81 research outputs found

    A Survey of Automated Process Planning Approaches in Machining

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    Global industrial trend is shifting towards next industrial revolution Industry 4.0. It is becoming increasingly important for modern manufacturing industries to develop a Computer Integrated Manufacturing (CIM) system by integrating the various operational and information processing functions in design and manufacturing. In spite of being active in research for almost four decades, it is clear that new functionalities are needed to integrate and realize a completely optimal process planning which can be fully compliant towards Smart Factory. In order to develop a CIM system, Computer Aided Process Planning (CAPP) plays a key role and therefore it has been the focus of many researchers. In order to gain insight into the current state-of-the-art of CAPP methodologies, 96 research papers have been reviewed. Subsequent sections discuss the different CAPP approaches adopted by researchers to automate different process planning tasks. This paper aims at addressing the key approaches involved and future directions towards Smart Manufacturing

    CIM implementation in developed and developing countries

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    Implementing integrated advanced technologies is an effective approach towards solving most problems in today’s competitive global market Computer Integrated Manufacturing (CIM) technologies are presented as a solution to manufacturing organisations which need to perform well. This research describes the major issues and problems facing developing countnes that wish to implement CIM. In this investigation, Libya is taken as an example of a developing country, while Ireland is used as a model of a more developed country, which has already implemented components of the CIM technology in some of its industrial companies. This research demonstrates the effect of CIM technology on Irish industry by investigating the cost effectiveness of implementing CIM, reduction of the production time, reduction of the product cost and management efficiency. To carry out this study, 267 questionnaires were distributed to manufacturing companies in Ireland in order to help establish the status of CIM within manufacturing companies, to study the effect of CIM on Irish industries. To study CIM in Libyan industries, four Libyan companies were investigated to assess the CIM level in their companies and the possibility of implementing CIM technology in Libyan companies as a developing country. The mam findings of this research are that successful implementation of CIM depends on sufficient initial and continued investment from within the country and outside. Furthermore, in order to implement CIM successfully it is vital that there is sufficient expertise and trained workers

    Critical appraisal of product development expertise in Irish SMEs

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    The focus of this research was on the product development expertise of Irish SMEs. In particular, SMEs developing physical products (a physical product is defined as an electronic, medical device, plastic or general engineering product). A survey of Irish SMEs was conducted across industry sectors developing physical products with the objective of understanding how indigenous SMEs and therefore Ireland is progressing towards becoming a knowledge economy. SME characteristics (customers and markets, organisational structures, systems, processes and procedures, human and financial resources, culture and behaviour) were researched and used to understand the issues SMEs have with product development (PD research is mostly considered from the perspective of large companies). In relation to product development: strategy, innovation and learning, strategic techniques, organisational structure, product development process design, types of product development processes, tools and methodologies, technology, intellectual property, change management, marketing and branding and performance measurement were all examined. Survey items (variables) were identified from the literature review and used to create a survey designed based on ‘best practice’ PD and SME characteristics. This survey was conducted based on identified survey best practice in order to increase response rate and went through two pre-tests and a pilot before the final study. Descriptive analysis, reliability/consistency analysis and regression analysis were conducted on the constructs of product development. Specific relationships identified in the literature review were examined. The results of this analysis revealed that Irish SMEs are operating in a ‘Knowledge Based Development’ or learning environment. They carry out many of the techniques associated with various tools and methodologies but reported no use of these T&M which could aid their approach. There is a high use of technology, especially CAD and technology is mostly developed within the product development process. There was a high use of Cross Functional Teams and in general strategy and fuzzy front end/voice of the customer usage was carried out well. There were no issues with change management and in relation to intellectual property the use of an IP policy, strategy and portfolios was low. Generally, Irish SMEs are ready to reach the next stage of company evolution by linking ‘organisational (innovation) processes’

    A novel method for information rich costing in CNC manufacture

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    An intelligent knowledge based cost modelling system for innovative product development

