OPTIMIZATION OF TEST/DIAGNOSIS/REWORK LOCATION(S) AND CHARACTERISTICS IN ELECTRONIC SYSTEMS ASSEMBLY

ABSTRACT Title of Dissertation: OPTIMIZATION OF TEST/DIAGNOSIS/REWORK LOCATION(S) AND CHARACTERISTICS IN ELECTRONIC SYSTEMS ASSEMBLY Zhen Shi, Doctor of Philosophy, 2004 Dissertation directed by: Associate Professor Peter A. Sandborn Department of Mechanical Engineering For electronic systems it is not uncommon for 60% or more of the recurring cost to be associated with testing. Performing tradeoffs associated with where in a process to test and what level of test, diagnosis and rework to perform are key to optimizing the cost and yield of an electronic system's assembly. In this dissertation, a methodology that uses a real-coded genetic algorithm has been developed to minimize the yielded cost of electronic products by optimizing the locations of test, diagnosis and rework operations and their characteristics. This dissertation presents a test, diagnosis, and rework analysis model for use in electronic systems assembly. The approach includes a model of functional test operations characterized by fault coverage, false positives, and defects introduced in test; in addition, rework and diagnosis operations (diagnostic test) have variable success rates and their own defect introduction mechanisms. The model accommodates multiple rework attempts on a product instance. For use in practical assembly processes, the model has been extended by defining a general form of the relationship between test cost and fault coverage. The model is applied within a framework for optimizing the location(s) and characteristics (fault coverage/test cost and rework attempts) of Test/Diagnosis/Rework (TDR) operations in a general assembly process. A new search algorithm called Waiting Sequence Search (WSS) is applied to traverse a general process flow to perform the cumulative calculation of a yielded cost objective function. Real-Coded Genetic Algorithms (RCGAs) are used to perform a multi-variable optimization that minimizes yielded cost. Several simple cases are analyzed for validation and general complex process flows are used to demonstrate the applicability of the algorithm. A real multichip module (MCM) manufacturing and assembly process is used to demonstrate that the optimization methodology developed in this dissertation can find test and rework solutions that have lower yielded cost than solutions calculated by manually choosing the test strategies and characteristics. The optimization methodology with Monte Carlo methods included for the process flow under uncertain inputs is also addressed in this dissertation. It is anticipated that this research will improve the ability of manufacturing engineers to place TDR operations in a process flow. The ability to optimize the TDR operations can also be used as a feedback to a Design for Test (DFT) analysis of the electronic systems showing which portion of the system should be redesigned to accommodate testing for a higher level of fault coverage, and where there is less need for test

A Hierarchical Core Reference Ontology for New Technology Insertion Design in Long Life Cycle, Complex Mission Critical Systems

Organizations, including government, commercial and others, face numerous challenges in maintaining and upgrading long life-cycle, complex, mission critical systems. Maintaining and upgrading these systems requires the insertion and integration of new technology to avoid obsolescence of hardware software, and human skills, to improve performance, to maintain and improve security, and to extend useful life. This is particularly true of information technology (IT) intensive systems. The lack of a coherent body of knowledge to organize new technology insertion theory and practice is a significant contributor to this difficulty. This research organized the existing design, technology road mapping, obsolescence, and sustainability literature into an ontology of theory and application as the foundation for a technology design and technology insertion design hierarchical core reference ontology and laid the foundation for body of knowledge that better integrates the new technology insertion problem into the technology design architecture

Analytical Methods for Performance Enhancement in Unreliable Multistage Manufacturing Systems with Imperfect Production

Ph.DDOCTOR OF PHILOSOPH

Design and Management of Manufacturing Systems

Although the design and management of manufacturing systems have been explored in the literature for many years now, they still remain topical problems in the current scientific research. The changing market trends, globalization, the constant pressure to reduce production costs, and technical and technological progress make it necessary to search for new manufacturing methods and ways of organizing them, and to modify manufacturing system design paradigms. This book presents current research in different areas connected with the design and management of manufacturing systems and covers such subject areas as: methods supporting the design of manufacturing systems, methods of improving maintenance processes in companies, the design and improvement of manufacturing processes, the control of production processes in modern manufacturing systems production methods and techniques used in modern manufacturing systems and environmental aspects of production and their impact on the design and management of manufacturing systems. The wide range of research findings reported in this book confirms that the design of manufacturing systems is a complex problem and that the achievement of goals set for modern manufacturing systems requires interdisciplinary knowledge and the simultaneous design of the product, process and system, as well as the knowledge of modern manufacturing and organizational methods and techniques

