A modular hybrid simulation framework for complex manufacturing system design

For complex manufacturing systems, the current hybrid Agent-Based Modelling and Discrete Event Simulation (ABM–DES) frameworks are limited to component and system levels of representation and present a degree of static complexity to study optimal resource planning. To address these limitations, a modular hybrid simulation framework for complex manufacturing system design is presented. A manufacturing system with highly regulated and manual handling processes, composed of multiple repeating modules, is considered. In this framework, the concept of modular hybrid ABM–DES technique is introduced to demonstrate a novel simulation method using a dynamic system of parallel multi-agent discrete events. In this context, to create a modular model, the stochastic finite dynamical system is extended to allow the description of discrete event states inside the agent for manufacturing repeating modules (meso level). Moreover, dynamic complexity regarding uncertain processing time and resources is considered. This framework guides the user step-by-step through the system design and modular hybrid model. A real case study in the cell and gene therapy industry is conducted to test the validity of the framework. The simulation results are compared against the data from the studied case; excellent agreement with 1.038% error margin is found in terms of the company performance. The optimal resource planning and the uncertainty of the processing time for manufacturing phases (exo level), in the presence of dynamic complexity is calculated

Technology transfer from NASA to targeted industries, volume 2

This volume contains the following materials to support Volume 1: (1) Survey of Metal Fabrication Industry in Alabama; (2) Survey of Electronics Manufacturing/Assembly Industry in Alabama; (3) Apparel Modular Manufacturing Simulators; (4) Synopsis of a Stereolithography Project; (5) Transferring Modular Manufacturing Technology to an Apparel Firm; (6) Letters of Support; (7) Fact Sheets; (8) Publications; and (9) One Stop Access to NASA Technology Brochure

A review of modular strategies and architecture within manufacturing operations

This paper reviews existing modularity and modularization literature within manufacturing operations. Its purpose is to examine the tools, techniques, and concepts relating to modular production, to draw together key issues currently dominating the literature, to assess managerial implications associated with the emerging modular paradigm, and to present an agenda for future research directions. The review is based on journal papers included in the ABI/Inform electronic database and other noteworthy research published as part of significant research programmes. The research methodology concerns reviewing existing literature to identify key modular concepts, to determine modular developments, and to present a review of significant contributions to the field. The findings indicate that the modular paradigm is being adopted in a number of manufacturing organizations. As a result a range of conceptual tools, techniques, and frameworks has emerged and the field of modular enquiry is in the process of codifying the modular lexicon and developing appropriate modular strategies commensurate with the needs of manufacturers. Modular strategies and modular architecture were identified as two key issues currently dominating the modular landscape. Based on this review, the present authors suggest that future research areas need to focus on the development and subsequent standardization of interface protocols, cross-brand module use, supply chain power, transparency, and trust. This is the first review of the modular landscape and as such provides insights into, first, the development of modularization and, second, issues relating to designing modular products and modular supply chains

Modular switched reluctance machines to be used in automotive applications

In the last decades industry, including also that of electrical machines and drives, was pushed near to its limits by the high market demands and fierce competition. As a response to the demanding challenges, improvements were made both in the design and manufacturing of electrical machines and drives. One of the introduced advanced technological solutions was the modular construction. This approach enables on a hand easier and higher productivity manufacturing, and on the other hand fast repairing in exploitation. Switched reluctance machines (SRMs) are very well fitted for modular construction, since the magnetic insulation of the phases is a basic design requirement. The paper is a survey of the main achievements in the field of modular electrical machines, (especially SRMs), setting the focus on the machines designed to be used in automotive applications

Realising the open virtual commissioning of modular automation systems

To address the challenges in the automotive industry posed by the need to rapidly manufacture more product variants, and the resultant need for more adaptable production systems, radical changes are now required in the way in which such systems are developed and implemented. In this context, two enabling approaches for achieving more agile manufacturing, namely modular automation systems and virtual commissioning, are briefly reviewed in this contribution. Ongoing research conducted at Loughborough University which aims to provide a modular approach to automation systems design coupled with a virtual engineering toolset for the (re)configuration of such manufacturing automation systems is reported. The problems faced in the virtual commissioning of modular automation systems are outlined. AutomationML - an emerging neutral data format which has potential to address integration problems is discussed. The paper proposes and illustrates a collaborative framework in which AutomationML is adopted for the data exchange and data representation of related models to enable efficient open virtual prototype construction and virtual commissioning of modular automation systems. A case study is provided to show how to create the data model based on AutomationML for describing a modular automation system

