Modeling, design and scheduling of computer integrated manufacturing and demanufacturing systems

This doctoral dissertation work aims to provide a discrete-event system-based methodology for design, implementation, and operation of flexible and agile manufacturing and demanufacturing systems. After a review of the current academic and industrial activities in these fields, a Virtual Production Lines (VPLs) design methodology is proposed to facilitate a Manufacturing Execution System integrated with a shop floor system. A case study on a back-end semiconductor line is performed to demonstrate that the proposed methodology is effective to increase system throughput and decrease tardiness. An adaptive algorithm is proposed to deal with the machine failure and maintenance. To minimize the environmental impacts caused by end-of-life or faulty products, this research addresses the fundamental design and implementation issues of an integrated flexible demanufacturing system (IFDS). In virtue of the success of the VPL design and differences between disassembly and assembly, a systematic approach is developed for disassembly line design. This thesis presents a novel disassembly planning and demanufacturing scheduling method for such a system. Case studies on the disassembly of personal computers are performed illustrating how the proposed approaches work

Assembly line balancing by using axiomatic design principles: An application from cooler manufacturing industry

[EN] The philosophy of production without waste is the fundamental belief behind lean manufacturing that should be adopted by enterprises. One of the waste elimination methods is assembly line balancing for lean manufacturing, i.e. Yamazumi. The assembly line balancing is to assign tasks to the workstations by minimizing the number of workstations to the required values. There should be no workstation with the excessively high or low workload, and all workstations must ideally work with balanced workloads. Accordingly, in this study, the axiomatic design method is applied for assembly line balancing in order to achieve maximum output with the installed capacity. In order to achieve this aim, all improvement opportunities are defined and utilized as an output of the study. Computational results indicate that the proposed method is effective to reduce operators’ idle time by 12%, imbalance workload between workstations by 38%, and the total number of workers by 12%. As a result of these improYilmaz, ÖF.; Demirel, ÖF.; Zaim, S.; Sevim, S. (2020). Assembly line balancing by using axiomatic design principles: An application from cooler manufacturing industry. International Journal of Production Management and Engineering. 8(1):31-43. https://doi.org/10.4995/ijpme.2020.11953OJS314381Ağpak, K , Gökçen, H , Saray, N , Özel, S . (2013). Stokastik Görev Zamanlı Tek Modelli U Tipi Montaj Hattı Dengeleme Problemleri İçin Bir Sezgisel. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi , 17 (4). Retrieved from https://dergipark.org.tr/en/pub/gazimmfd/issue/6654/89311Alcorta, L. (1999). Flexible automation and location of production in developing countries. The European Journal of Development Research, 11(1), 147-175. https://doi.org/10.1080/09578819908426731Babic, B. (1999). Axiomatic design of flexible manufacturing systems. International Journal of Production Research, 37(5), 1159-1173. https://doi.org/10.1080/002075499191454Black, J. 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Analysis of product design characteristics for remanufacturing using Fuzzy AHP and Axiomatic Design. Journal of Engineering Design, 28(5), 338-368. https://doi.org/10.1080/09544828.2017.1316014Cochran, D. S., Eversheim, W., Kubin, G., Sesterhenn, M. L. (2000). The application of axiomatic design and lean management principles in the scope of production system segmentation. International Journal of Production Research,38(6), 1377-1396. https://doi.org/10.1080/002075400188906Dolgui, A., Ihnatsenka, I. (2009). Branch and bound algorithm for a transfer line design problem: Stations with sequentially activated multi-spindle heads.European Journal of Operational Research, 197(3), 1119-1132. https://doi.org/10.1016/j.ejor.2008.03.028Durmusoglu, M. B., Satoglu, S. I. (2011). Axiomatic design of hybrid manufacturing systems in erratic demand conditions. International Journal of Production Research, 49(17), 5231-5261. https://doi.org/10.1080/00207543.2010.510487Ertay, T., Satoğlu, S. I. (2012). System parameter selection with information axiom for the new product introduction to the hybrid manufacturing systems under dual-resource constraint. International Journal of Production Research, 50(7), 1825-1839. https://doi.org/10.1080/00207543.2011.560205Ghosh, S., Gagnon, R. J. (1989). A comprehensive literature review and analysis of the design, balancing and scheduling of assembly systems. The International Journal of Production Research, 27(4), 637-670. https://doi.org/10.1080/00207548908942574Graves, S. C., Lamar, B. W. (1983). An integer programming procedure for assembly system design problems. Operations Research, 31(3), 