An intelligent manufacturing system for heat treatment scheduling

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.This research is focused on the integration problem of process planning and scheduling in steel heat treatment operations environment using artificial intelligent techniques that are capable of dealing with such problems. This work addresses the issues involved in developing a suitable methodology for scheduling heat treatment operations of steel. Several intelligent algorithms have been developed for these propose namely, Genetic Algorithm (GA), Sexual Genetic Algorithm (SGA), Genetic Algorithm with Chromosome differentiation (GACD), Age Genetic Algorithm (AGA), and Mimetic Genetic Algorithm (MGA). These algorithms have been employed to develop an efficient intelligent algorithm using Algorithm Portfolio methodology. After that all the algorithms have been tested on two types of scheduling benchmarks. To apply these algorithms on heat treatment scheduling, a furnace model is developed for optimisation proposes. Furthermore, a system that is capable of selecting the optimal heat treatment regime is developed so the required metal properties can be achieved with the least energy consumption and the shortest time using Neuro-Fuzzy (NF) and Particle Swarm Optimisation (PSO) methodologies. Based on this system, PSO is used to optimise the heat treatment process by selecting different heat treatment conditions. The selected conditions are evaluated so the best selection can be identified. This work addresses the issues involved in developing a suitable methodology for developing an NF system and PSO for mechanical properties of the steel. Using the optimisers, furnace model and heat treatment system model, the intelligent system model is developed and implemented successfully. The results of this system were exciting and the optimisers were working correctly

Energy efficiency in discrete-manufacturing systems: insights, trends, and control strategies

Since the depletion of fossil energy sources, rising energy prices, and governmental regulation restrictions, the current manufacturing industry is shifting towards more efficient and sustainable systems. This transformation has promoted the identification of energy saving opportunities and the development of new technologies and strategies oriented to improve the energy efficiency of such systems. This paper outlines and discusses most of the research reported during the last decade regarding energy efficiency in manufacturing systems, the current technologies and strategies to improve that efficiency, identifying and remarking those related to the design of management/control strategies. Based on this fact, this paper aims to provide a review of strategies for reducing energy consumption and optimizing the use of resources within a plant into the context of discrete manufacturing. The review performed concerning the current context of manufacturing systems, control systems implemented, and their transformation towards Industry 4.0 might be useful in both the academic and industrial dimension to identify trends and critical points and suggest further research lines.Peer ReviewedPreprin

A review and classification of computer-based manufacturing scheduling tools

Computer-based manufacturing scheduling tools can play a key role in the management of industrial operations, as obtaining economic and reliable schedules is at the core of excellence in customer service and of efficiency in manufacturing companies. As a consequence, this topic has been receiving an increasing interest in the last decades, resulting in a number of case studies and descriptions of implementation of these tools. However, to the best of our knowledge, there is no review of these cases in order to classify existing references and to identify relevant issues still not properly addressed. Therefore, in this paper we carry out a systematic review of case studies of manufacturing scheduling tools. In order to provide a coherent taxonomy for the analysis of these tools, we develop a classification based on the functionalities of the manufacturing scheduling tools. Using this framework, existing contributions are classified and discussed, and a number of conclusions and open issues are identified. We hope that our work can establish a coherent picture of the topic so it serves as a starting point for future research

International Conference on Mechatronics, System Engineering and Robotics & Information System and Engineering

UBT Annual International Conference is the 8th international interdisciplinary peer reviewed conference which publishes works of the scientists as well as practitioners in the area where UBT is active in Education, Research and Development. The UBT aims to implement an integrated strategy to establish itself as an internationally competitive, research-intensive university, committed to the transfer of knowledge and the provision of a world-class education to the most talented students from all background. The main perspective of the conference is to connect the scientists and practitioners from different disciplines in the same place and make them be aware of the recent advancements in different research fields, and provide them with a unique forum to share their experiences. It is also the place to support the new academic staff for doing research and publish their work in international standard level. This conference consists of sub conferences in different fields like: – Computer Science and Communication Engineering– Management, Business and Economics– Mechatronics, System Engineering and Robotics– Energy Efficiency Engineering– Information Systems and Security– Architecture – Spatial Planning– Civil Engineering , Infrastructure and Environment– Law– Political Science– Journalism , Media and Communication– Food Science and Technology– Pharmaceutical and Natural Sciences– Design– Psychology– Education and Development– Fashion– Music– Art and Digital Media– Dentistry– Applied Medicine– Nursing This conference is the major scientific event of the UBT. It is organizing annually and always in cooperation with the partner universities from the region and Europe. We have to thank all Authors, partners, sponsors and also the conference organizing team making this event a real international scientific event. Edmond Hajrizi, President of UBT UBT – Higher Education Institutio

