monte Carlo (MC) dropout-based interval prediction technique is explored in the third part of this dissertation. A conservative interval prediction technique for the linear and polynomial regression model is also developed using linear optimization. Applications of different data-driven methods in manufacturing are useful to analyze situations, gain insights, and make essential decisions. But, the prediction by data-driven methods may be physically inconsistent. Thus, in the fourth part of this dissertation, a physics-informed machine learning (PIML) technique is proposed to incorporate physics-based knowledge with collected data for improving prediction accuracy and generating physically consistent outcomes. Each numerical analysis section is presented with case studies that involve conventional or additive manufacturing applications. Based on various case studies carried out, it can be concluded that advanced numerical modeling methods are essential to be incorporated in manufacturing applications to gain advantages in the era of Industry 4.0 and Industry 5.0. Although the case study for the advanced numerical modeling proposed in this dissertation is only presented in manufacturing-related applications, the methods presented in this dissertation is not exhaustive to manufacturing application and can also be expanded to other data-driven engineering and system applications

Evaluation and Selection of the Quality Methods for Manufacturing Process Reliability Improvement-Intuitionistic Fuzzy Sets and Genetic Algorithm Approach

The aim of this research is to propose a hybrid decision-making model for evaluation and selection of quality methods whose application leads to improved reliability of manufacturing in the process industry. Evaluation of failures and determination of their priorities are based on failure mode and effect analysis (FMEA), which is a widely used framework in practice combining with triangular intuitionistic fuzzy numbers (TIFNs). The all-existing uncertainties in the relative importance of the risk factors (RFs), their values, applicability of the quality methods, as well as implementation costs are described by pre-defined linguistic terms which are modeled by the TIFNs. The selection of quality methods is stated as the rubber knapsack problem which is decomposed into subproblems with a certain number of solution elements. The solution of this problem is found by using genetic algorithm (GA). The model is verified through the case study with the real-life data originating from a significant number of organizations from one region. It is shown that the proposed model is highly suitable as a decision-making tool for improving the manufacturing process reliability in small and medium enterprises (SMEs) of process industry

Evaluation and Selection of the Quality Methods for Manufacturing Process Reliability Improvement-Intuitionistic Fuzzy Sets and Genetic Algorithm Approach

The aim of this research is to propose a hybrid decision-making model for evaluation and selection of quality methods whose application leads to improved reliability of manufacturing in the process industry. Evaluation of failures and determination of their priorities are based on failure mode and effect analysis (FMEA), which is a widely used framework in practice combining with triangular intuitionistic fuzzy numbers (TIFNs). The all-existing uncertainties in the relative importance of the risk factors (RFs), their values, applicability of the quality methods, as well as implementation costs are described by pre-defined linguistic terms which are modeled by the TIFNs. The selection of quality methods is stated as the rubber knapsack problem which is decomposed into subproblems with a certain number of solution elements. The solution of this problem is found by using genetic algorithm (GA). The model is verified through the case study with the real-life data originating from a significant number of organizations from one region. It is shown that the proposed model is highly suitable as a decision-making tool for improving the manufacturing process reliability in small and medium enterprises (SMEs) of process industry

Methods to Measure Importance of Data Attributes to Consumers of Information Products

Errors in data sources of information product (IP) manufacturing systems can degrade overall IP quality as perceived by consumers. Data defects from inputs propagate throughout the IP manufacturing process. Information Quality (IQ) research has focused on improving the quality of inputs to mitigate error propagation and ensure an IP will be fit for use by consumers. However, the feedback loop from IP consumers to IP producers is often incomplete since the overall quality of the IP is not based solely on quality of inputs but rather by the IP’s fitness for use as a whole. It remains uncertain that high quality inputs directly correlate to a high quality IP. The methods proposed in this paper investigate the effects of intentionally decreasing, or disrupting, quality of inputs, measuring the consumers\u27 evaluations as compared to an undisrupted IP, and proposes scenarios illustrating the advantage of these methods over traditional survey methods. Fitness for use may then be increased using those attributes deemed “important” by consumers in future IP revisions

A Comparison of Manufacturing Methods, Accuracy, Quality Control and Testing Methods a They Relate to High Head Low Flow Impeller Efficiency and Overall Compressor Performance

LectureThis paper presents a detailed analysis and evaluation of impeller efficiency and overall compressor performance as they relate to specific impeller manufacturing methods, manufacturing tolerances, and quality control. The manufacturing process used in the construction of an impeller has a direct influence on the impeller’s performance The authors explain and compare different manufacturing methods and introduce the Taguchi Method Application as an available tool for statistical evaluation of key manufacturing parameters influence on impeller performance. As a best practice, manufacturing techniques for one piece impeller production are presented. In the case of high pressure centrifugal compressor applications with very narrow tip width impellers, and corrosive gas applications requiring special materials, EDM (Electrical Discharge Machining) and ECM (Electrolytic Machining) can be applied as a manufacturing process to improve quality control over conventional manufacturing methods. In response to a compressor performance discrepancy encountered during OEM FAT, a review was initiated into improving quality control and performance prediction based on enhanced impeller manufacturing processes for narrow tip width impellers. In this analysis, two compressor rotors are evaluated and compared; the first using traditional, two piece welded impellers and the second with one piece impellers machined via EDM and ECM. The resulting data from both series of tests suggests a significant improvement in individual impeller performance, as well as overall compressor performance for the single piece impeller compared to the two piece impeller

