Optimisation of compressed air system’s energy usage through discrete event simulation: Compressor performance

Compressed air systems (CAS) utilised in manufacturing processes require significant energy input for operation. The estimated cost of producing compressed air is considered high with little transparency available when assessing its value in manufacturing. There is currently poor awareness of the performance of CAS in relation to its equipment utilisation and energy optimisation. This paper presents a modified approach to the Energy Blocks methodology for representation and simplification of compressed airflow profiles in discrete event simulations (DES). The presented AirBlocks methodology significantly reduces the aggregate data required to represent the dynamic and interdependent nature of CAS. Combining the AirBlocks approach with manufacturing throughout productivity simulations allows a productivity oriented compressed air demand profile to be developed. This offers the capacity to estimate periods of sustained peak, average and minimum air demand, incidents of production stoppages due to air demand, incidents of production due to air starvation and, identify waste and saving potential in the system. This paper includes an industrial case study where the AirBlocks approach was used in evaluating the performance of an existing CAS. Through simulation - poor compressor utilisation and regular incidents of air starvation were identified as symptoms of insufficient CAS volumetric capacity and an oversized compressor system in an automotive engine manufacturing plant

Energy usage and temperature distribution in old mega factories

Global environmental problems and the rising cost of energy puts industries under pressure to reduce energy consumption and lower their carbon footprint. Old “mega factories” use a lot of energy to maintain the production and working environment in an optimal condition when compared to newer factories. Heating cost can amount to more than 26% of the annual utility bill despite the mild climate of the United Kingdom. Intelligent cost reduction solutions, suitable management strategies and contemporary low carbon policies can significantly reduce this energy consumption without incorporating the latest and expensive technical solutions. Extensive research was carried out at a manufacturing plant with large old buildings to investigate multifarious solutions of low cost energy saving methods. Environmental plant data was obtained and analysed to understand thermal characteristics of the factory space. Non-uniform temperature distribution, consistently high average temperatures and an unstable machine environment all contributed to unnecessary expenses. Cost effective implementations, such as secure high speed doors, management strategies and employee awareness, consistent temperature monitoring and communication can create more uniform temperature distribution for a more stable working and manufacturing environment. The average temperature within this plant could be reduced by adequate measures and the comfort for employees and the machinery environment could be simultaneously improved to guarantee smoother operations and lower carbon footprint

A simple energy usage toolkit from manufacturing simulation data

A fundamental problem in energy management is the inability to clearly predict any possible energy saving opportunities. The cost of both under or overestimating potential returns on investment can be prohibitive to a decision maker. In recent years the simulation of energy usage using existing manufacturing simulation tools has increased in popularity among researchers, but it is energy managers who need to see the benefits of this discipline. This paper proposes an interactive manufacturing energy management tool which makes use of existing productivity simulation models for the prediction of energy usage. An interactive Microsoft® Excel® based tool is developed to control Lanner’s WITNESS® discrete-event simulation software using Microsoft® Visual Basic® for Applications. The tool has the ability to predict potential areas where energy saving opportunities can be made within a complex manufacturing line, and is accessible from management presentations and proposals. The interactivity of the tool provides an environment which facilitates efficient hypothesis testing. The paper includes an industrial case study where the approach was used to quantify theoretical savings from certain energy usage reduction scenarios within a complex automotive engine manufacturing line

Computer simulation of atomic-scale processes in Fe-Cu alloys

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Linking simulation, critical success factors and enterprise resource planning in small and medium size enterprises

Since the mid-2000s enterprise resource planning (ERP) vendors have been actively developing and implementing scaled down, pre-configured low cost ERP versions to suit small and medium-sized enterprises (SMEs. Further, ERP implementations are neither standard nor information technology (IT) projects. Despite the awareness of such information, up to 57% of ERP projects either fail to realise any benefit, run over-budget or time. Critical success factors (CSFs) are subjective and change as per ERP project and stages. Only a few publications explicitly focus on CSFs and dynamic interrelationships between CSFs in make-to-order (MTO) manufacturing SMEs. Additionally, these dynamic interrelationships cannot be visualised as a project is implemented. This paper, based on a 30-month ERP implementation project at a UK MTO SME presents a discrete event (DE) simulation modelling framework for studying relationships among CSFs using WITNESS software. The framework and concept are intended to improve the percentage of ERP projects realising their true benefits

Make to order manufacturing and operational management strategies – a case study at Priorclave Ltd.

Accurate due date setting and lead time management are difficult tasks for Make to Order (MTO) manufacturing firms and require effective capacity management. To remain competitive accurate due date prediction and shorter lead times are key. Within a backdrop of a Small and Medium Enterprise (SME) the development of a Prototype Planning and Scheduling System (PPSS) and the subsequent implementation of an Enterprise Resource Planning (ERP) System are explained. Proposed work and trials to integrate the ERP system to the PPSS is detailed. Thus PPSS becomes a secondary level of control, with its inputs from the ERP system