Optimization of product assignment to assembly lines

Dissertação de mestrado em Industrial engineering and ManagementThe work presented in this dissertation was developed in an industrial context integrated in the production control and management department of the Bosch Car Multimedia Portugal S.A – Braga automatic insertion. The problem addressed in this dissertation was finding the best distribution of product families to assign in different lines according to the physical and technical constraints of the assembly lines. In the approach of the problem, it was used tools and techniques of the Operational Research discipline through mathematical modeling, in order to analyze complex situation and obtain more efficient solutions to help in the decision-making process. Based on production data, production needs forecasts and assembly line physical availability, models with different sets of constraints and objective functions were created to present solutions that best fit the question and the specific problem of the present production context. Through specific software that suited the problem, the previously created models were solved, and the solutions were analyzed and evaluated to suit the company’s current needs and for possible and feasible implementation of the solutions.O trabalho apresentado nesta dissertação foi desenvolvido em contexto industrial integrado no departamento de planeamento e controlo de produção da área de inserção automática da Bosch Car Multimédia Portugal S.A - Braga. O problema abordado nesta dissertação foi encontrar a melhor distribuição de famílias de produtos a alocar nas diferentes linhas de produção de acordo com as suas restrições físicas e técnicas. Na abordagem do problema recorreu-se a técnicas de Investigação Operacional através de modelação matemática, para analisar situações complexas e obter soluções mais eficientes. Tendo como base dados da produção, previsões de necessidades e disponibilidade física da produção, foram criados modelos com diferentes conjuntos de restrições e funções objetivo por forma a apresentar soluções que melhor se adequassem à pergunta e ao problema específico do contexto produtivo presente. Através da utilização de software, foram resolvidos os modelos criados anteriormente, sendo que as soluções foram analisadas e avaliadas para a adequação às necessidades atuais da empresa e para a sua possível e viável implementação

The Development of an Automated Production System

This paper describes the development of an automated production system recently completed by the Martin Marietta Aerospace Division, Orlando, Florida, for the assembly, inspection and test of printed circuit boards. The project began in January 1981 with the purpose of increasing the then existing production capability and to create the building block for the total automation of the printed circuit board assembly area of the plant in Ocala, Florida. The system was implemented using a combination of off the shelf equipment modified and integrated to create a single production system. The system employs much of the new production philosophies tailored to meet the particular needs of Martin Marietta and to fulfill present production requirements as well as future production projections. During the development and implementation of this project, flexibility within the team was required to accommodate for the unforeseen problems which surfaced. The actual work required to perform this task far exceeded the expectations of the team and the company. This document covers all facets of this project, from inception to operation, and describes the problems encountered and lessons learned throughout the project

The printed circuit board assembly and test operation : toward a better process

Thesis (M.S.)--Massachusetts Institute of Technology, Sloan School of Management, 1983.MICROFICHE COPY AVAILABLE IN ARCHIVES AND DEWEYBibliography: leaves 90-91.by James Francis Reda.M.S

A real-time defect detection in printed circuit boards applying deep learning

Inspection of defects in the printed circuit boards (PCBs) has both safety and economic significance in the 4.0 industrial manufacturing. Nevertheless, it is still a challenging problem to be studied in-depth due to the complexity of the PCB layouts and the shrinking down tendency of the electronic component size. In this paper, a real-time automated supervision algorithm is proposed to test the PCBs quality among different scenarios. The density of the PCBs layout and the complexity on the surface are analyzed based on deep learning and image feature extraction algorithms. To be more detailed, the ORB feature and the Brute-force matching method are utilized to match perfectly the input images with the PCB templates. After transferring images by aiding the RANSAC algorithm, a hybrid method using modern computer vision algorithms is developed to segment defective areas on the PCBs surface. Then, by applying the enhanced Residual Network –50, the proposed algorithm can classify the groove defects on the surface mount technology electronic components which minimum size up to 1x3 mm. After the training process, the proposed system is capable to categorize various types of overproduced, recycled, and cloned PCBs. The speed of the quality testing operation maintains at a high level with an average precision rate up to 96.29 % in case of good brightness conditions. Finally, the computational experiments demonstrate that the proposed system based on deep learning can obtain superior results and it outperforms several existing works in terms of speed, precision, and robustnes

A predictive maintenance approach based in big data analysis

With the evolution of information systems, the data flow escalated into new boundaries, allowing enterprises to further develop their approach to important sectors, such as production, logistic, IT and especially maintenance. This last field accompanied industry developments hand in hand in each of the four iterations. More specifically, the fourth iteration (Industry 4.0) marked the capability to connect machines and further enhance data extraction, which allowed companies to use a new data-driven approach into their specific problems. Nevertheless, with a wider flow of data being generated, understanding data became a priority for maintenance-related decision-making processes. Therefore, the correct elaboration of a roadmap to apply predictive maintenance (PM) is a key step for companies. A roadmap can allow a safe approach, where resources may be placed strategically with a ratio of low risk and high reward. By analysing multiple approaches to PM, a generic model is proposed, which contains an array of guidelines. This combination aims to assist maintenance departments that wish to understand the feasibility of implementing a predictive maintenance solution in their company. To understand the utility of the developed artefact, a practical application was conducted to a production line of HFA, a Portuguese Small and Medium Enterprise.Através da evolução dos sistemas de informação (SI), o fluxo de dados atingiu novos limites, permitindo assim às empresas desenvolver diferentes focos e aplicar novas perspetivas nos departamentos fulcrais à sua atividade, tais como produção, logística e, mais especificamente, a manutenção. Esta última componente evolui paralelamente à indústria, evidenciando novos desenvolvimentos em cada iteração da mesma. Particularmente, a quarta revolução industrial destacou-se pela capacidade de conectar máquinas entre si e pela evolução posterior do processo de extração de dados. Assim, surgiu uma nova perspetiva focada na utilização dos dados extraídos para resolução de problemas. Consequentemente, esta inovação fomentou uma redefinição das prioridades nas decisões tomadas relativas à manutenção, dando primazia à compreensão dos dados gerados. Por conseguinte, a correta elaboração de um plano de implementação de manutenção preditiva (MP) destaca-se como um passo fulcral para as empresas. Este plano tem como objetivo permitir uma abordagem mais segura, possibilitando assim alocar os recursos estrategicamente, reduzindo o risco e potenciando a recompensa. Mediante a análise de múltiplas abordagens de MP, é proposto um modelo genérico que reúne um conjunto diretrizes. Este tem intuito de auxiliar os departamentos de manutenção que pretendem compreender a viabilidade da instalação de uma solução de MP na empresa. A fim de perceber a utilidade dos artefactos desenvolvidos, foi realizada uma aplicação prática do modelo numa pequena e média empresa (PME)