Komponenttien luokittelu ja parhaat käytännöt tuotantosimulaation mallinnuksessa

Production simulation software plays a major role in validation, optimization and illustration of production systems. Operation of production simulation is generally based on components and their interaction. Components typically represent factory floor devices, but in addition, there can be components to provide visualization, statistics, control or other input to simulation. The demand for having high-quality, easy-to-use and compatible components emphasizes the importance of component modelling. The objectives of this thesis were to develop component classes based on industrial devices, to standardize component modelling solutions and best practices in component modelling. Other objectives were to identify and analyse future prospects of production simulation. This focuses on the concept of digital twin, which could be described as reflective real-time simulation model from the physical system. In addition, focus is also set on formal modelling languages. The outcome of this thesis presents component classes and best practices in component modelling. In component classification, the focus was set to development of generic components, which can be controlled with signal-based logic. This enables components from the software to be externally controlled. In addition, automatic model creation tool wizard, is implemented to instantly generate components based on the defined component classes. Best practices were based on the selected modelling fields that are most relevant for general use. In the development of best practices, interviewing method was utilized to receive input from simulation experts.Tuotantosimulaatio on tärkeässä osassa tuotantojärjestelmien validoinnissa, optimoinnissa ja visualisoinnissa. Tuotantosimulaation toiminta perustuu yleisesti komponentteihin ja niiden väliseen vuorovaikutukseen. Komponentit esittävät tyypillisesti tehtaasta löytyviä laitteita ja esineitä, mutta komponentteja voidaan käyttää myös visualisointiin, statistiikan keräämiseen, järjestelmän ohjaukseen tai muuhun tarpeeseen simuloinnissa. Tämän diplomityön tavoitteita oli kehittää komponenttiluokkia teollisuudesta valittujen laitteiden perusteella, mikä mahdollistaa mallinnusratkaisujen standardoinnin. Sen lisäksi tavoitteena oli kehittää parhaat käytännöt komponenttimallinnukseen. Muita tavoitteita oli tunnistaa ja analysoida tulevaisuuden näkymiä tuotantosimulaatiolle. Tämä keskittyi pääosin digitaaliseen kaksoseen, jota voidaan kuvata reaaliaikaisesti peilautuvaksi simulaatiomalliksi todellisesta järjestelmästä. Tämän lisäksi työssä keskityttiin formaaleihin mallinnuskieliin. Diplomityön lopputulos esittää kehitetyt komponenttiluokat ja parhaat käytännöt komponenttimallinnuksessa. Komponenttien luokittelussa keskityttiin kehittämään geneerisiä komponentteja, joita voidaan ohjata signaalipohjaisilla komennoilla. Tämä mahdollistaa komponentin ohjaamisen myös simulointiohjelman ulkopuolelta. Tämän lisäksi automaattista komponenttien luomistyökalua käytettiin luokiteltujen komponenttien luomisessa. Parhaat käytännöt komponenttimallinnuksessa pohjautuivat mallinnuksen oleellisimpiin osa-alueisiin tavanomaisissa mallinnustilanteissa. Parhaiden käytäntöjen kehityksessä haastateltiin simulointiammattilaisia, joiden mielipiteistä muodostettiin perusta käytäntöjen kehitykselle

