A Systematic Approach to Quality Oriented Product Sequencing for Multistage Manufacturing Systems

Product sequencing is one way to reduce cost and improve product quality for multistage manufacturing systems (MMS). However, systematically evaluating the influence of product sequence on quality performance for MMS is still a challenge. By considering the rate of incoming conforming product, manufacturing system quality transition between batch to batch, and quality propagation along stages, this paper investigates the appropriate batch policies and product sequencing for MMS so that satisfied quality performance can be achieved. A model to analyze the relationship between the product sequencing and quality performance is conducted just by using the quality inspection data and the complex engineering knowledge used in the variation method is avoided. Based on Markov Chain processes methodology, quality performance is modeled as a function of transition states jointly determined by multistage condition, product sequencing, incoming part quality, and propagation of the rate of conforming products among multistage. Quality related batch strategies are discussed for optimal quality performance. Two kinds of quality efficiency are put forward to facilitate the modeling and the discussion. The results of the model will lead to guidelines for quality management in multistage manufacturing systems

A Systematic Approach to Quality Oriented Product Sequencing for Multistage Manufacturing Systems

Product sequencing is one way to reduce cost and improve product quality for multistage manufacturing systems (MMS). However, systematically evaluating the influence of product sequence on quality performance for MMS is still a challenge. By considering the rate of incoming conforming product, manufacturing system quality transition between batch to batch, and quality propagation along stages, this paper investigates the appropriate batch policies and product sequencing for MMS so that satisfied quality performance can be achieved. A model to analyze the relationship between the product sequencing and quality performance is conducted just by using the quality inspection data and the complex engineering knowledge used in the variation method is avoided. Based on Markov Chain processes methodology, quality performance is modeled as a function of transition states jointly determined by multistage condition, product sequencing, incoming part quality, and propagation of the rate of conforming products among multistage. Quality related batch strategies are discussed for optimal quality performance. Two kinds of quality efficiency are put forward to facilitate the modeling and the discussion. The results of the model will lead to guidelines for quality management in multistage manufacturing systems

Nonlinear Material Behavior Analysis under High Compression Pressure in Dynamic Conditions

Gun chamber pressure is an important parameter in proofing of ammunition to ensure safety and reliability. It can be measured using copper crushers or piezoelectric sensor. Pressure calculations in copper crusher method are based on linear plastic deformation of copper after firing. However, crusher pressure deformation at high pressures deviates from the corresponding values measured by piezoelectric pressure transducers due to strain rate dependence of copper. The nonlinear deformation rate of copper at high pressure measurements causes actual readings from copper crusher gauge to deviate from true pressure values. Comparative analysis of gun chamber pressure was conducted for 7.62 × 51 mm ammunition using Electronic Pressure, Velocity, and Action Time (EPVAT) system with piezoelectric pressure transducers and conventional crusher gauge. Ammunitions of two different brands were used to measure chamber pressure, namely, NATO standard ammunition and non-NATO standard ammunition. The deformation of copper crushers has also been simulated to compare its deformation with real time firing. The results indicate erratic behavior for chamber pressure by copper crusher as per standard deviation and relative spread and thus prove piezo sensor as more reliable and consistent mode of peak pressure measurement. The results from simulation, cost benefit analysis, and accuracy clearly provide piezo sensors with an edge over conventional, inaccurate, and costly method of copper crusher for ballistic measurements due to its nonlinear behavior

Multi-objective optimization of turning titanium-based alloy Ti-6Al-4V under dry, wet, and cryogenic conditions using gray relational analysis (GRA).

