Applied Mechanics and Materials Vols. 789-790

Abstract: Selecting the optimum machine configurations for any product flow line has direct implications on the system performance. In the present paper, an evolutionary algorithm based methodology has been proposed for optimal machine assignment based on a weighted objective function. The objective function includes reliability, cost, production time and operational capability as performance indicators. The methodology demonstrates how several performance parameters can be dealt with, in order to select optimal machine configurations for distinct stages across any serial product flow line. The proposed approach can possibly be employed in handling the RMS performance issues and optimal trade-offs among the various performance parameters.

Abstract: The purpose of this paper is to demonstrate a productivity improvement through waste reduction and line balancing. One of the obstacles of a manual assembly line nowadays is an awkward line design with over manpower, a lot of wastes, and low balance efficiency. As a result, the production line may not satisfy customer demand and ends up with low production line efficiency. This is due to the fact that this type of production line is operated by human and the customer demand or requirements are frequently fluctuated. Human workers are prone to make mistakes, inefficient, and unorganized. Thus, the major causes of production line down time are discussed with suggestion of remedy actions to improve the productivity. In addition, calculation of line balancing is demonstrated. One of the actual manual assembly lines will be used as a case study. It is found that after improvement line balance efficiency is increased from 46.49 to 86.66 percent with the productivity improvement of 159 percent.

Abstract: Printed circuit board (PCB) assembly planning problem has been given lot of attention to efficiently manage the orders of different PCB products. However, little effort has been paid to describe its comprehensive model which can demonstrate all the planning problems collectively considering in the surface mount technology (SMT) lines. A mixed integer model for PCB assembly line which includes the integration of different levels of the planning problems and considered component allocation problem (line balancing), PCB model sequencing problem (mixed model sequencing problem), feeder arrangement problem and component placement sequencing problem on different SMT machines collectively. Current research is significant to solve different planning problems of the PCB assembly line simultaneously to get the overall global solution of the problem in future.

Abstract: In manufacturing business, variability in customer demand over time-periods has led to production flexibility on the shop floor area. Placement of machines in a limited manufacturing area is one of the essential plant designs in material flow between machines. Shortened material handling distance can be considered a key performance index of internal logistic activity in a manufacturing firm. This paper presents the application of the Genetic Algorithm for designing machine layouts that minimise total material handling cost based on demand uncertainty during time-periods. The experimental study was computationally conducted based on two scenarios: re-layout after demand changing; and robust layout (no machine movement even if demand changes). A trade-off between the shortened handling distance and total cost was discussed as being a business decision-making tool.

Abstract: Industrial Parks thrive in China in the last few decades, but they face the problems of weak accumulative effect, low utilization rate of idle resources and loose regional bonds. To solve these problems, a cloud manufacturing platform is proposed to share services in Industrial Parks. Specially, the principles, architecture and operational model of CMPSS are discussed and investigated to facilitate the inter-enterprises collaboration. Furthermore, four key technologies to implement CMPSS including resource servitization, task decomposition, optimal service allocation and service trust evaluation are conducted to lay a foundation for further research and applications.

Abstract: Smart phone market has been growing larger and larger in recent years. This fact makes enormous competitiveness in its supply chain. Therefore, the product quality is the most importance part to improve business competitiveness, especially a flexible printed circuit which is a main assembly component in smart phones. This paper presents the approach to improve the quality control plan of the flexible printed circuit backend process. Failure Mode Effective Analysis (FMEA) was adopted to prioritize the defective and analyze weak points in the original quality control plan. Then, Statistical Process Control (SPC), optimizing inspection method and working procedure of inspection process, were introduced to improve the detection ability of the quality control plan. The results showed that the implementation of the new quality control plan could reduce escaped defective parts and the expense of escaped defect parts significantly.

Abstract: One of the objectives of process planning optimization is to diminish machining time. Nowadays a lot of research papers presented different algorithms to solve this classic problem. Thus, the optimal sequence of parts in the machining operations by considering fixture faces, part faces, number of operations and number of tools is presented in this paper. The mathematical model based on the integer linear programming is developed to minimize the total production time of the prismatic parts manufactured on a CNC machining center equipped with the tombstone-type fixture. The time required for machining, tool traveling and tool changing is taken into consideration under relevant constraints such as precedence, fixture and available cutting tools. The optimal process plan can be obtained from the mathematical model and it is considered practical and acceptable.

Abstract: This paper discusses the possibilities of applying Virtual Reality (VR) technologies to Manufacturing Engineering, and in particular assesses its role in the Factory of the Future (FoF). We review, classify and compare the recommendations given by four major European reports on the challenges that have to be met for a successful deployment of the FoF, and we identify the potential contributions of VR to this vision in terms of new technologies, worker-factory relationship, modular infrastructure and production efficiency. We argue that VR can be a key technology to support the FoF at all levels of the Systems Engineering approach, either directly by applying it in standard engineering processes, or indirectly by leveraging other useful technologies.

Abstract: The purpose of this paper is to increase the productivity of a ceramic tile manufacturing process using lean manufacturing technique. The current system of the ceramic tile manufacturing process has been mapped using Value Stream Mapping (VSM) tool, which is a lean manufacturing tool and the wastages in the current system are identified. Afterwards, future state has been created by using VSM tool, which has enhanced process ration by decreasing maximum possible waste in the manufacturing process. The case study demonstrates how the VSM tool has been used to identify and reduce waste in the manufacturing process by 26%, unnecessary inventory by 8.33% and working time of the color-mixing department by 21.57%. This flexibility enhancement causes 2.67% shorter lead time, 2.70% higher value-added ratio and frequent product delivery leading to more profits.

Abstract: Consistency and on timely delivery are among some of the factors that can keep a customer loyal and committed to a manufacturing industry. Almost all manufacturing facilities need to use production scheduling systems to increase productivity, reduce production costs and time. Most manufacturing industries invest huge amount of money to manufacture and supply products on time in order to meet customers demand and objectives but due to unforeseen disruptions, these objectives are difficult to achieve. In Real-life, production operations are subject to a large number of unexpected disruptions that may invalidate an original schedule. Being able to cope or react to these disruptions determines a company’s out-put and profitability. Productivity expression and simulation models are employed to assist in determining operational characteristics and also by comparing results from undisrupted system with that which is disrupted. These proposed models are tested on different tile manufacturing industry lay-outs in CMR and it is demonstrated that the leading source of disruption varies with different industry-layout and geographical regions. The study revealed that, the most common cause of disruption are power failure, machine breakdown, advert whether and employees absenteeism).This can be concluded from an industrial engineering point of view that, disruption during tile manufacturing is the main cause of low productivity or out-put in CMR tile manufacturing industries.