Coupling of interactive manufacturing operations simulation and immersive virtual reality

This paper presents a novel general-purpose simulation analysis application that combines concurrent operations simulation with the advanced data interrogation and user interaction capabilities of immersive virtual reality systems. The application allows for interactive modification of the simulation parameters, while providing the users with the available simulation information by effectively placing the operator in the midst of the environment being simulated. The major contribution of this research is the total integration of the immersive virtual reality environment with the simulation, allowing users in the environment to interactively change the inputs to the simulation as it is running. Implementation and functionality details of the developed application are presented. The experience of using the application to analyze a manufacturing operation in a collaborative scenario is also discussed

The Integration of Process Planning and Shop Floor Scheduling in Small Batch Part Manufacturing

In this paper we explore possibilities to cut manufacturing leadtimes and to improve delivery performance in a small batch part manufacturing shop by integrating process planning and shop floor scheduling. Using a set of initial process plans (one for each order in the shop), we exploit a resource decomposition procedure to determine schedules to determine schedules which minimize the maximum lateness, given these process plans. If the resulting schedule is still unsatisfactory, a critical path analysis is performed to select jobs as candidates for alternative process plans. In this way, an excellent due date performance can be achieved, with a minimum of process planning and scheduling effort

A framework for a computer aided design system for product oriented manufacturing systems

In this paper we present a framework and an associated support system for the design of Product Oriented Manufacturing Systems (POMS). This includes the characterization and description of the structure and components of the support system, including database, user interface and knowledge base. The framework components are integrated into an organized system called CADS_POMS (Computer Aided Design System for POMS)

A computer aided design system for product oriented manufacturing systems reconfiguration

Product Oriented Manufacturing Systems (POMS) are systems designed for variable product demand markets, and dynamically reconfigured for the manufacture of a single type of product or a family of similar products at a time. POMS systems can take several forms and result from exploring the use of flexible resources, a variety of new design philosophies, technologies and approaches to manufacture, including Cellular, Lean, Agile, Quick Response and Fit Manufacturing. In this paper a computer aided design system for the design and reconfiguration of POMS is addressed. A characterization and description of the structure and components of the design system, including a database, a user interface and a knowledge base and the description of some important data sets, are presented

A simulation-based approach to decision support for lean practitioners

In today’s global competition, having a lean production system is a must for companies to remain competitive. By identifying and eliminating waste throughout a product’s entire value stream by means of a set of LM tools, companies are able to produce and assemble any product range in any order or quantity. In order to do these, personnel needs to have the expertise in deciding which LM tool to implement at the right time and on the right place. However, this expertise is not always available. Therefore, this paper proposes a simulation-based decision support (SDS) tool to assist the decision making in LM tool implementation. The SDS tool provides five functions through an interactive use of process simulation. The functions are layout, zoom-in/zoom-out, task status, Key Performance Indicators (KPI) status and R.A.G (Red, Amber and Green) status (quantifying waste). These functions are incorporated into a process model of coolant hose manufacturing (CHM) factory which was developed in this study. Layout function provides a bird’s eye view of the whole process model and shows how the manufacturing process runs with the flow of materials and products. Zoom-in/zoom-out function provides a detail view of manufacturing processes of the factory. For KPI and RAG status functions, examples of LM tool implementations are used to show how different parameters affect the outcome of manufacturing process. Bar charts of KPIs are also available during simulation. Feasibility study showed how SDS tool enhance the visual perception and analysis capabilities of lean practitioners through availability of specific functions in the simulation model. Hence, decisions in LM implementation could be made correctly and with increased confidence by lean practitioners

Assessment of VR Technology and its Applications to Engineering Problems

Virtual reality applications are making valuable contributions to the field of product realization. This paper presents an assessment of the hardware and software capabilities of VR technology needed to support a meaningful integration of VR applications in the product life cycle analysis. Several examples of VR applications for the various stages of the product life cycle engineering are presented as case studies. These case studies describe research results, fielded systems, technical issues, and implementation issues in the areas of virtual design, virtual manufacturing, virtual assembly, engineering analysis, visualization of analysis results, and collaborative virtual environments. Current issues and problems related to the creation, use, and implementation of virtual environments for engineering design, analysis, and manufacturing are also discussed

Brownfield Factory Layout Planning using Realistic Virtual Models

To stay competitive in an increasingly digitalised and global context, manufacturing companies need to increase productivity and decrease waste. This means their production systems must improve; something they can achieve in a multitude of ways. For example, increasing the level of automation, improving scheduling and improving product and process flows. Often, these production system improvements entail redesigning the system to incorporate these ensuing changes; a unique and temporary endeavour that is often structured as a project. One part of the production system design process is layout planning, in which the positions of operators, workstations, machines and other parts of the system are decided. This planning process can have a major impact on the overall efficiency of operations.In industrial settings, factory layout planning is often conducted in brownfield settings. In other words, in operational facilities. Since every production system and facility is unique, so is every factory layout planning project. Each such project has different preconditions, existing knowledge, availability and quality of data, lead-times, expectations and driving forces, to name just a few. If factory layout planning were treated as a design problem (more subjective than mathematical in nature), it would be hard to produce a mathematical solution for an optimal layout that would also work in reality. Instead, if a layout is developed and adapted to all real constraints and factors while it is being developed, the result would more likely be installable and work as expected.The long-term vision of this thesis is of a future in which sustainable manufacturing industry continues playing a vital role in society, because its contribution is more than just economic. A future in which the manufacturing industry is appreciated and engaged with by the local community; in which high performance is connected to the successful adoption and efficient use of digital tools in developing and improving existing brownfield production systems. This thesis aims to ensure that manufacturing industry adopts realistic virtual models in its brownfield factory layout planning processes. It does this by identifying and describing common challenges and how they may be reduced by developing and using realistic virtual models. This leads to improvements in the planning, installation and operational phases of production systems.The findings of this thesis show that brownfield factory layout planning represents a significant proportion of industrial layout planning. Its challenges lie mainly in the areas of data accuracy and richness. There are difficulties in grasping scale and perspective, communicating ideas and gathering input in the layout planning phase. By applying 3D laser scanning to provide accurate data and virtual reality to provide immersion and scale, realistic virtual models have been created. These reduce or eliminate the challenges stated above and allow more employees to be involved in the layout planning process. This, in turn, results in the identification of flaws in the layout and improvements in the early stages, rather than during or after installation. There is also an overall improvement to brownfield factory change processes, with costs that pale by comparison to the total cost of layout changes