Application of Optimization in Production, Logistics, Inventory, Supply Chain Management and Block Chain

The evolution of industrial development since the 18th century is now experiencing the fourth industrial revolution. The effect of the development has propagated into almost every sector of the industry. From inventory to the circular economy, the effectiveness of technology has been fruitful for industry. The recent trends in research, with new ideas and methodologies, are included in this book. Several new ideas and business strategies are developed in the area of the supply chain management, logistics, optimization, and forecasting for the improvement of the economy of the society and the environment. The proposed technologies and ideas are either novel or help modify several other new ideas. Different real life problems with different dimensions are discussed in the book so that readers may connect with the recent issues in society and industry. The collection of the articles provides a glimpse into the new research trends in technology, business, and the environment

Improving project management planning and control in service operations environment.

Projects have evidently become the core activity in most companies and organisations where they are investing significant amount of resources in different types of projects as building new services, process improvement, etc. This research has focused on service sector in attempt to improve project management planning and control activities. The research is concerned with improving the planning and control of software development projects. Existing software development models are analysed and their best practices identified and these have been used to build the proposed model in this research. The research extended the existing planning and control approaches by considering uncertainty in customer requirements, resource flexibility and risks level variability. In considering these issues, the research has adopted lean principles for planning and control software development projects. A novel approach introduced within this research through the integration of simulation modelling techniques with Taguchi analysis to investigate ‗what if‘ project scenarios. Such scenarios reflect the different combinations of the factors affecting project completion time and deliverables. In addition, the research has adopted the concept of Quality Function Deployment (QFD) to develop an automated Operations Project Management Deployment (OPMD) model. The model acts as an iterative manner uses ‗what if‘ scenario performance outputs to identify constraints that may affect the completion of a certain task or phase. Any changes made during the project phases will then automatically update the performance metrics for each software development phases. In addition, optimisation routines have been developed that can be used to provide management response and to react to the different levels of uncertainty. Therefore, this research has looked at providing a comprehensive and visual overview of important project tasks i.e. progress, scheduled work, different resources, deliverables and completion that will make it easier for project members to communicate with each other to reach consensus on goals, status and required changes. Risk is important aspect that has been included in the model as well to avoid failure. The research emphasised on customer involvement, top management involvement as well as team members to be among the operational factors that escalate variability levels 3 and effect project completion time and deliverables. Therefore, commitment from everyone can improve chances of success. Although the role of different project management techniques to implement projects successfully has been widely established in areas such as the planning and control of time, cost and quality; still, the distinction between the project and project management is less than precise and a little was done in investigating different levels of uncertainty and risk levels that may occur during different project phase.United Arab Emirates Governmen

A fuzzy clustering methodology to analyze interfaces and assess integration risks in large-scale systems

“Interface analysis and integration risk assessment for a large-scale, complex system is a difficult systems engineering task, but critical to the success of engineering systems with extraordinary capabilities. When dealing with large-scale systems there is little time for data gathering and often the analysis can be overwhelmed by unknowns and sometimes important factors are not measurable because of the complexities of the interconnections within the system. This research examines the significance of interface analysis and management, identifies weaknesses in literature on risk assessment for a complex system, and exploits the benefits of soft computing approaches in the interface analysis in a complex system and in the risk assessment of system integration readiness. The research aims to address some of the interface analysis challenges in a large-scale system development lifecycle such as the ones often experienced in aircraft development. The resulting product from this research is contributed to systems engineering by providing an easy-to-use interface assessment and methodology for a trained systems engineer to break the system into communities of dense interfaces and determine the integration readiness and risks based on those communities. As a proof of concept this methodology is applied on a power seat system in a commercial aircraft with data from the Critical Design Review”--Abstract, page iv

Sustainable Construction Engineering and Management

This Book is a Printed Edition of the Special Issue which covers sustainability as an emerging requirement in the fields of construction management, project management and engineering. We invited authors to submit their theoretical or experimental research articles that address the challenges and opportunities for sustainable construction in all its facets, including technical topics and specific operational or procedural solutions, as well as strategic approaches aimed at the project, company or industry level. Central to developments are smart technologies and sophisticated decision-making mechanisms that augment sustainable outcomes. The Special Issue was received with great interest by the research community and attracted a high number of submissions. The selection process sought to balance the inclusion of a broad representative spread of topics against research quality, with editors and reviewers settling on thirty-three articles for publication. The Editors invite all participating researchers and those interested in sustainable construction engineering and management to read the summary of the Special Issue and of course to access the full-text articles provided in the Book for deeper analyses