Integrated production quality and condition-based maintenance optimisation for a stochastically deteriorating manufacturing system

This paper investigates the problem of optimally integrating production quality and condition-based maintenance in a stochastically deteriorating single- product, single-machine production system. Inspections are periodically performed on the system to assess its actual degradation status. The system is considered to be in ‘fail mode’ whenever its degradation level exceeds a predetermined threshold. The proportion of non-conforming items, those that are produced during the time interval where the degradation is beyond the specification threshold, are replaced either via overtime production or spot market purchases. To optimise preventive maintenance costs and at the same time reduce production of non-conforming items, the degradation of the system must be optimally monitored so that preventive maintenance is carried out at appropriate time intervals. In this paper, an integrated optimisation model is developed to determine the optimal inspection cycle and the degradation threshold level, beyond which preventive maintenance should be carried out, while minimising the sum of inspection and maintenance costs, in addition to the production of non-conforming items and inventory costs. An expression for the total expected cost rate over an infinite time horizon is developed and solution method for the resulting model is discussed. Numerical experiments are provided to illustrate the proposed approach

Tooling adjustment strategy for acceptable product quality in assembly processes

This paper develops an approach to minimize the number of process tooling adjustments and deliver an acceptable fraction of non-conforming products based on given product quality specification limits in assembly processes. A linear model is developed to describe the relationships between product quality and process tooling locating positions. Based on the model, the process mean shifts of tooling locating positions are estimated for both deterministic and stochastic cases by using the least-square estimation or linear mixed model estimation, respectively. A simultaneous confidence interval is obtained to construct the estimation region of a process mean shift under the given false alarm rate. Furthermore, a tooling adjustment strategy is proposed to determine when the process adjustment is essentially needed in order to ensure an acceptable fraction of non-conforming units based on the given product quality specification limits. Finally, a case study is conducted to illustrate the developed methodology by using a real-world autobody assembly process. Copyright © 2010 John Wiley & Sons, Ltd.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/78245/1/1128_ftp.pd

Reliability Modeling and Optimization Strategy for Manufacturing System Based on RQR Chain

Accurate and dynamic reliability modeling for the running manufacturing system is the prerequisite to implement preventive maintenance. However, existing studies could not output the reliability value in real time because their abandonment of the quality inspection data originated in the operation process of manufacturing system. Therefore, this paper presents an approach to model the manufacturing system reliability dynamically based on their operation data of process quality and output data of product reliability. Firstly, on the basis of importance explanation of the quality variations in manufacturing process as the linkage for the manufacturing system reliability and product inherent reliability, the RQR chain which could represent the relationships between them is put forward, and the product qualified probability is proposed to quantify the impacts of quality variation in manufacturing process on the reliability of manufacturing system further. Secondly, the impact of qualified probability on the product inherent reliability is expounded, and the modeling approach of manufacturing system reliability based on the qualified probability is presented. Thirdly, the preventive maintenance optimization strategy for manufacturing system driven by the loss of manufacturing quality variation is proposed. Finally, the validity of the proposed approach is verified by the reliability analysis and optimization example of engine cover manufacturing system

Feasibility study of an Integrated Program for Aerospace-vehicle Design (IPAD) system. Volume 2: Characterization of the IPAD system, phase 1, task 1

The aircraft design process is discussed along with the degree of participation of the various engineering disciplines considered in this feasibility study

Internet-based solutions to support distributed manufacturing

With the globalisation and constant changes in the marketplace, enterprises are adapting themselves to face new challenges. Therefore, strategic corporate alliances to share knowledge, expertise and resources represent an advantage in an increasing competitive world. This has led the integration of companies, customers, suppliers and partners using networked environments. This thesis presents three novel solutions in the tooling area, developed for Seco tools Ltd, UK. These approaches implement a proposed distributed computing architecture using Internet technologies to assist geographically dispersed tooling engineers in process planning tasks. The systems are summarised as follows. TTS is a Web-based system to support engineers and technical staff in the task of providing technical advice to clients. Seco sales engineers access the system from remote machining sites and submit/retrieve/update the required tooling data located in databases at the company headquarters. The communication platform used for this system provides an effective mechanism to share information nationwide. This system implements efficient methods, such as data relaxation techniques, confidence score and importance levels of attributes, to help the user in finding the closest solutions when specific requirements are not fully matched In the database. Cluster-F has been developed to assist engineers and clients in the assessment of cutting parameters for the tooling process. In this approach the Internet acts as a vehicle to transport the data between users and the database. Cluster-F is a KD approach that makes use of clustering and fuzzy set techniques. The novel proposal In this system is the implementation of fuzzy set concepts to obtain the proximity matrix that will lead the classification of the data. Then hierarchical clustering methods are applied on these data to link the closest objects. A general KD methodology applying rough set concepts Is proposed In this research. This covers aspects of data redundancy, Identification of relevant attributes, detection of data inconsistency, and generation of knowledge rules. R-sets, the third proposed solution, has been developed using this KD methodology. This system evaluates the variables of the tooling database to analyse known and unknown relationships in the data generated after the execution of technical trials. The aim is to discover cause-effect patterns from selected attributes contained In the database. A fourth system was also developed. It is called DBManager and was conceived to administrate the systems users accounts, sales engineers’ accounts and tool trial monitoring process of the data. This supports the implementation of the proposed distributed architecture and the maintenance of the users' accounts for the access restrictions to the system running under this architecture

