Virtual ergonomics and time optimization of a railway coach assembly line

The recent drive towards timely multiple product realizations has caused most Manufacturing Enterprises (MEs) to develop more flexible assembly lines supported by better manufacturing design and planning. The aim of this work is to develop a methodology which will support feasibility analyses of assembly tasks, in order to simulate either a manufacturing process or a single work-cell in which digital human models act. The methodology has been applied in a case study relating to a railway industry. Simulations were applied to help standardize the methodology and suggest new solutions for realizing ergonomic and efficient assembly processes in the railway industry

The integrated use of enterprise and system dynamics modelling techniques in manufacturing enterprises

Enterprise modelling (EM) techniques support manufacturing process (re) engineering by capturing ‘as-is’ processes and based on perceived outputs, support the design of ‘to-be’ process models capable of meeting manufacturing systems requirements. On the other hand, system dynamics (SD) modelling tools are used extensively for policy analysis and modelling aspects of dynamics which impact on businesses. In this paper, the use of EM and SD modelling techniques has been integrated to facilitate qualitative and quantitative reasoning about the structures and behaviours of processes and resource systems used by a Manufacturing Enterprise (ME) during the production of composite bearings

The evolution of manufacturing SPECIES

This research aims to develop hierarchical and cladistic classifications of manufacturing system evolution, incorporating evolving and interacting product, process and production system features. The objectives then are to systematically organise manufacturing systems and their characteristics in classifications Forty-six candidate species of manufacturing systems have been identified and organised in a 4th generation hierarchical classification with 14 ‘genera’, 6 ‘families’ 3 ‘orders’ and 1 ‘class’ of discrete manufacturing. The accompanying cladistic classification hypothesises the evolutionary history of manufacturing, using ‘descriptors’ drawn from a library of 12 characters and 66 states. These are consistent and synthesise many of the established typologies in the literature

Digital modelling methodology for effective cost assessment

Research advances in digital factory design has led to a number of simulation techniques and tools which have the capability to represent aspects of the lifecycle of manufacturing systems. Although this is the case, analysis of key performance indicators (such as cost) are not very advanced when compared with other digital manufacturing simulation applications. To address this gap, this paper proposes a dynamic cost modelling (Product, Process, Resource, Cost-PPRC) methodology which is based on an initial digital modelling of the (perceived or real) production system and then associating product features with the capabilities of the production system. The paper reports a case application of the PPRC methodology for remote laser welding (RLW) of a car door. The methodology provides a basis for economic justification of product, process and resource related changes

Integrated ontologies in support of factory systems design

Digital factory modelling based on virtual design and simulation has emerged as part of the mainstream activities geared towards reducing product design cycle. Some basic industrial systems are currently integrated via semantic modelling technologies so that products matching processes and resource requirements are integrated to fulfil customer demands. Despite these achievements, product design is still dependent on the knowledge of designers and do not benefit from existing process and resource knowledge, which are in separate domains. This paper therefore presents an integration method based on semantic technologies and PPR ontologies to enable the reuse of known and unknown knowledge. The method relies on the use of cloud manufacturing to improve the efficiency of responsesgenerated by querying the PPR ontology

Review of semantic modelling technologies in support of virtual factory design

Comprehensive data models and standardised terminologies are required across tools and their developers to rapidly design and prototype digitised virtual factories. Also, various types of software are required to be integrated for cost-effective modelling exercises. To meet this requirement, semantic modelling technologies involving ontologies have featured prominently in many manufacturing applications. This paper considers, extensively, the current semantic requirements for digitised virtual factory design and prototyping and compares them with the capabilities of existing semantic technologies. As a result, a review of methodologies, tools and languages for creating ontologies has been reported. The review concludes with the next generation requirements for methodologies, tools and languages for creating ontologies suitable for the virtual factory design process, and further explains ongoing work associated with the creation of ontologies and reasoning mechanisms through the integrated use of ObjectLogic, OntoStudio and OntoBroker.</p

Digital modelling methodology for effective cost assessment

Abstract Research advances in digital factory design has led to a number of simulation techniques and tools which have the capability to represent aspects of the lifecycle of manufacturing systems. Although this is the case, analysis of key performance indicators (such as cost) are not very advanced when compared with other digital manufacturing simulation applications. To address this gap, this paper proposes a dynamic cost modelling (Product, Process, Resource, Cost-PPRC) methodology which is based on an initial digital modelling of the (perceived or real) production system and then associating product features with the capabilities of the production system. The paper reports a case application of the PPRC methodology for remote laser welding (RLW) of a car door. The methodology provides a basis for economic justification of product, process and resource related changes

A Methodology for Assessing the Cost Effectiveness of Assembly Processes

Part 6: Process Selecting and Modelling TechniquesInternational audienceAssembly processes are undergoing frequent changes as a result of the current drive for agility and rapid product solutions. These changes induce complexities and dynamics in the survival of most Manufacturing Enterprises (MEs). To remain competitive, MEs have to continuously and flexibly adjust through the redesign and organisation of their manufacturing and assembly processes as well as resource elements, with the aim to improve ‘cost’ and ‘values’ generated. Cost and values are part of key performance indicators necessary for determining the economic viability of assembly processes. The paper therefore presents a methodology capable of capturing, modelling and using information related to cost and value generation for in-depth assembly process analysis. This form of analysis can help determine assembly process efficiency and therefore support the selection or redesign of assembly processes for maximum value realisation at minimal cost