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    This research work aims to develop an intelligent knowledge-based system for product cost modelling and design for automation at an early design stage of the product development cycle, that would enable designers/manufacturing planners to make more accurate estimates of the product cost. Consequently, a quicker response to customers’ expectations. The main objectives of the research are to: (1) develop a prototype system that assists an inexperienced designer to estimate the manufacturing cost of the product, (2) advise designers on how to eliminate design and manufacturing related conflicts that may arise during the product development process, (3) recommend the most economic assembly technique for the product in order to consider this technique during the design process and provide design improvement suggestions to simplify the assembly operations (i.e. to provide an opportunity for designers to design for assembly (DFA)), (4) apply a fuzzy logic approach to certain cases, and (5) evaluate the developed prototype system through five case studies. The developed system for cost modelling comprises of a CAD solid modelling system, a material selection module, knowledge-based system (KBS), process optimisation module, design for assembly module, cost estimation technique module, and a user interface. In addition, the system encompasses two types of databases, permanent (static) and temporary (dynamic). These databases are categorised into five separate groups of database, Feature database, Material database, Machinability database, Machine database, and Mould database. The system development process has passed through four major steps: firstly, constructing the knowledge-based and process optimisation system, secondly developing a design for assembly module. Thirdly, integrating the KBS with both material selection database and a CAD system. Finally, developing and implementing a ii fuzzy logic approach to generate reliable estimation of cost and to handle the uncertainty in cost estimation model that cannot be addressed by traditional analytical methods. The developed system has, besides estimating the total cost of a product, the capability to: (1) select a material as well as the machining processes, their sequence and machining parameters based on a set of design and production parameters that the user provides to the system, and (2) recommend the most economic assembly technique for a product and provide design improvement suggestion, in the early stages of the design process, based on a design feasibility technique. It provides recommendations when a design cannot be manufactured with the available manufacturing resources and capabilities. In addition, a feature-by-feature cost estimation report was generated using the system to highlight the features of high manufacturing cost. The system can be applied without the need for detailed design information, so that it can be implemented at an early design stage and consequently cost redesign, and longer lead-time can be avoided. One of the tangible advantages of this system is that it warns users of features that are costly and difficult to manufacture. In addition, the system is developed in such a way that, users can modify the product design at any stage of the design processes. This research dealt with cost modelling of both machined components and injection moulded components. The developed cost effective design environment was evaluated on real products, including a scientific calculator, a telephone handset, and two machined components. Conclusions drawn from the system indicated that the developed prototype system could help companies reducing product cost and lead time by estimating the total product cost throughout the entire product development cycle including assembly cost. Case studies demonstrated that designing a product using the developed system is more cost effective than using traditional systems. The cost estimated for a number of products used in the case studies was almost 10 to 15% less than cost estimated by the traditional system since the latter does not take into consideration process optimisation, design alternatives, nor design for assembly issue

    Mass Production Processes

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    It is always hard to set manufacturing systems to produce large quantities of standardized parts. Controlling these mass production lines needs deep knowledge, hard experience, and the required related tools as well. The use of modern methods and techniques to produce a large quantity of products within productive manufacturing processes provides improvements in manufacturing costs and product quality. In order to serve these purposes, this book aims to reflect on the advanced manufacturing systems of different alloys in production with related components and automation technologies. Additionally, it focuses on mass production processes designed according to Industry 4.0 considering different kinds of quality and improvement works in mass production systems for high productive and sustainable manufacturing. This book may be interesting to researchers, industrial employees, or any other partners who work for better quality manufacturing at any stage of the mass production processes

    A Methodological Approach to Knowledge-Based Engineering Systems for Manufacturing

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    A survey of implementations of the knowledge-based engineering approach in different technological sectors is presented. The main objectives and techniques of examined applications are pointed out to illustrate the trends and peculiarities for a number of manufacturing field. Existing methods for the development of these engineering systems are then examined in order to identify critical aspects when applied to manufacturing. A new methodological approach is proposed to overcome some specific limitations that emerged from the above-mentioned survey. The aim is to provide an innovative method for the implementation of knowledge-based engineering applications in the field of industrial production. As a starting point, the field of application of the system is defined using a spatial representation. The conceptual design phase is carried out with the aid of a matrix structure containing the most relevant elements of the system and their relations. In particular, objectives, descriptors, inputs and actions are defined and qualified using categorical attributes. The proposed method is then applied to three case studies with different locations in the applicability space. All the relevant elements of the detailed implementation of these systems are described. The relations with assumptions made during the design are highlighted to validate the effectiveness of the proposed method. The adoption of case studies with notably different applications also reveals the versatility in the application of the method

