An integrated model driven approach in support of next generation

Shortened product life cycles and globalization have induced dynamism and uncertainty into world markets. Hence manufacturing enterprises (MEs) can gain competitive advantage from being reconfigurable. But appropriate application of agile and lean Manufacturing philosophies must complement the application of reconfiguration techniques. However, choosing and applying the best philosophies and techniques are far from being well understood and well structured processes because most MEs deploy complex and unique configurations of processes and resource systems, and seek economies of scope and scale in respect of a number of distinctive product flows. It follows that systematic methods of achieving model driven configuration of component based manufacturing systems are required to design, engineer and change next generation MEs. This paper discusses research aimed at developing and prototyping a model-driven environment for the design, optimization and control of reconfigurable manufacturing enterprises with an embedded capability to handle various types of change. The developed environment supports the engineering of common types of strategic, tactical and operational process found in many MEs. Also reported are initial findings of manufacturing case study work in which coherent multi-perspective models of a specific ME have facilitated process reengineering and associated resource system configuration. The paper outlines key areas for future research including the need for research into unified modelling approaches and interoperation of partial models in support of complex organisation design and change (OD&C)

Integrated modelling approach in support of change-capable PPC strategy realisation

The increasing demand for customization, reduced time to market and globalization are the real challenges for today’s manufacturing enterprises (MEs). Therefore MEs can reduce these competitive pressures by becoming more and more change-capable. The agile and lean manufacturing philosophies must complement the application of reconfiguration techniques. However, choosing and applying the best philosophies and techniques are far from being well understood and well structured processes because most MEs deploy complex and unique configurations of processes and resource systems, and seek economies of scope and scale in respect of a number of distinctive product flows. It follows that systematic methods of achieving model driven reconfiguration and interoperation of component based manufacturing systems are required to design, engineer and change next generation MEs. This paper discusses research aimed at developing and prototyping a model-driven environment for the design, optimization and control of enterprises with an embedded capability to handle various types of change in an example of a production planning and control (PPC) scenario. The developed environment supports the engineering of common types of strategic, tactical and operational process found in many MEs. Also reported are initial findings of manufacturing case study work in which coherent multi-perspective models of a specific ME have facilitated process reengineering and associated resource system configuration and interoperation. In order to understand the system prior to realisation of any PPC strategy, multiple process segments of organisations need to be modelled. The paper considers key PPC strategies and describes a novel systematic approach to create coherent sets of unified models that facilitate the engineering of PPC strategies. Case study models are presented with capability to enable PPC decision making processes in support of complex organisation design and change (OD&C). The paper outlines key areas for future research including the need for research into unified modelling approaches and interoperation of partial models in support of complex OD&C

A computer integrated unified modelling approach to responsive manufacturing

Computer modelling approaches have significant potential to enable decision-making about various aspects of responsive manufacturing. In order to understand the system prior to the selection of any responsiveness strategy, multiple process segments of organisations need to be modelled. The article presents a novel systematic approach for creating coherent sets of unified enterprise, simulation and other supporting models that collectively facilitate responsiveness. In this approach, enterprise models are used to explicitly define relatively enduring relationships between (i) production planning and control (PPC) processes, that implement a particular strategy and (ii) process-oriented elements of production systems, that are work loaded by the PPC processes. Coherent simulation models, can in part be derived from the enterprise models, so that they computer execute production system behaviours. In this way, time-based performance outcomes can be simulated; so that the impacts of alternative PPC strategies on the planning and controlling historical or forecasted patterns of workflow, through (current and possible future) production system models, can be analysed. The article describes the unified modelling approach conceived and its application in a furniture industry case study small and medium enterprise (SME)

Generalized approach to the modelling of modular machines

This paper describes a method of graphically simulating modular machines within a computer aided design environment. This forms part of a much larger Science and Engineering Research Council (SERC) funded programme aimed at advancing modern practices when designing and building manufacturing machines. A generalized approach to the synthesis of the generic features of various kinematic motion pairs is presented and prismatic and revolute motion primitives generalized in their functional and geometric aspects. A hierarchical ring and tree data structure has been designed and implemented to comprehensively represent these motion pairs and to simulate their performance. More complex modular manufacturing machines can be represented using information from a library of up to three degree of freedom motion modules. Seven two degree of freedom motion primitives and twelve three degree of freedom motion primitives with articulation configurations have been analyzed and included in the motion primitive library. The configuration of modular machines comprised of physically separate but logically connected distributed motion primitives are described. Examples of a two-finger industrial robot gripper and a three-finger industrial robot hand are used to demonstrate the general principles

An intelligent task programming system for modular manufacturing machines

Modular manufacturing machines characterised by their configuration flexibility and low initial investment have increasingly gained more recognition as one of the flexible and responsive manufacturing machinery in current competitive manufacturing industry. Programming of a modular machine is a very important part of an entire machine design and simulation environment. This paper focuses on the programming issue of a modular machine design and simulation environment. A programming study is made of the features of modular machines in manufacturing, and a general systematic approach towards high level utilisation and control of modular machines is outlined. A three-level machine task programming approach within the simulation environment is described and finally an example task program and its execution in simulation environment is illustrated to demonstrate the system capability