In modern manufacturing industries, the importance of multi-objective optimization cannot be overemphasized particularly when the desired responses are differing in nature towards each other. With the emergence of new technologies, the need to achieve overall efficiency in terms of energy, output, and tooling is on the rise. Resultantly, endeavor is to make the machining process sustainable, productive, and efficient simultaneously. In this research, the effects of machining parameters (feed, cutting speed, depth of cut, and cutting condition including dry, wet, and cryogenic) were analyzed. Since sustainable production demands a balance between production quality and energy consumption, therefore, response parameters including specific cutting energy, tool wear, surface roughness, and material removal rate were considered. Taguchi-gray integrated approach was adopted in this study. Multi-objective function was developed using gray relational methodology, and its regression analysis was conducted. Response surface optimization was carried out to optimize the formulated multi-objective function and derive the optimum machining parameters. Concurrent responses were optimized with best-suited values of input parameters to make the most out of the machining process. Analysis of variance results showed that feed is the most effective parameter followed by cutting condition in terms of overall contribution in multi-objective function. The proposed optimum parameters resulted in improvement of tool wear and surface roughness by 30% and 22%, respectively, whereas specific cutting energy was reduced by 4%

A Novel Idea for Optimizing Condition-Based Maintenance Using Genetic Algorithms and Continuous Event Simulation Techniques

Effective maintenance strategies are of utmost significance for system engineering due to their direct linkage with financial aspects and safety of the plants’ operation. At a point where the state of a system, for instance, level of its deterioration, can be constantly observed, a strategy based on condition-based maintenance (CBM) may be affected; wherein upkeep of the system is done progressively on the premise of monitored state of the system. In this article, a multicomponent framework is considered that is continuously kept under observation. In order to decide an optimal deterioration stage for the said system, Genetic Algorithm (GA) technique has been utilized that figures out when its preventive maintenance should be carried out. The system is configured into a multiobjective problem that is aimed at optimizing the two desired objectives, namely, profitability and accessibility. For the sake of reality, a prognostic model portraying the advancements of deteriorating system has been employed that will be based on utilization of continuous event simulation techniques. In this regard, Monte Carlo (MC) simulation has been shortlisted as it can take into account a wide range of probable options that can help in reducing uncertainty. The inherent benefits proffered by the said simulation technique are fully utilized to display various elements of a deteriorating system working under stressed environment. The proposed synergic model (GA and MC) is considered to be more effective due to the employment of “drop-by-drop approach” that permits successful drive of the related search process with regard to the best optimal solutions

Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions.

Productivity and economy are key elements of any sustainable manufacturing system. While productivity is associated to quantity and quality, economy focuses on energy efficient processes achieving an overall high output to input ratio. Machining of hard-to-cut materials has always posed a challenge due to increased tool wear and energy loss. Cryogenics have emerged as an effective means to improve sustainability in the recent past. In the present research the use of cooling conditions has been investigated as an input variable to analyze its effect on tool wear, specific cutting energy and surface roughness in combination with other input machining parameters of feed rate, cutting speed and depth of cut. Experimental design was based on Taguchi design of experiment. Analysis of Variance (ANOVA) was carried out to ascertain the contribution ratio of each input. Results showed the positive effect of coolant usage, particularly cryogenic, on process responses. Tool wear was improved by 33% whereas specific cutting energy and surface roughness were improved by 10% and 9% respectively by adapting the optimum machining conditions

Modal analysis of ship's mast structure using effective mass participation factor

Background/Objectives: Each structure tends to vibrate at particular frequencies, called resonant or natural frequencies. When a structure is excited by dynamic load with frequency coinciding one of its natural frequencies the structure experiences stresses and large displacements. In this paper effective mass participation factor criterion is used to solve the vibration problem in the ship mast. Methods/Statistical Analysis: The effective mass participation factor provides a measure of the energy contained within each resonant mode. Vibration problem originated when one of the antenna at top of mast was replaced by a new antenna with greater mass at same location. The overall mast structure started vibrating because of the resonance of natural frequencies of the mast structure with natural frequencies of rotary equipment. Findings: It caused interruption in sensitivity of equipment installed on the mast structure. Instead of fabricating the new mast structure, some alteration has been carried out on the basis of results obtained from modal analysis. Application/Improvements: The study is very effective to overcome the vibration problems in ship mast