522-545. https://doi.org/10.1287/opre.31.3.522Gunasekera, J. S., Ali, A. F. (1995). A three-step approach to designing a metal-forming process. JOM, 47(6), 22-25. https://doi.org/10.1007/BF03221198Guschinskaya, O., Dolgui, A., Guschinsky, N., Levin, G. (2008). A heuristic multi-start decomposition approach for optimal design of serial machining lines. European Journal of Operational Research, 189(3), 902-913. https://doi.org/10.1016/j.ejor.2006.03.072Hager, T., Wafik, H., Faouzi, M. (2017). Manufacturing system design based on axiomatic design: Case of assembly line. Journal of Industrial Engineering and Management, 10(1), 111-139. https://doi.org/10.3926/jiem.728Han, W. M., Zhao, J. L., Chen, Y. (2013). A Virtual Cellular Manufacturing System Design Model Based on Axiomatic Design Theory. In Applied Mechanics and Materials (Vol. 271, pp. 1478-1484). Trans Tech Publications. https://doi.org/10.4028/www.scientific.net/AMM.271-272.1478Holzner, P., Rauch, E., Spena, P. R., Matt, D. T. (2015). Systematic Design of SME Manufacturing and Assembly Systems Based on Axiomatic Design.Procedia CIRP, 34, 81-86. https://doi.org/10.1016/j.procir.2015.07.010Houshmand, M., Jamshidnezhad, B. (2002). Conceptual design of lean production systems through an axiomatic approach. In Proceedings of ICAD2002 Second International Conference on Axiomatic Design.Houshmand, M., Jamshidnezhad, B. (2004). A lean manufacturing roadmap for an automotive body assembly line within axiomatic design framework. International Journal of Engineering Transactions, 17(1), 51-72.Houshmand, M., Jamshidnezhad, B. (2006). An extended model of design process of lean production systems by means of process variables. Robotics and Computer-Integrated Manufacturing, 22(1), 1-16. https://doi.org/10.1016/j.rcim.2005.01.004Khandekar, A. V., Chakraborty, S. (2016). Application of fuzzy axiomatic design principles for selection of non-traditional machining processes. The International Journal of Advanced Manufacturing Technology, 83(1-4), 529-543.Kulak, O., Durmusoglu, M. B., Tufekci, S. (2005). A complete cellular manufacturing system design methodology based on axiomatic design principles. Computers & Industrial Engineering, 48(4), 765-787. https://doi.org/10.1016/j.cie.2004.12.006Lipson, H., Suh, N. P. (2000). Towards a universal knowledge database for design automation. In Proceeding of ICAD2000, First International Conference on Axiomatic Design, pg (Vol. 250258, pp. 21-23).Matt, D. T. (2008). Template based production system design. Journal of Manufacturing Technology Management, 19(7), 783-797. https://doi.org/10.1108/17410380810898741Matt, D. T. (2012). Application of Axiomatic Design principles to control complexity dynamics in a mixed-model assembly system: a case analysis.International Journal of Production Research, 50(7), 1850-1861. https://doi.org/10.1080/00207543.2011.565086Matt, D. T. (2013). Design of a scalable assembly system for product variety: a case study. Assembly Automation, 33(2), 117-126. https://doi.org/10.1108/01445151311306627McMullen, P. R., Frazier, G. V. (1998). Using simulated annealing to solve a multiobjective assembly line balancing problem with parallel workstations. International Journal of Production Research, 36(10), 2717-2741. https://doi.org/10.1080/002075498192454Nakao, M., Kobayashi, N., Hamada, K., Totsuka, T., Yamada, S. (2007). Decoupling executions in navigating manufacturing processes for shortening lead time and its implementation to an unmanned machine shop. CIRP Annals-Manufacturing Technology, 56(1), 171-174. https://doi.org/10.1016/j.cirp.2007.05.041Nordlund, M., Tate, D., Suh, N. P. (1996). Growth of axiomatic design through industrial practice. In 3rd CIRP Workshop on Design and the Implementation of Intelligent Manufacturing Systems, Tokyo, Japan (Vol. 6, pp. 77-84).Rauch, E., Spena, P. R., Matt, D. T. (2019). Axiomatic design guidelines for the design of flexible and agile manufacturing and assembly systems for SMEs. International Journal on Interactive Design and Manufacturing (IJIDeM), 13(1), 1-22. https://doi.org/10.1007/s12008-018-0460-1Reynal, V. A., Cochran, D. S. (1996). Understanding lean manufacturing according to axiomatic design principles.Suh, N. P. (1990). The principles of design (Vol. 990). New York: Oxford University Press.Suh, N. P. (1995). Designing-in of quality through axiomatic design. IEEE Transactions on Reliability, 44(2), 256-264. https://doi.org/10.1109/24.387380Suh, N. P. (1997). Design of systems. CIRP Annals-Manufacturing Technology,46(1), 75-80. https://doi.org/10.1016/S0007-8506(07)60779-3Suh, N. P. (2001). Axiomatic Design: Advances and Applications (The Oxford Series on Advanced Manufacturing).Vinodh, S., Aravindraj, S. (2012). Axiomatic modeling of lean manufacturing system. Journal of Engineering, Design and Technology, 10(2), 199-216. https://doi.org/10.1108/17260531211241185Yilmaz, O. F., Cevikcan, E., Durmusoglu, M. B. (2016). Scheduling batches in multi hybrid cell manufacturing system considering worker resources: A case study from pipeline industry. Advances in Production Engineering & Management, 11(3). https://doi.org/10.14743/apem2016.3.22