    Build-Up an Economical Tool for Machining Operations Cost Estimation

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    Currently, there is a lack of affordable and simple tools for the estimation of these costs, especially for machining operations. This is particularly true for manufacturing SMEs, in which the cost estimation of machined parts is usually performed based only on required material for part production, or involves a time-consuming, non-standardized technical analysis. Therefore, a cost estimation tool was developed, based on the calculated machining times and amount of required material, based on the final drawing of the requested workpiece. The tool was developed primarily for milling machines, considering milling, drilling, and boring/threading operations. Regarding the considered materials, these were primarily aluminum alloys. However, some polymer materials were also considered. The tool first estimates the required time for total part production and then calculates the total cost. The total production time is estimated based on the required machining operations, as well as drawing, programming, and machine setup time. A part complexity level was also introduced, based on the number of details and operations required for each workpiece, which will inflate the estimated times. The estimation tool was tested in a company setting, comparing the estimated operation time values with the real ones, for a wide variety of parts of differing complexity. An average error of 14% for machining operation times was registered, which is quite satisfactory, as this time is the most impactful in terms of machining cost. However, there are still some problems regarding the accuracy in estimating finishing operation timesinfo:eu-repo/semantics/publishedVersio

    A reference model for extended enterprise

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    In today's highly competitive, volatile and increasingly global manufacturing environment, manufacturing companies are increasingly aware of the need for agility and effectiveness at the supply-chain level, rather than simply at company level. Business Process Re-engineering and the resulting emphasis on core competence has influenced a move towards de-centralisation, flatter organisation structures and increased use of "outsourcing". It has been said that it is now supply-chain versus supply-chain and that this poses both opportunity and threat for SMEs. While some work has been done in relation to developing the concept of integrated supply-chains, relatively little has been published with respect to the concept of "Extended Enterprise (EE)", the "highest' 'level of inter-enterprise integration. This thesis provides a thorough review of literature with respect to supply-chain integration and Extended Enterprise. Current practice is evaluated on the basis of the literature review and an analysis of a questionnaire and some Case Study companies. A detailed description of Extended Enterprise is provided and a conceptual reference model is developed, with the aim of providing a strategic planning tool, which will help organisations to identify the extent to which they operate as part of an EE. The model is intended also to help organisations in their evolution towards more effective operation within EE. One of the key characteristics/enablers of EE is stated as the existence of an organisational structure, which supports the effective identification, rationalisation and deployment of core competence within an EE. An approach based upon the concept of a "Process Breakdown Structure" is introduced and is evaluated in the context of a Case Study Company

    Modelling, analysis and design of computer integrated manufacturing systems.

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    In the present climate of global competition, manufacturing organisations consider and seek strategies, means and tools to assist them to stay competitive. Computer Integrated Manufacturing (CIM) offers a number of potential opportunities for improving manufacturing systems. However, a number of researchers have reported the difficulties which arise during the analysis, design and implementation of CIM due to a lack of effective modelling methodologies and techniques and the complexity of the systems. The work reported in this thesis is related to the development of an integrated modelling method to support the analysis and design of advanced manufacturing systems. A survey of various modelling methods and techniques is carried out. The methods SSADM, IDEFO, IDEF1X, IDEF3, IDEF4, OOM, SADT, GRAI, PN, 10A MERISE, GIM and SIMULATION are reviewed. The majorities of these contain graphical components and therefore, fulfil basic modelling requirements. In addition, these methods represent a comprehensive sample of manufacturing systems modelling methods. A manufacturing system comprises different sub-systems including physical, information and decisions sub-systems. These sub-systems can be modelled using a combination of the methods described i.e. GRAI for decision systems, IDEFO for physical systems, simulation for dynamic aspects, etc. A novel framework for comparing the modelling methods selected is developed using a number of factors derived from CIM and modelling requirements. The study discovered that no single modelling method or technique could model all the different aspects of a manufacturing system or achieve integration between system domains at both static and dynamic levels. As a result, it was concluded that there was a need for an integrated modelling method for the analysis and design of complex manufacturing systems. To overcome these problems, a novel integrated modelling method called GI-SIM has been developed. The method is composed of four modelling components GRAI grid, IDEFO, IDEF1X and SIMAN/ARENA. GI-SIM integrates these four tools to form a complete method, which combines the advantages of existing modelling methods and eliminates their shortcomings. The method developed is evaluated using a case study carried out in a UK company manufacturing electric motors. It is also tested for the design and specification of CIM system components (CAD, CAPP, CAM, etc.). The case studies demonstrate that GISIM achieves two important types of modelling integration; the first is a vertical integration between different levels of abstraction (conceptual, structural and dynamic) and the second is a horizontal integration between five modelling domains (decision, functional, information, physical and dynamic). In addition, the method is easy to learn and use, and sufficiently flexible to model any system function according to its related objectives. The findings of this research and recommendation for future research are presented in the final chapter
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