573 research outputs found
Design and management of reconfigurable assembly lines in the automotive industry
Automotive suppliers are facing the challenge of continuously adapting their production targets to variable demand requirements due to the frequent introduction of new model variants, materials and assembly technologies. In this context, the profitable management of the product, process and system co-evolution is of paramount importance for the company competitiveness. In this paper, a methodology for the design and reconfiguration management of modular assembly systems is proposed. It addresses the selection of the technological modules, their integration in the assembly cell, and the reconfiguration policies to handle volume and lot size variability. The results are demonstrated in a real automotive case study. (C) 2016 CIRP
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)
Prefabricated Construction using Digitally Integrated Industrial Manufacturing
The paper describes research being carried out in relation to prefabricated high density affordable housing under a grant from the Partnership for the Advancement of Technology in Housing (PATH) and the National Science Foundation (NSF) in the USA. The objective is to demonstrate how a new paradigm for the conceptualization and construction of buildings can be conceived of as an entirely factory based process that creates advantages for construction through industrial systems technology transfer. Our approach is intended to transform design methodology through demonstrating how alternative construction concepts, using entirely pre-manufactured volumetric units, can be adopted. This involves digital modeling that facilitates parametric variations for creating customized prefabricated products from design conceptualization through to final product delivery. The paper discusses key areas under investigation in relation to a manufacturing paradigm used in the automotive industry that integrates virtual prototyping and industrial manufacturing systems. Our research explores a type of monocoque volumetric unit prefabricated in steel, which will be pre-finished as part of a modular factory-built approach using industrialized methodologies that will facilitate customized manufacture of a high quality energy efficient product for affordable housing. The paper addresses the automotive industry methods of manufacture that have served increased automobile performance and economics through mass production for over a century. In stark contrast, the building industry and in particular the housing industry is still a century behind. It is suggested that a move away from tradition will require an industry wide initiative, just like Henry Ford led the way with mass production. By embracing the increasing sophistication and capability that digital technology offers, it is shown how digital tools are implemented towards mass customization in house design using virtual modeling in the context of a prefabricated manufacturing approach. This includes industrialized modular sub-assembly design, where the information on parts, assemblies and modules can be transferred to digital and robotic technology, as seen in the automotive industry, as well as achieving enhanced production efficiency through a ‘supply chain' process, which is condensed. The paper discusses how these models for manufacture can be transferred into the housing market in order to revolutionize the cost and quality base of construction. Our research objective is to disseminate knowledge on this process, and showing how through integrated transfer of automotive technologies we can implement an industrialized fabrication process for mass housing, not previously known in the building industry. A key focus of our evolving research and development is to enable mass customization or delayed differentiation through virtual prototyping that becomes the central organizing element for design. This transfers through to the supply and implementation of housing using industrialized production line manufacture of a product. The expected outcomes of this research and the conclusions drawn in this paper will demonstrate the means by which to achieve more accessibility to affordable housing for society at large and how through successful design integration and an industrial basis for manufacture will provide an adaptable set of affordable housing typologies for diverse demographic needs
Vehicle Interior Access Deployable Worksurface Mechanism Concept Product Design
by
Premchand Gunachandran
The University of Wisconsin-Milwaukee, 2019
Under the Supervision of Professor Mohammad Habibur Rahman
Easy access and adjusting the vehicle interior configuration to a variety of situations and uses is the general desire for any vehicle user. To meet such desire an attempt has been made in this study to conceptualize a design to develop a new mechatronic product called re-configurable vehicle interior console mechanism to deploy a worksurface (DWS), which will provide flexible use of the vehicle’s interior of both partial and fully autonomous vehicles. This re-configurable vehicle interior console will deploy the DWS using a power sliding mechanism concept enabled by electrical and electronic control unit circuits. This DWS will have 2 degrees of freedom (DOF) in its operation. Each user can access a DWS by pressing the nearby button. The console will move towards the center of the leg space and the electrical motor actuator and lead screw inside the console will drive the DWS by sliding it up and the DWS will down fold over the lap level of the user to offer a convenient individual worksurface. The inner side of the console body is designed to accommodate four DWS units, two each on its right and left sides, to cater to four users in a vehicle. The DWS power sliding mechanism concept product design will address the problems faced by the extreme users in the carpooling group of office goers, business travellers, family and friends going on a long road travel vacation trips. This DWS mechanism product’s performance and size can be customized, re-designed and modified to assemble inside the console body for the user’s accessibility, personalized and sharing experience in vehicle interiors of SUV, minivan and autonomous vehicles as well.