Komponenttien luokittelu ja parhaat käytännöt tuotantosimulaation mallinnuksessa

Production simulation software plays a major role in validation, optimization and illustration of production systems. Operation of production simulation is generally based on components and their interaction. Components typically represent factory floor devices, but in addition, there can be components to provide visualization, statistics, control or other input to simulation. The demand for having high-quality, easy-to-use and compatible components emphasizes the importance of component modelling. The objectives of this thesis were to develop component classes based on industrial devices, to standardize component modelling solutions and best practices in component modelling. Other objectives were to identify and analyse future prospects of production simulation. This focuses on the concept of digital twin, which could be described as reflective real-time simulation model from the physical system. In addition, focus is also set on formal modelling languages. The outcome of this thesis presents component classes and best practices in component modelling. In component classification, the focus was set to development of generic components, which can be controlled with signal-based logic. This enables components from the software to be externally controlled. In addition, automatic model creation tool wizard, is implemented to instantly generate components based on the defined component classes. Best practices were based on the selected modelling fields that are most relevant for general use. In the development of best practices, interviewing method was utilized to receive input from simulation experts.Tuotantosimulaatio on tärkeässä osassa tuotantojärjestelmien validoinnissa, optimoinnissa ja visualisoinnissa. Tuotantosimulaation toiminta perustuu yleisesti komponentteihin ja niiden väliseen vuorovaikutukseen. Komponentit esittävät tyypillisesti tehtaasta löytyviä laitteita ja esineitä, mutta komponentteja voidaan käyttää myös visualisointiin, statistiikan keräämiseen, järjestelmän ohjaukseen tai muuhun tarpeeseen simuloinnissa. Tämän diplomityön tavoitteita oli kehittää komponenttiluokkia teollisuudesta valittujen laitteiden perusteella, mikä mahdollistaa mallinnusratkaisujen standardoinnin. Sen lisäksi tavoitteena oli kehittää parhaat käytännöt komponenttimallinnukseen. Muita tavoitteita oli tunnistaa ja analysoida tulevaisuuden näkymiä tuotantosimulaatiolle. Tämä keskittyi pääosin digitaaliseen kaksoseen, jota voidaan kuvata reaaliaikaisesti peilautuvaksi simulaatiomalliksi todellisesta järjestelmästä. Tämän lisäksi työssä keskityttiin formaaleihin mallinnuskieliin. Diplomityön lopputulos esittää kehitetyt komponenttiluokat ja parhaat käytännöt komponenttimallinnuksessa. Komponenttien luokittelussa keskityttiin kehittämään geneerisiä komponentteja, joita voidaan ohjata signaalipohjaisilla komennoilla. Tämä mahdollistaa komponentin ohjaamisen myös simulointiohjelman ulkopuolelta. Tämän lisäksi automaattista komponenttien luomistyökalua käytettiin luokiteltujen komponenttien luomisessa. Parhaat käytännöt komponenttimallinnuksessa pohjautuivat mallinnuksen oleellisimpiin osa-alueisiin tavanomaisissa mallinnustilanteissa. Parhaiden käytäntöjen kehityksessä haastateltiin simulointiammattilaisia, joiden mielipiteistä muodostettiin perusta käytäntöjen kehitykselle

Assembly Line

An assembly line is a manufacturing process in which parts are added to a product in a sequential manner using optimally planned logistics to create a finished product in the fastest possible way. It is a flow-oriented production system where the productive units performing the operations, referred to as stations, are aligned in a serial manner. The present edited book is a collection of 12 chapters written by experts and well-known professionals of the field. The volume is organized in three parts according to the last research works in assembly line subject. The first part of the book is devoted to the assembly line balancing problem. It includes chapters dealing with different problems of ALBP. In the second part of the book some optimization problems in assembly line structure are considered. In many situations there are several contradictory goals that have to be satisfied simultaneously. The third part of the book deals with testing problems in assembly line. This section gives an overview on new trends, techniques and methodologies for testing the quality of a product at the end of the assembling line

Advances in Condition Monitoring, Optimization and Control for Complex Industrial Processes

The book documents 25 papers collected from the Special Issue “Advances in Condition Monitoring, Optimization and Control for Complex Industrial Processes”, highlighting recent research trends in complex industrial processes. The book aims to stimulate the research field and be of benefit to readers from both academic institutes and industrial sectors

Methodology for managing shipbuilding projectby integrated optimality

PhD ThesisSmall to medium shipyards in developing shipbuilding countries face a persistent challenge to contain project cost and deadline due mainly to the ongoing development in facility and assorted product types. A methodology has been proposed to optimize project activities at the global level of project planning based on strength of dependencies between activities and subsequent production units at the local level. To achieve an optimal performance for enhanced competitiveness, both the global and local level of shipbuilding processes must be addressed. This integrated optimization model first uses Dependency Structure Matrix (DSM) to derive an optimal sequence of project activities based on Triangularization algorithm. Once optimality of project activities in the global level is realized then further optimization is applied to the local levels, which are the corresponding production processes of already optimized project activities. A robust optimization tool, Response Surface Method (RSM), is applied to ascertain optimum setting of various factors and resources at the production activities. Data from a South Asian shipyard has been applied to validate the fitness of the proposed method. Project data and computer simulated data are combined to carry out experiments according to the suggested layout of Design of Experiments (DOE). With the application of this model, it is possible to study the bottleneck dynamics of the production process. An optimum output of the yard, thus, may be achieved by the integrated optimization of project activities and corresponding production processes with respect to resource allocation. Therefore, this research may have a useful significance towards the improvement in shipbuilding project management

