The load of sustainability for Additive Manufacturing processes

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Human–Robot Interaction for Improving Fuselage Assembly Tasks: A Case Study

In current industrial systems, automation is a very important aspect for assessing manufacturing production performance related to working times, accuracy of operations and quality. In particular, the introduction of a robotic system in the working area should guarantee some improvements, such as risks reduction for human operators, better quality results and a speed increase for production processes. In this context, human action remains still necessary to carry out part of the subtasks, as in the case of composites assembly processes. This study aims at presenting a case study regarding the reorganization of the working activity carried out in workstation in which a composite fuselage panel is assembled in order to demonstrate, by means of simulation tool, that some of the advantages previously listed can be achieved also in aerospace industry. In particular, an entire working process for composite fuselage panel assembling will be simulated and analyzed in order to demonstrate and verify the applicability and effectiveness of human-robot interaction (HRI), focusing on working times and ergonomics and respecting the constraints imposed by standards ISO 10218 and ISO TS 15066. Results show the effectiveness of HRI both in terms of assembly performance, by reducing working times and ergonomics-for which the simulation provides a very low risk index

Digital Twin for Monitoring Ergonomics during Manufacturing Production

Within the era of smart factories, concerning the ergonomics related to production processes, the Digital Twin (DT) is the key to set up novel models for monitoring the performance of manual work activities, which are able to provide results in near real time and to support the decision-making process for improving the working conditions. This paper aims to propose a methodological framework that, by implementing a human DT, and supports the monitoring and the decision making regarding the ergonomics performances of manual production lines. A case study, carried out in a laboratory, is presented for demonstrating the applicability and the effectiveness of the proposed framework. The results show how it is possible to identify the operational issues of a manual workstation and how it is possible to propose and test improving solutions

Production Management Fundamentals for Additive Manufacturing

The additive manufacturing (AM) is a new way to produce parts, which in the last years had a significant application in the traditional production environment, since it demonstrated its capability to produce parts without particular defects and with good mechanical properties. During the last two decades the AM was firstly used to produce polymers’ products and after metals’ products; this evolution made possible the breakthrough in the traditional industrial sectors such as the aerospace, the mechanical, and other related sectors. Nevertheless, the introduction of this technology in this context put on the table of the researchers and practitioners some questions about the management of this technology in a more complex context, characterized by the integration with other machines. Aim of this chapter is to present a literature review of the principal facets of the AM related to the field of operations management and trying to define a model to account the costs of production and to schedule the machine activity

The impact of Additive Manufacturing on Supply Chain design: a simulation study

Additive Manufacturing is a production technology, which completely differs from the traditional subtractive approach. Because its different nature, its application could cause strong changes in supply chains and it could affect the relationship between the supply chain players. This paper proposes a quantitative evaluation of the Additive Manufacturing effects on the supply chain performance, considering different system configurations. A simulation model has been implemented in order to reproduce the behavior of the players and compare different scenarios. Both additive and traditional technologies have been modelled in order to compare their efficiency. Moreover, different supply chain configurations have been tested to assess the additive production feasibility combined with different supply chain structures. Results confirm that Additive Manufacturing provides good improvements in supply chain performances offering significant benefits in the decentralized solution

Economic and Environmental Sustainability for Aircrafts Service Life

Aircrafts are responsible for a significant environmental impact mainly due to the air pollution caused by their motors. The use of composite materials for their production is a way to significantly reduce the weight of the structures and to maximise the ratio between the payload weight and the gasoline consumption. Moreover, the design phase has to consider the cost of different operations performed during the aircraft service life. During the entire life cycle, one of the main costs is the maintenance one. In the current literature, there is a lack of knowledge of methods for maintenance cost estimation in the aircraft industry; moreover, very few environmental assessment methods have been developed. Thus, the aim of this paper is to define a new method to support the aircraft design process; both the environmental and the economic dimensions have been included with the purpose of assessing the aircraft sustainability during its service life. A green index has been identified mixing the maintenance cost and an environmental parameter with the aim of identifying the greenest solution. A final practical application shows the feasibility and the simple application of the proposed approach

A Cost Estimation Approach for Aircraft Design Enhancement

This paper presents a novel reliability-based parametric methodology for quantifying the reliability of cost estimates for new composite aircraft components. In recent years, the aircraft production sector has increased its attention on optimizing their composite manufacturing operations. It has become clear that a key factor in the success of these operations is the consideration that not only technical factors, but also economic ones as well are relevant. Composite manufacturing variability is greatly influenced by many of these factors, and since manufacturing with composites is significantly more difficult than with more traditional materials, there are many sources of uncertainty that could influence the reliability of manufacturing cost estimates for new composite aircraft components. Therefore, it is worth considering these sources of uncertainty during the cost estimation process and to quantify the reliability of the cost estimates. To demonstrate the proposed methodology, a numerical example featuring a real-life composite aircraft component from a Boeing 787, with real-life data, is presented. Results show that the proposed methodology can quantify the uncertainty associated with cost estimates for new composite aircraft components in an effective manner, thereby supporting engineers in optimising the cost of their designs, helping them avoid errors in budget definition, and enabling them to allocate resources more efficiently

Workers’ Aging Management—Human Fatigue at Work: An Experimental Offices Study

The aging issue in the work context is becoming a significant element of the future sustainability of service and industrial companies. It is well known that with increasing worker age the problem of maintaining the performance and the safety level when fatigue increases is a crucial point, and fatigue increases with the age. Due to social and political developments, especially in Western countries, the retirement age is increasing and companies operate with a higher workforce mean age. Therefore, the problem of recognizing and measuring fatigue has become a key aspect in the management of aging. Note that in the scientific engineering field, the problem of fatigue evaluation when a worker is performing his/her work activities is an important issue in the industrial and service world and especially in the context of the researchers that are investigating the human reliability assessment. As it is clear from the literature, the industrial operations management are suffering from some misleading concepts that only the medicine scientific context can clarify. Therefore, the aim of this paper is to define what are the open issues and the misleading concepts present in the classical fatigue evaluation methods, and second to define two experimental curves of fatigue that will help the decision makers to minimize the impact of fatigue on the workers, thus maximizing the sustainability of the working tasks assigned. This aim is achieved by examining the medical literature about the measurement of a particular kind of fatigue related to the circadian cycle, i.e., the cognitive one; after that, a survey about the possible technologies for measurements is performed. On the basis of technology selection, an experiment on real work activities is performed and some remarkable results about the fatigue in the workers observed and the technology use and its limitations are defined

Towards Digital Twin Implementation for Assessing Production Line Performance and Balancing

The optimization of production processes has always been one of the cornerstones for manufacturing companies, aimed to increase their productivity, minimizing the related costs. In the Industry 4.0 era, some innovative technologies, perceived as far away until a few years ago, have become reachable by everyone. The massive introduction of these technologies directly in the factories allows interconnecting the resources (machines and humans) and the entire production chain to be kept under control, thanks to the collection and the analyses of real production data, supporting the decision making process. This article aims to propose a methodological framework that, thanks to the use of Industrial Internet of Things—IoT devices, in particular the wearable sensors, and simulation tools, supports the analyses of production line performance parameters, by considering both experimental and numerical data, allowing a continuous monitoring of the line balancing and performance at varying of the production demand. A case study, regarding a manual task of a real manufacturing production line, is presented to demonstrate the applicability and the effectiveness of the proposed procedure