Keywords: Vehicle Interior Access, Deployable Worksurface (DWS), Re-configurable Console, Original Equipment Manufacturer (OEM
Prefabricated Construction using Digitally Integrated Industrial Manufacturing
The paper describes research being carried out in relation to prefabricated high density affordablehousing under a grant from the Partnership for the Advancement of Technology in Housing(PATH) and the National Science Foundation (NSF) in the USA. The objective is to demonstratehow a new paradigm for the conceptualization and construction of buildings can be conceivedof as an entirely factory based process that creates advantages for construction through industrialsystems technology transfer. Our approach is intended to transform design methodologythrough demonstrating how alternative construction concepts, using entirely pre-manufacturedvolumetric units, can be adopted. This involves digital modeling that facilitates parametric variationsfor creating customized prefabricated products from design conceptualization through tofinal product delivery. The paper discusses key areas under investigation in relation to a manufacturingparadigm used in the automotive industry that integrates virtual prototyping and industrialmanufacturing systems. Our research explores a type of monocoque volumetric unit prefabricatedin steel, which will be pre-finished as part of a modular factory-built approach usingindustrialized methodologies that will facilitate customized manufacture of a high quality energyefficient product for affordable housing.The paper addresses the automotive industry methods of manufacture that have served increasedautomobile performance and economics through mass production for over a century. In starkcontrast, the building industry and in particular the housing industry is still a century behind. It issuggested that a move away from tradition will require an industry wide initiative, just like HenryFord led the way with mass production. By embracing the increasing sophistication and capabilitythat digital technology offers, it is shown how digital tools are implemented towards masscustomization in house design using virtual modeling in the context of a prefabricated manufacturingapproach. This includes industrialized modular sub-assembly design, where the informationon parts, assemblies and modules can be transferred to digital and robotic technology, asseen in the automotive industry, as well as achieving enhanced production efficiency through a‘supply chain' process, which is condensed. The paper discusses how these models for manufacturecan be transferred into the housing market in order to revolutionize the cost and qualitybase of construction. Our research objective is to disseminate knowledge on this process, andshowing how through integrated transfer of automotive technologies we can implement an industrializedfabrication process for mass housing, not previously known in the building industry
Collective intelligence in self-organized industrial cyber-physical systems
Cyber-physical systems (CPS) play an important role in the implementation of new Industry 4.0 solutions, acting as the backbone infrastructure to host distributed intelligence capabilities and promote the collective intelligence that emerges from the interactions among individuals. This collective intelligence concept provides an alternative way to design complex systems with several benefits, such as modularity, flexibility, robustness, and reconfigurability to condition changes, but it also presents several challenges to be managed (e.g., non-linearity, self-organization, and myopia). With this in mind, this paper discusses the factors that characterize collective intelligence, particularly that associated with industrial CPS, analyzing the enabling concepts, technologies, and application sectors, and providing an illustrative example of its application in an automotive assembly line. The main contribution of the paper focuses on a comprehensive review and analysis of the main aspects, challenges, and research opportunities to be considered for implementing collective intelligence in industrial CPS. The identified challenges are clustered according to five different categories, namely decentralization, emergency, intelligent machines and products, infrastructures and methods, and human integration and ethics. Although the research indicates some potential benefits of using collective intelligence to achieve the desired levels of autonomy and dynamic adaptation of industrial CPS, such approaches are still in the early stages, with perspectives to increase in the coming years. Based on that, they need to be further developed considering some main aspects, for example, related to balancing the distribution of intelligence by the vertical and horizontal dimensions and controlling the nervousness in self-organized systems.info:eu-repo/semantics/publishedVersio
Developing a framework to evaluate the existence of a complexity threshold
Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Civil and Environmental Engineering; and, (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; in conjunction with the Leaders for Manufacturing Program at MIT, 2006.Includes bibliographical references (leaves 49-51).An automotive manufacturer facing decreasing average product volumes as a result of market fragmentation while simultaneously reducing its manufacturing plant footprint must adapt to the difficult challenge of increased product mix within its manufacturing system. The increase in complexity resulting from greater product mix is considered to be a significant driver in increasing plant investment cost and reducing plant operating effectiveness. Thus, the ability to fully understand and more effectively balance the complexity trade-offs associated with different product-to-manufacturing plant allocation scenarios is critically important, as the manufacturer formulates its strategy and analyzes the associated costs and benefits. The ultimate question to be addressed is whether there exists a "complexity threshold" in terms of the maximum number of differentiated body styles (unique vehicle models) to be produced inside a single assembly plant. This thesis analyzes the challenge of manufacturing system and plant complexity by first developing a competitive benchmark study of body-style complexity at the major North American OEMs' plants. Then, manufacturing and operations data is analyzed for evidence of a "complexity threshold" in one manufacturer's operations.(cont.) Finally, a linear-program based optimization model is developed to enable a Manufacturing Planning group to better understand the company's tolerance for plant complexity by quantifying manufacturing costs associated with various product-to-manufacturing plant allocation scenarios. This tool enables the planner to simultaneously consider thousands of different possible combinations of which products to produce in which plants, by analyzing manufacturing investment and per-vehicle operating cost estimates for each combination. The ability to impose constraints on the maximum number of body styles produced at any one plant yields insight on the value of pursuing a higher-mix (in terms of body styles) manufacturing strategy in particular plants, or across the entire plant footprint.by Matthew J. Hasik.M.B.A.S.M
Reviewing Digital Manufacturing concept in the Industry 4.0 paradigm
Digitalization of manufacturing is once again on the industry application research agenda and Digital Manufacturing plays a fundamental role in this process. However, there is a lack of commonality in the literature about the purpose of Digital Manufacturing. The purpose of this paper is to analyze the concept and application domain of Digital Manufacturing considering the increasingly established Industry 4.0 paradigm. Based on a content analysis concepts are framed, and new technological characteristics identified. The paper contributes to a better understanding of the future challenges that companies face by positioning Digital Manufacturing conceptually and delimiting its application domain
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