Model-based observer proposal for surface roughness monitoring

Comunicación presentada a MESIC 2019 8th Manufacturing Engineering Society International Conference (Madrid, 19-21 de Junio de 2019)In the literature, many different machining monitoring systems for surface roughness and tool condition have been proposed and validated experimentally. However, these approaches commonly require costly equipment and experimentation. In this paper, we propose an alternative monitoring system for surface roughness based on a model-based observer considering simple relationships between tool wear, power consumption and surface roughness. The system estimates the surface roughness according to simple models and updates the estimation fusing the information from quality inspection and power consumption. This monitoring strategy is aligned with the industry 4.0 practices and promotes the fusion of data at different shop-floor levels

A Preliminary Study of Applying Lean Six Sigma Methods to Machine Tool Measurement

Many manufacturers aim to increase their levels of high-quality production in order to improve their market competitiveness. Continuous improvement of maintenance strategies is a key factor to be capable of delivering high quality products and services on-time with minimal operating costs. However, the cost of maintaining quality is often perceived as a non-added-value task. Improving the efficiency and effectiveness of the measurement procedures necessary to guarantee accuracy of production is a more complex task than many other maintenance functions and so deserves particular analysis. This paper investigates the feasibility of producing a concise yet effective framework that will provide a preliminary approach for integrating Lean and Six Sigma philosophies to the specific goal of reducing unnecessary downtime on manufacturing machines while maintaining its ability to machine to the required tolerance. The purpose of this study is to show how a Six Sigma infrastructure is used to investigate the root causes of complication occurring during the machine tool measurement. This work recognises issues of the uncertainty of data, and the measurement procedures in parallel with the main tools of Six Sigma’s Define-Measure-Analyse-Improve-Control (DMAIC). The significance of this work is that machine tool accuracy is critical for high value manufacturing. Over-measuring the machine to ensure accuracy potentially reduces production volume. However, not measuring them or ignoring accuracy aspects possibly lead to production waste. This piece of work aims to present a lean guidance to lessen measurement uncertainties and optimise the machine tool benchmarking procedures, while adopting the DMAIC strategy to reduce unnecessary downtime

Applications of lean thinking: a briefing document

This report has been put together by the Health and Care Infrastructure Research and Innovation Centre (HaCIRIC) at the University of Salford for the Department of Health. The need for the report grew out of two main simple questions, o Is Lean applicable in sectors other than manufacturing? o Can the service delivery sector learn from the success of lean in manufacturing and realise the benefits of its implementation?The aim of the report is to list together examples of lean thinking as it is evidenced in the public and private service sector. Following a review of various sources a catalogue of evidence is put together in an organised manner which demonstrates that Lean principles and techniques, when applied rigorously and throughout an entire organization/unit, they can have a positive impact on productivity, cost, quality, and timely delivery of services

Leanness and agility as means for improving supply chains. A case study on Egypt

Supply chain management has received greater attention from the academics and the practitioners, however the literature review lacks a comprehensive view for supply chain management practices and how its members should act to contribute to its overall success (Li el at., 2005). In this era, where the business organisations are working in several challenging threats and opportunities, greater attention is given to supply chain management. Nowadays, companies are always searching for means to improve their supply chains. The main aim of this research is to show "how leanness and agility approaches can be used within the same enterprise as complementary means for improving its supply chain". To achieve this research objective, the research has provided an assessment and summarised the literature on the supply chain management, lean thinking and agility thinking including their importance; their definitions; their practices and the relationship between lean and agility. The resulted proposed framework deduced from the literature has been applied in the Egyptian Manufacturing Business to show the relationship between the agility principles, lean principles, entity performance and the successful supply chain

The potential of additive manufacturing in the smart factory industrial 4.0: A review

Additive manufacturing (AM) or three-dimensional (3D) printing has introduced a novel production method in design, manufacturing, and distribution to end-users. This technology has provided great freedom in design for creating complex components, highly customizable products, and efficient waste minimization. The last industrial revolution, namely industry 4.0, employs the integration of smart manufacturing systems and developed information technologies. Accordingly, AM plays a principal role in industry 4.0 thanks to numerous benefits, such as time and material saving, rapid prototyping, high efficiency, and decentralized production methods. This review paper is to organize a comprehensive study on AM technology and present the latest achievements and industrial applications. Besides that, this paper investigates the sustainability dimensions of the AM process and the added values in economic, social, and environment sections. Finally, the paper concludes by pointing out the future trend of AM in technology, applications, and materials aspects that have the potential to come up with new ideas for the future of AM explorations