Applied Mechanics and Materials Vol. 761

Abstract: In the early stage of planning or design, it is desired to support the informal communication between remote sites. In this study, informal communication environment between remote places was constructed by using the interactive tiled display wall.This system measures the user's gesture as well as captures the user's image by using the multiple fish-eye cameras. Then, the remote users can communicate with each other by using the touch interaction in the shared space. This system was applied to the remote communication and the effectiveness of this method in the informal communication was experimentally evaluated.

Abstract: Robots are not rare applications anymore due to the advanced technology today. Everyone knows robots have been used in many fields. Humanoid robots are especially desirable in human society as they can work well in indoor environments that have been designed for humans. The technical characteristics for humanoid robot teacher listed in this paper are facial expression, walking, speaking and hearing, body gestures, and vision. These characteristics are believed to be essential in every humanoid robot involved in education. Technical explanations for each characteristic are provided throughout this paper. The list of robots that can be used as a robotic teacher is also given in this paper.

Abstract: A study on Autonomous Maintenance (AM) implementation was conducted for CNC machine at automotive components manufacturing line in order to identify and measure equipment losses related to availability, performance and quality rate. These values were used to determine the overall equipment effectiveness (OEE) of the manufacturing line before and after AM implementation. The project started with AM team formation before it was continued with 5S activities and fuguai (abnormality) detection and restoration. Kaizen was used for continuous improvement to restore deteriorated parts and components of the machine. Autonomous Maintenance standards such as cleaning, lubricating and inspection were developed. The AM team members consistently followed the operator maintenance standards to ensure that machine is always in good working condition. The OEE results were taken daily after AM implementation and compared with the data before the implementation. The average OEE result shows significant improvement from 65.8% to 80.4% after the AM implementation. However, the result still did not achieve the company’s target. The main reason was because the machine was very old, which almost reaches deterioration stage according to the bath tub curve. Some recommendations are suggested as to push the OEE value closer to the company’s target including a review on other pillars in Total Productive Maintenance (TPM).

Abstract: This paper describes the proposal of Poka Yoke Roller Coaster (PKYC) jig as a device to detect nut weld missing of door patch base line model (BLM) at assembly line station. The PKYC was proposed in order to detect nut weld missing problem and to reduce cycle time and manpower that lead to higher cost by applying quality management concept as a problem-solving tool. This special purpose tool was capable to meet specific job based on industrial need by providing repeatability, interchangeability and accuracy in the manufacturing of products. A Quality Control (QC) approachcalled the Zero Quality Control (ZQC) was used to achieve zero defects at production line. In order to reach zero defects, poka yoke method was applied in this research. Outcomes indicate that PKYC can be utilised as a custom-tailored jig for detecting nut weld missing as well as fulfilling other objectives.

Abstract: In the fast moving technological world, few researchers are trying to formulate systems with automatic mould design processes in order to reduce mould design and development time and produce a consistent mould's quality. Currently, no commercial software are able to generate core and cavity without user intervention during the process. Thus, an algorithm is proposed in this research to automatically generate core and cavity of moulds by using slicing and Boolean-based approach. A 3D moulded part in a standard CAD file format is used as an input for the algorithm and the output is presented as a set of core and cavity in 3D model. Two criteria to define the best generated core and cavity are considered at this stage which is undercut and floating lump.

Abstract: Today competitive manufacturing requires innovative approaches in the production management, as well as for customer satisfaction. Production management requires an effective and efficient maintenance management system. One approach to improve the performance of the maintenance system is through the implementation of Total Productive Maintenance (TPM). The key performance index to measure the effectiveness of TPM implementation is Overall Equipment Effectiveness (OEE). The TPM activities will eliminate equipment losses related to availability, performance rate, and quality rate. Hence, the TPM implementation will increase the OEE value. This paper outlines the theories of TPM and OEE. The paper also presents the studies carried out by different authors to show the improvement of OEE through implementation of TPM in manufacturing, such as electronic industry, steel manufacturer, as well as locomotive components manufacturer.

Abstract: A new tool allocation method is proposed in this paper to consider both the load balancing and optimization of a transportation based on a mathematical problem. The proposed tool allocation method consists of two steps. In the first step, the individual tools are divided into tool sets based on 0-1 programming problem in order to balance a total machining time by using the individual tool sets and reducing a total number of transportation processes. In the second step, the individual tool sets are allocated to the Machining Centers (MCs) based on a quadratic assignment problem in order to minimize transportation total distances of jobs.

Abstract: An accumulator is an auxiliary component in a hydraulic system as it stores the energy and avoids the pump from running continuously through the system which can reduce the pumps life. The accumulator is also used as the power source in the hydraulic hybrid system to accelerate the vehicle. A common hydraulic system uses the hydraulic oil as their working medium, but there is an application using water due to the high accessibility and environmental concern. In this paper, an accumulator is developed by using weighing method to increase the pressure in the system. This system uses water as a medium to provide clean environment as well as safe for mobile purpose. The system includes electric motor, water pump, directional control valve, pressure control valve and motor hydraulic. The performance of the accumulator is obtained by measuring the ratio of output and input pressure. The source of electricity is varied by using an inverter to control the frequency and the power of the pump. From the experiment, the pressure output and flow rate decreased with the increasing of the loads on top of the accumulator, while the pressure loss increased with the number of load. The operational frequency is optimal at a low reading compared to a higher frequency.

Abstract: TRIZ has been well-established and is widely applied in multi-national enterprises to enhance design innovation and problem solving for design and manufacturing problems. Most applications of TRIZ utilise the engineering contradiction tools to solve design and manufacturing problems. This paper initially applied the engineering contradiction matrix to solve a semi-processed material transfer misalignment problem while passing through a furnace via a long mesh metal conveyor belt in the productions of automotive parts. Then, using another TRIZ tool, substance-field analysis to verify the solutions obtained earlier. This verification is to reduce the possible of errors in solving problems using the engineering contradiction matrix.

Abstract: A built-in test circuit is proposed to detect an open defect in a CMOS IC by means of appearance time of dynamic supply current of the IC. A layout of an IC embedding the test circuit is designed. It is shown by Spice simulation that an open defect in the IC can be detected with the test circuit.