A verification library for multibody simulation software

A multibody dynamics verification library, that maintains and manages test and validation data is proposed, based on RRC Robot arm and CASE backhoe validation and a comparitive study of DADS, DISCOS, and CONTOPS that are existing public domain and commercial multibody dynamic simulation programs. Using simple representative problems, simulation results from each program are cross checked, and the validation results are presented. Functionalities of the verification library are defined, in order to automate validation procedure

Dual-side and three-dimensional microelectrode arrays fabricated from ultra-thin silicon substrates

A method for fabricating planar implantable microelectrode arrays was demonstrated using a process that relied on ultra-thin silicon substrates, which ranged in thickness from 25 to 50 µm. The challenge of handling these fragile materials was met via a temporary substrate support mechanism. In order to compensate for putative electrical shielding of extracellular neuronal fields, separately addressable electrode arrays were defined on each side of the silicon device. Deep reactive ion etching was employed to create sharp implantable shafts with lengths of up to 5 mm. The devices were flip-chip bonded onto printed circuit boards (PCBs) by means of an anisotropic conductive adhesive film. This scalable assembly technique enabled three-dimensional (3D) integration through formation of stacks of multiple silicon and PCB layers. Simulations and measurements of microelectrode noise appear to suggest that low impedance surfaces, which could be formed by electrodeposition of gold or other materials, are required to ensure an optimal signal-to-noise ratio as well a low level of interchannel crosstalk

Limiting the valence: advancements and new perspectives on patchy colloids, soft functionalized nanoparticles and biomolecules

Limited bonding valence, usually accompanied by well-defined directional interactions and selective bonding mechanisms, is nowadays considered among the key ingredients to create complex structures with tailored properties: even though isotropically interacting units already guarantee access to a vast range of functional materials, anisotropic interactions can provide extra instructions to steer the assembly of specific architectures. The anisotropy of effective interactions gives rise to a wealth of self-assembled structures both in the realm of suitably synthesized nano- and micro-sized building blocks and in nature, where the isotropy of interactions is often a zero-th order description of the complicated reality. In this review, we span a vast range of systems characterized by limited bonding valence, from patchy colloids of new generation to polymer-based functionalized nanoparticles, DNA-based systems and proteins, and describe how the interaction patterns of the single building blocks can be designed to tailor the properties of the target final structures

MISAT: Designing a Series of Powerful Small Satellites Based upon Micro Systems Technology

MISAT is a research and development cluster which will create a small satellite platform based on Micro Systems Technology (MST) aiming at innovative space as well as terrestrial applications. MISAT is part of the Dutch MicroNed program which has established a microsystems infrastructure to fully exploit the MST knowledge chain involving public and industrial partners alike. The cluster covers MST-related developments for the spacecraft bus and payload, as well as the satellite architecture. Particular emphasis is given to distributed systems in space to fully exploit the potential of miniaturization for future mission concepts. Examples of current developments are wireless sensor and actuator networks with plug and play characteristics, autonomous digital Sun sensors, re-configurable radio front ends with minimum power consumption, or micro-machined electrostatic accelerometer and gradiometer system for scientific research in fundamental physics as well as geophysics. As a result of MISAT, a first nano-satellite will be launched in 2007 to demonstrate the next generation of Sun sensors, power subsystems and satellite architecture technology. Rapid access to in-orbit technology demonstration and verification will be provided by a series of small satellites. This will include a formation flying mission, which will increasingly rely on MISAT technology to improve functionality and reduce size, mass and power for advanced technology demonstration and novel scientific applications.