Eye and Voice-Controlled Human Machine Interface System for Wheelchairs Using Image Gradient Approach

© 2020 The Author(s). This is an open access article distributed under the Creative Commons Attribution License (https://creativecommons.org/licenses/by/4.0/) which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.Rehabilitative mobility aids are being used extensively for physically impaired people. Efforts are being made to develop human machine interfaces (HMIs), manipulating the biosignals to better control the electromechanical mobility aids, especially the wheelchairs. Creating precise control commands such as move forward, left, right, backward and stop, via biosignals, in an appropriate HMI is the actual challenge, as the people with a high level of disability (quadriplegia and paralysis, etc.) are unable to drive conventional wheelchairs. Therefore, a novel system driven by optical signals addressing the needs of such a physically impaired population is introduced in this paper. The present system is divided into two parts: the first part comprises of detection of eyeball movements together with the processing of the optical signal, and the second part encompasses the mechanical assembly module, i.e., control of the wheelchair through motor driving circuitry. A web camera is used to capture real-time images. The processor used is Raspberry-Pi with Linux operating system. In order to make the system more congenial and reliable, the voice-controlled mode is incorporated in the wheelchair. To appraise the system’s performance, a basic wheelchair skill test (WST) is carried out. Basic skills like movement on plain and rough surfaces in forward, reverse direction and turning capability were analyzed for easier comparison with other existing wheelchair setups on the bases of controlling mechanisms, compatibility, design models, and usability in diverse conditions. System successfully operates with average response time of 3 s for eye and 3.4 s for voice control mode.Peer reviewedFinal Published versio

Recent Research Trends in Genetic Algorithm Based Flexible Job Shop Scheduling Problems

Flexible Job Shop Scheduling Problem (FJSSP) is an extension of the classical Job Shop Scheduling Problem (JSSP). The FJSSP is known to be NP-hard problem with regard to optimization and it is very difficult to find reasonably accurate solutions of the problem instances in a rational time. Extensive research has been carried out in this area especially over the span of the last 20 years in which the hybrid approaches involving Genetic Algorithm (GA) have gained the most popularity. Keeping in view this aspect, this article presents a comprehensive literature review of the FJSSPs solved using the GA. The survey is further extended by the inclusion of the hybrid GA (hGA) techniques used in the solution of the problem. This review will give readers an insight into use of certain parameters in their future research along with future research directions

Global age-sex-specific mortality, life expectancy, and population estimates in 204 countries and territories and 811 subnational locations, 1950–2021, and the impact of the COVID-19 pandemic: a comprehensive demographic analysis for the Global Burden of Disease Study 2021