Web-based strategies in the manufacturing industry

The explosive growth of Internet-based architectures is allowing an efficient access to information resources over geographically dispersed areas. This fact is exerting a major influence on current manufacturing practices. Business activities involving customers, partners, employees and suppliers are being rapidly and efficiently integrated through networked information management environments. Therefore, efforts are required to take advantage of distributed infrastructures that can satisfy information integration and collaborative work strategies in corporate environments. In this research, Internet-based distributed solutions focused on the manufacturing industry are proposed. Three different systems have been developed for the tooling sector, specifically for the company Seco Tools UK Ltd (industrial collaborator). They are summarised as follows. SELTOOL is a Web-based open tool selection system involving the analysis of technical criteria to establish appropriate selection of inserts, toolholders and cutting data for turning, threading and grooving operations. It has been oriented to world-wide Seco customers. SELTOOL provides an interactive and crossed-way of searching for tooling parameters, rather than conventional representation schemes provided by catalogues. Mechanisms were developed to filter, convert and migrate data from different formats to the database (SQL-based) used by SELTOOL.TTS (Tool Trials System) is a Web-based system developed by the author and two other researchers to support Seco sales engineers and technical staff, who would perform tooling trials in geographically dispersed machining centres and benefit from sharing data and results generated by these tests. Through TTS tooling engineers (authorised users) can submit and retrieve highly specific technical tooling data for both milling and turning operations. Moreover, it is possible for tooling engineers to avoid the execution of new tool trials knowing the results of trials carried out in physically distant places, when another engineer had previously executed these trials. The system incorporates encrypted security features suitable for restricted use on the World Wide Web. An urgent need exists for tools to make sense of raw data, extracting useful knowledge from increasingly large collections of data now being constructed and made available from networked information environments. This explosive growth in the availability of information is overwhelming the capabilities of traditional information management systems, to provide efficient ways of detecting anomalies and significant patterns in large sets of data. Inexorably, the tooling industry is generating valuable experimental data. It is a potential and unexplored sector regarding the application of knowledge capturing systems. Hence, to address this issue, a knowledge discovery system called DISKOVER was developed. DISKOVER is an integrated Java-application consisting of five data mining modules, able to be operated through the Internet. Kluster and Q-Fast are two of these modules, entirely developed by the author. Fuzzy-K has been developed by the author in collaboration with another research student in the group at Durham. The final two modules (R-Set and MQG) have been developed by another member of the Durham group. To develop Kluster, a complete clustering methodology was proposed. Kluster is a clustering application able to combine the analysis of quantitative as well as categorical data (conceptual clustering) to establish data classification processes. This module incorporates two original contributions. Specifically, consistent indicators to measure the quality of the final classification and application of optimisation methods to the final groups obtained. Kluster provides the possibility, to users, of introducing case-studies to generate cutting parameters for particular Input requirements. Fuzzy-K is an application having the advantages of hierarchical clustering, while applying fuzzy membership functions to support the generation of similarity measures. The implementation of fuzzy membership functions helped to optimise the grouping of categorical data containing missing or imprecise values. As the tooling database is accessed through the Internet, which is a relatively slow access platform, it was decided to rely on faster Information retrieval mechanisms. Q-fast is an SQL-based exploratory data analysis (EDA) application, Implemented for this purpose

Uses and applications of artificial intelligence in manufacturing

The purpose of the THESIS is to provide engineers and personnels with a overview of the concepts that underline Artificial Intelligence and Expert Systems. Artificial Intelligence is concerned with the developments of theories and techniques required to provide a computational engine with the abilities to perceive, think and act, in an intelligent manner in a complex environment. Expert system is branch of Artificial Intelligence where the methods of reasoning emulate those of human experts. Artificial Intelligence derives it\u27s power from its ability to represent complex forms of knowledge, some of it common sense, heuristic and symbolic, and the ability to apply the knowledge in searching for solutions. The Thesis will review : The components of an intelligent system, The basics of knowledge representation, Search based problem solving methods, Expert system technologies, Uses and applications of AI in various manufacturing areas like Design, Process Planning, Production Management, Energy Management, Quality Assurance, Manufacturing Simulation, Robotics, Machine Vision etc. Prime objectives of the Thesis are to understand the basic concepts underlying Artificial Intelligence and be able to identify where the technology may be applied in the field of Manufacturing Engineering