An intelligent task programming system for modular manufacturing machines

Modular manufacturing machines characterised by their configuration flexibility and low initial investment have increasingly gained more recognition as one of the flexible and responsive manufacturing machinery in current competitive manufacturing industry. Programming of a modular machine is a very important part of an entire machine design and simulation environment. This paper focuses on the programming issue of a modular machine design and simulation environment. A programming study is made of the features of modular machines in manufacturing, and a general systematic approach towards high level utilisation and control of modular machines is outlined. A three-level machine task programming approach within the simulation environment is described and finally an example task program and its execution in simulation environment is illustrated to demonstrate the system capability

Modular synthesis of discrete controllers

This paper presents supervisory control theory in a process-algebraic setting, and proposes a way of synthesising modular supervisors that guarantee nonblocking. The framework used includes the possibility of hiding actions which results in nondeterminism. As modularity crucially depends on the process equivalence used, the paper studies possible equivalences and points out that, in order to be consistent with respect to the nonblocking property and to supervisor synthesis, a conflict-preserving equivalence must be used. It applies the results to synthesise nonblocking modular supervisors for a manufacturing system

A novel architecture for a reconfigurable micro machining cell

There is a growing demand for machine tools that are specifically designed for the manufacture of micro-scale components. Such machine tools are integrated into flexible micro-manufacturing systems. Design objectives for such tools include energy efficiency, small footprint and importantly flexibility, with the ability to easily reconfigure the manufacturing system in response to process requirements and product demands. Such systems find application in medical, photonics, automotive and electronic industries. In this paper, a new architecture for a reconfigurable micro manufacturing system is presented. The proposed architecture comprises a micro manufacturing cell with the key design feature being a hexagonal-base on which three tool heads can be attached to three of its sides. Each such machine-tool head, or processing module, is able to perform a different manufacturing process. These tool heads are interchangeable, enabling the cell to be configured to process a wide range of components with different materials, dimensions, tolerances and specification. Additional components of the cell include manipulation robots and an automated buffer unit. Such cells can be integrated into a manufacturing system via a modular conveyor belt to transfer parts from one cell to another and into assembly. A key consideration of the architecture is a control system that is also modular and reconfigurable; such that when new processing modules are introduced the control system is aware of the change and adjusts accordingly. Further to this coordination, issues between modules and machining cells are also considered. Other design considerations include work-piece holding and manipulation. This paper provides an overview of the architecture, the key design and implementation challenges as well as a high level operational performance assessment by means of a discrete event simulation model of the micro factory cell

Bio-inspired Tensegrity Soft Modular Robots

In this paper, we introduce a design principle to develop novel soft modular robots based on tensegrity structures and inspired by the cytoskeleton of living cells. We describe a novel strategy to realize tensegrity structures using planar manufacturing techniques, such as 3D printing. We use this strategy to develop icosahedron tensegrity structures with programmable variable stiffness that can deform in a three-dimensional space. We also describe a tendon-driven contraction mechanism to actively control the deformation of the tensegrity mod-ules. Finally, we validate the approach in a modular locomotory worm as a proof of concept.Comment: 12 pages, 7 figures, submitted to Living Machine conference 201

The Complementary Effect of Manufacturing Process Modularity and IS Flexibility on Agility in Manufacturing

In the situation of shortened product life cycles, modular product design enables organizations to adapt to unanticipated changes in their environments. This study extends modular systems theory to manufacturing process design and posits that: (i) firms can design their manufacturing processes for the same product into either an integrated or modularized structure, thereby being agile in dynamic environments, and (ii) the effect of manufacturing process modularity on agility is complemented by information systems (IS) flexibility. Conceptually, this study explains how important the congruence between the IS and manufacturing processes is to achieving agility in manufacturing and seeks to demonstrate how an IS adapts to shape agility. For practice, this study suggests that firms should focus their efforts on both IS flexibility and manufacturing process modularity, as well as their harmonization, in addition to modular product design