Background: Estimates of demographic metrics are crucial to assess levels and trends of population health outcomes. The profound impact of the COVID-19 pandemic on populations worldwide has underscored the need for timely estimates to understand this unprecedented event within the context of long-term population health trends. The Global Burden of Diseases, Injuries, and Risk Factors Study (GBD) 2021 provides new demographic estimates for 204 countries and territories and 811 additional subnational locations from 1950 to 2021, with a particular emphasis on changes in mortality and life expectancy that occurred during the 2020–21 COVID-19 pandemic period. Methods: 22 223 data sources from vital registration, sample registration, surveys, censuses, and other sources were used to estimate mortality, with a subset of these sources used exclusively to estimate excess mortality due to the COVID-19 pandemic. 2026 data sources were used for population estimation. Additional sources were used to estimate migration; the effects of the HIV epidemic; and demographic discontinuities due to conflicts, famines, natural disasters, and pandemics, which are used as inputs for estimating mortality and population. Spatiotemporal Gaussian process regression (ST-GPR) was used to generate under-5 mortality rates, which synthesised 30 763 location-years of vital registration and sample registration data, 1365 surveys and censuses, and 80 other sources. ST-GPR was also used to estimate adult mortality (between ages 15 and 59 years) based on information from 31 642 location-years of vital registration and sample registration data, 355 surveys and censuses, and 24 other sources. Estimates of child and adult mortality rates were then used to generate life tables with a relational model life table system. For countries with large HIV epidemics, life tables were adjusted using independent estimates of HIV-specific mortality generated via an epidemiological analysis of HIV prevalence surveys, antenatal clinic serosurveillance, and other data sources. Excess mortality due to the COVID-19 pandemic in 2020 and 2021 was determined by subtracting observed all-cause mortality (adjusted for late registration and mortality anomalies) from the mortality expected in the absence of the pandemic. Expected mortality was calculated based on historical trends using an ensemble of models. In location-years where all-cause mortality data were unavailable, we estimated excess mortality rates using a regression model with covariates pertaining to the pandemic. Population size was computed using a Bayesian hierarchical cohort component model. Life expectancy was calculated using age-specific mortality rates and standard demographic methods. Uncertainty intervals (UIs) were calculated for every metric using the 25th and 975th ordered values from a 1000-draw posterior distribution. Findings: Global all-cause mortality followed two distinct patterns over the study period: age-standardised mortality rates declined between 1950 and 2019 (a 62·8% [95% UI 60·5–65·1] decline), and increased during the COVID-19 pandemic period (2020–21; 5·1% [0·9–9·6] increase). In contrast with the overall reverse in mortality trends during the pandemic period, child mortality continued to decline, with 4·66 million (3·98–5·50) global deaths in children younger than 5 years in 2021 compared with 5·21 million (4·50–6·01) in 2019. An estimated 131 million (126–137) people died globally from all causes in 2020 and 2021 combined, of which 15·9 million (14·7–17·2) were due to the COVID-19 pandemic (measured by excess mortality, which includes deaths directly due to SARS-CoV-2 infection and those indirectly due to other social, economic, or behavioural changes associated with the pandemic). Excess mortality rates exceeded 150 deaths per 100 000 population during at least one year of the pandemic in 80 countries and territories, whereas 20 nations had a negative excess mortality rate in 2020 or 2021, indicating that all-cause mortality in these countries was lower during the pandemic than expected based on historical trends. Between 1950 and 2021, global life expectancy at birth increased by 22·7 years (20·8–24·8), from 49·0 years (46·7–51·3) to 71·7 years (70·9–72·5). Global life expectancy at birth declined by 1·6 years (1·0–2·2) between 2019 and 2021, reversing historical trends. An increase in life expectancy was only observed in 32 (15·7%) of 204 countries and territories between 2019 and 2021. The global population reached 7·89 billion (7·67–8·13) people in 2021, by which time 56 of 204 countries and territories had peaked and subsequently populations have declined. The largest proportion of population growth between 2020 and 2021 was in sub-Saharan Africa (39·5% [28·4–52·7]) and south Asia (26·3% [9·0–44·7]). From 2000 to 2021, the ratio of the population aged 65 years and older to the population aged younger than 15 years increased in 188 (92·2%) of 204 nations. Interpretation: Global adult mortality rates markedly increased during the COVID-19 pandemic in 2020 and 2021, reversing past decreasing trends, while child mortality rates continued to decline, albeit more slowly than in earlier years. Although COVID-19 had a substantial impact on many demographic indicators during the first 2 years of the pandemic, overall global health progress over the 72 years evaluated has been profound, with considerable improvements in mortality and life expectancy. Additionally, we observed a deceleration of global population growth since 2017, despite steady or increasing growth in lower-income countries, combined with a continued global shift of population age structures towards older ages. These demographic changes will likely present future challenges to health systems, economies, and societies. The comprehensive demographic estimates reported here will enable researchers, policy makers, health practitioners, and other key stakeholders to better understand and address the profound changes that have occurred in the global health landscape following the first 2 years of the COVID-19 pandemic, and longer-term trends beyond the pandemic