Advanced architecture for universal machine control

Computer control of machines is now commonplace in industrial, commercial and domestic situations. Digitally controlled equipment is available from many sources and can be configured in various ways to produce software controlled industrial machines. However, despite major technological developments in real-time control there is still a pressing need for a methodology to facilitate its widespread utilization. The variety of equipment available and range of manufacturers involved has resulted in the emergence of a great many techniques and standards relating to communication, information exchange and programming. However, where standards exist they are often de facto and non-conformity is common. The performance capabilities of computer controlled machines should reflect the state-of-the-art with respect to the enabling technology. Progress both in technical and commercial terms can be rapid, with frequent changes in the leading suppliers. No single supplier is likely to have the expertise or resources to develop and maintain a leading position as the source of all the items needed to create integrated systems. A system builder wishing to optimize his design must therefore use proprietary building blocks from a number of different sources. However, this means that large amounts of time and effort must be allocated to the development of custom software to integrate different manufacturer's equipment. The alternative is to limit the choice to known items from a restricted range of suppliers, but the associated risks are well known. At best, the system builder is likely to be cut off from the progress of the technology and at worst he may be unable to obtain equipment support and supply

Simulation support of lean layout considerations for new products: a case from large scale products

Planning a new production line for a product presents many opportunities to build best practice techniques into the new system. Set against the unknown quantities may be certain requirements for the production system to be lean, to have the flexibility to respond to market changes or make use of existing equipment of factory space. The unknown quantities can include: anticipated demand volumes, assembly and processing sequences, the specific production processes, lead-times of parts and components and even late changes to the product design after manufacturing/production decisions have been made. Simulations of a production system can be used to consider different scenarios and compare how well alternative approaches meet the defined requirements. [Continues.

Development of a new learning methodology for discrete event simulation by reutilising previous software experience

New discrete event simulation software available to industry has significantly reduced the modelling efforts of complex manufacturing problems. These tools enable analysts to assess the viability of potential solutions that better conform to previously defined requirements. Thus, analysts must be conversant in new technologies applications to deliver top quality solutions to the enterprises analysed. Traditional approaches of learning a new technology tend to isolate previous knowledge the analyst possesses in similar application fields and concentrate on features and strengths of the particular application under study. A new approach is therefore needed to capitalise on previous experience an analyst might have, enabling reduction of learning a new technological application by minimising the learning curve effort spent learning the technology, and increasing focus on quantitative and qualitative analysis. [Continues.

A machine control shell for next generation manufacturing machines

There is a growing pressure on many manufacturing oganisations to produce products in small volumes. However, to date, most automation projects have centred on high volume production. The major impediment to the application of programmable automation lies in the high cost of engineering solutions. Already a range of control system components are available to produce flexible automation schemes but as yet the selection and use of those components is a highly specialised exercise which is generally not well understood. This paper describes the need for an open control architecture for programmable machines and outlines findings of a proof of concept research project aimed at formalising the design of control systems. The work has resulted in a “motion control shell' which can much reduce the cost and time involved when building machine controllers

Enterprise modelling in support of methods based engineering: lean implementation in an SME

Popular ‘methods-based’ approaches to engineering enterprises include: BPR, Continuous Improvement, Kaizen, TQM, JIT, Lean and Agile Manufacturing. Generally the industrial application of such methods-based approaches leads to long lead-times, high costs, and poorly justified engineering projects that do not prepare the organization for future change. These outcomes are to be expected because (1) invariably Manufacturing Enterprises (MEs) constitute very complex and dynamic systems that naturally require complex design and change processes and (2) current methods-based approaches to organizational design and change are not analytically well founded. Therefore the authors argue that a framework and modelling toolset are required to facilitate ongoing and integrated application of methods-based engineering approaches, providing underlying modelling structures and concepts to ‘systemize’ and ‘quantify’ key aspects of organization design and change. Unless suitable decomposition, quantitative and qualitative modelling principles are used to underpin an approach such as a Lean Manufacturing, deficiencies will remain. Often, MEs adopt the “we need be lean” mindset without holistic understandings of causal and temporal impacts of such philosophies on ME processes, resource systems and current and possible future workflows. Enterprise Modelling (EM) partially addresses the aforementioned problems and can support the development of robust understandings about current enterprise processes and potential capabilities of systems. However in general, current EM techniques are geared best to capturing and organizing relatively enduring knowledge and data about any given organization but are themselves deficient in respect to replicating and predicting dynamic system behaviors. This paper presents a model driven approach to organization design and change in support of methods-based engineering, applying Lean Manufacturing principles, with a UK based bearing manufacturer. EM and various derivative Simulation Modelling (SM) views were generated to display system behaviors under changing scenarios