Decomposition of Manufacturing Processes: A Review

Manufacturing is a global activity that started during the industrial revolution in the late 19th century to cater for the large-scale production of products. Since then, manufacturing has changed tremendously through the innovations of technology, processes, materials, communication and transportation. The major challenge facing manufacturing is to produce more products using less material, less energy and less involvement of labour. To face these challenges, manufacturing companies must have a strategy and competitive priority in order for them to compete in a dynamic market. A review of the literature on the decomposition of manufacturing processes outlines three main processes, namely: high volume, medium volume and low volume. The decomposition shows that each sub process has its own characteristics and depends on the nature of the firm’s business. Two extreme processes are continuous line production (fast extreme) and project shop (slow extreme). Other processes are in between these two extremes of the manufacturing spectrum. Process flow patterns become less complex with cellular, line and continuous flow compared with jobbing and project. The review also indicates that when the product is high variety and low volume, project or functional production is applied

A comparison of processing techniques for producing prototype injection moulding inserts.

This project involves the investigation of processing techniques for producing low-cost moulding inserts used in the particulate injection moulding (PIM) process. Prototype moulds were made from both additive and subtractive processes as well as a combination of the two. The general motivation for this was to reduce the entry cost of users when considering PIM. PIM cavity inserts were first made by conventional machining from a polymer block using the pocket NC desktop mill. PIM cavity inserts were also made by fused filament deposition modelling using the Tiertime UP plus 3D printer. The injection moulding trials manifested in surface finish and part removal defects. The feedstock was a titanium metal blend which is brittle in comparison to commodity polymers. That in combination with the mesoscale features, small cross-sections and complex geometries were considered the main problems. For both processing methods, fixes were identified and made to test the theory. These consisted of a blended approach that saw a combination of both the additive and subtractive processes being used. The parts produced from the three processing methods are investigated and their respective merits and issues are discussed

Reducing risk in pre-production investigations through undergraduate engineering projects.

This poster is the culmination of final year Bachelor of Engineering Technology (B.Eng.Tech) student projects in 2017 and 2018. The B.Eng.Tech is a level seven qualification that aligns with the Sydney accord for a three-year engineering degree and hence is internationally benchmarked. The enabling mechanism of these projects is the industry connectivity that creates real-world projects and highlights the benefits of the investigation of process at the technologist level. The methodologies we use are basic and transparent, with enough depth of technical knowledge to ensure the industry partners gain from the collaboration process. The process we use minimizes the disconnect between the student and the industry supervisor while maintaining the academic freedom of the student and the commercial sensitivities of the supervisor. The general motivation for this approach is the reduction of the entry cost of the industry to enable consideration of new technologies and thereby reducing risk to core business and shareholder profits. The poster presents several images and interpretive dialogue to explain the positive and negative aspects of the student process

A Review of the Implementation of JIT Algorithms and Models in Production Systems

Intense competition in today’s economy, the shrinking life cycles of products, and the heightening expectations of customers have forced business enterprises to focus their attention on correctly arranging and controlling their production and supply chain systems. Thus, manufacturing firms/industries adopt JIT techniques to enjoy competitive advantage. In this paper, a literature review is presented to show the important applications of JIT Algorithms and Models in Production Systems. The purpose of this step is to review the results obtained from the implementation and to provide the practical recommendations for further improvement. This will help reveal practical issues encountered in the implementation. All these issues should become main concerns if the manufacturing Plant wants to get maximum benefits from the JIT implementation. This study bridged a research gap by identifying a framework for re-design of manufacturing systems into practical optimum Just-In-Time systems. The conventional JIT approach is mostly applicable to static production systems and the dynamic production systems require a more practical integrated JIT approach

Total Constraint Management for Improving Construction Work Flow in Liquefied Natural Gas Industry

Australia has benefited and will continue to benefit significantly from Liquefied Natural Gas (LNG) investments underway. Managing these LNG projects is challenging as they become increasingly complex and technologically demanding. The primary goal of this thesis is to develop a Total Constraint Management (TCM) method to improve construction work flow during LNG construction. Five controlled experiments were conducted and results show that successful implementation of TCM can significantly improve construction productivity and reduce schedule overruns