DESIGNING A MANUFACTURING SYSTEM TO REDUCE PRODUCTION LEARNING CURVE

The goal of this project was to design a new manufacturing system for Patio Pacific that would reduce the learning curve and the skilled labor required in the production process. Multiple ideas to decrease the scrap rate in the vert manufacturing process were tested. It was determined that outsourcing the manufacturing of the vertical frame piece was the most optimal because it would reduce overall cost and increase product quality. A new facility and production layout were designed in order to accommodate the new pre-manufactured parts. The approved facility design included a new production flow that transitioned manufacturing from single employees performing batch production methods to a component based manufacturing system. This included the introduction of job shops around the facility to reduce distance travelled by employees. To further increase standardization within the production process, the work benches were redesigned using 5S methods. The design was aimed to reduce strain on the employee during production and increase flexibility in the workplace. Many secondary results came from the start of implementation of these changes, such as: increased throughput, increased product quality, increased inventory accuracy and a reduced employee training time. Moving forward, Patio Pacific will continue to implement these designs and train their new employees accordingly

Cost-effective Design of Automotive Framing Systems Using Flexibility and Reconfigurability Principles

Manufacturing enterprises are entering an era of new challenges where manufacturing needs to compete in a global economy with open and unpredicted market changes. Manufacturing facilities need to possess a high degree of flexibility, enabling mass customization of production. Reconfigurable Manufacturing Systems (RMS) is a relatively new concept, which if adopted properly, will become a design foundation for the next generation of world-class production systems. They will help automotive companies achieve rapid response and cost-effective product delivery aligned with the current market demand. This research introduces new systematic methods dealing with a complete end-to-end design process to production systems, where the uncertainty of product variety is mapped to product attributes and manufacturing processes, then mapped into a production line using product decomposition into systems, sub-systems, and modular assembly. Graph network (NW), change propagation index (CPI) and hybrid design structure matrix (HDSM) were introduced. Design structures matrix (DSM) and hybrid design structure matrix (HDSM) were used along with axiomatic design (AD) to ensure customer needs are translated into action. A hierarchal structure has been developed for a body-in-white (BIW) framing system. Implementation for best practice and coordination between processes in all design stages is a prerequisite for other function requirements. Knowing systems level interaction early in the product developments process is critical for design concept selection, and systems architectures decisions. However, existing methods that address the system\u27s interaction, such as the design structure matrix (DSM), are good to analyze the systems but cannot be used during conceptual synthesis when most important designs are made. Systems level knowledge is critical to the success of the design of large systems and needs to be captured at the early stage of the design. Results of using the proposed methodology on a real case study shows that the proper implementation of flexibility and reconfigurability in the production system increase the capability and shows significant improvements in throughputs of production systems. Real production data was used to redesign the assembly line of production systems using digital manufacturing (DM) and production simulation. Simulation model of the state of practice was developed using DELMIA\u27s Digital Manufacturing solution (IGRIP)

Production Engineering and Management

The annual International Conference on Production Engineering and Management takes place for the sixth time his year, and can therefore be considered a well - established event that is the result of the joint effort of the OWL University of Applied Sciences and the University of Trieste. The conference has been established as an annual meeting under the Double Degree Master Program ‘Production Engineering and Management’ by the two partner universities. The main goal of the conference is to provide an opportunity for students, researchers and professionals from Germany, Italy and abroad, to meet and exchange information, discuss experiences, specific practices and technical solutions used in planning, design and management of production and service systems. In addition, the conference is a platform aimed at presenting research projects, introducing young academics to the tradition of Symposiums and promoting the exchange of ideas between the industry and the academy. Especially the contributions of successful graduates of the Double Degree Master Program ‘Production Engineering and Management’ and those of other postgraduate researchers from several European countries have been enforced. This year’s special focus is on Direct Digital Manufacturing in the context of Industry 4.0, a topic of great interest for the global industry. The concept is spreading, but the actual solutions must be presented in order to highlight the practical benefits to industry and customers. Indeed, as Henning Banthien, Secretary General of the German ‘Plattform Industrie 4.0’ project office, has recently remarked, “Industry 4.0 requires a close alliance amongst the private sector, academia, politics and trade unions” in order to be “translated into practice and be implemented now”. PEM 2016 takes place between September 29 and 30, 2016 at the OWL University of Applied Sciences in Lemgo. The program is defined by the Organizing and Scientific Committees and clustered into scientific sessions covering topics of main interest and importance to the participants of the conference. The scientific sessions deal with technical and engineering issues, as well as management topics, and include contributions by researchers from academia and industry. The extended abstracts and full papers of the contributions underwent a double - blind review process. The 24 accepted presentations are assigned, according to their subject, to one of the following sessions: ‘Direct Digital Manufacturing in the Context of Industry 4.0’, ‘Industrial Engineering and Lean Management’, ‘Management Techniques and Methodologies’, ‘Wood Processing Technologies and Furniture Production’ and ‘Innovation Techniques and Methodologies