Simulation-based support tool for operator performance in batch manufacturing

In industry, the workload and utilization of shop floor operators is often misunderstood. In this paper, we will present several real case studies, using Discrete Event Simulation (DES) models, which allow us to better understand operators in a batch manufacturing environment. The first study investigates labour in a machining plant consisting of multiple identical CNC machines that batch produce parts. The second study investigates labour in an eight station, gravity die casting rotary table. The results from these studies have shown that there can be potential improvements made by the production planners in the current labour configuration. In the first case study, a matrix is produced that estimates what the operator's utilization levels will be for various configurations. From this, the preferred operator to machine ratio over a range of cycle times is presented. In the second study, the results have shown that by reducing the casting cycle time, the operator would be overloaded. A discrete event simulation of these two cases highlighted areas that were misunderstood by plant management, and provided them with a useful decision support tool for production planning.

Kanban devs modelling, simulation and verification

Kanban Control Systems (KCS) have become a widely accepted form of inventory and production control. The creation of realistic Discrete Events Simulation (DES) models of KCS require specification of both information and material flow. There are several commercially available simulation packages that are able to model these systems although the use of an application specific modelling language provides means for rapid model development. A new Kanban specific simulation language as well as a high-speed execution engine is verified in this paper through the simulation of a single stage single part type production line. A single stage single part KCS is modelled with exhaustive enumeration of the decision variables of container sizes and number of Kanbans. Several performance measures were used; 95% Confidence Interval (CI) of container Flow Time (FT), mean line throughput as well as the Coefficient of Variance (CV) of FT and Cycle Time were used to determine the robustness of the control system.

Linear-motor based five-axis parallel machine for effective material processing

The aim of the work was to reduce the cost and improve the performance of five-axis machines. The main performance criteria were motion cycle-time and positioning accuracy/precision. A novel machine that utilizes the concept of parallel-kinematics and linear motor technology is proposed, designed, built and controlled for this sake.

Automation of a complex transfer operation using a polar manipulator

Purpose – The objective of this paper included developing a polar robot (SPBot) for rotating and transferring car engine block (CEB) around and along two different axes in a confined workspace envelope.

Design/methodology/approach – The complex transfer operations of the CEB requires sweeping complete surface of the half sphere, and thus a polar robot is best suited to such a task in a confined space. Considering the limited space for this operation, a specially designed manipulator is built comprising 2 degrees of freedom driven by electrical servo motors. Also due to the special form of CEB, an especially designed pneumatic gripper is developed. Kinematics models, static and dynamic equations, together with trajectory planning for such a manipulator are described.

Findings – The high-speed complex transfer in a limited environment is successfully implemented.

Originality/value – The developed polar robot provides for complex transfer operations that significantly increases the speed of the product line and thus reducing the cycle time from 60?s using manpower to just 20?s using the robot.

Time and energy constraints in demanding phases of the annual cycle : an example of time limitation in refuelling migratory swans

The daily metabolizable energy intake of an animal is potentially limited by either the available feeding time or by its capacity to process energy. Animals are generally considered not to be time-limited but rather to be energy-processing-limited. This is concluded from the common observation that an animal's feeding time per day increases with a decrease in food density. We argue that such changes in feeding time are in theory also expected when no constraints are operating. Thus, a study of the constraints on energy intakes of free-living animals should be performed during demanding phases of the year. As an example, we collected data on time and energy budgets of Bewick's swan (Cygnus columbianus bewickii) refuelling during migration on fennel pondweed (Potamogeton pectinatus) tubers in two years differing two-fold in tuber biomass density. As predicted by time limitation, the feeding time (defined as the time with the head submerged) did not change in response to a change in food biomass density, both within and between years (averaging 12.2 h d⁻¹). Contrary to energy-processing limitation, and again in line with time limitation, the daily metabolizable energy intake varied, being greater in the year with high than in the year with low food densities. We conclude that more studies are needed of animals operating under demanding conditions before it can be assessed whether free-living animals are generally energy-processing- or time-limited.

Survival misperception, time inconsistency, and implications for life-cycle saving and welfare

Some empirical studies firmly reveal that people tend to form overly pessimistic survival expectations for relatively less distant ages and overly optimistic survival expectations for relatively more distant ages. We incorporate this observation into a life-cycle continuous time overlapping-generations model of consumption/saving with a general form for a subjective survival function. Resulting time-inconsistent optimal control problem has been analytically solved. At the micro level, time inconsistency leads to higher consumption at young and old ages, but this alone fails to improve lifetime well-being since micro-level decisions made with a lack of information about true mortality are suboptimal. In general equilibrium, however, such time inconsistent behavior with survival misperception is conducive to aggregate capital accumulation and greater equilibrium bequest income. The latter effects can produce substantial welfare gains. We also note that empirically observed old age optimistic bias is an important phenomenon, as it helps to avoid unrealistic very old-age debt accumulation within a life-cycle model. In addition, if for a given level of optimistic bias we increase early-life pessimism, this would result in slower capital accumulation, lower bequest income, and thus be detrimental to welfare. Since recent literature reports that young-age survival pessimism has grown over time, it raises some concerns.

The influence of pacing during 6-minute supra-maximal cycle ergometer performance

The aim of this study was to evaluate the influence of pacing on performance, oxygen uptake (V̇O₂), oxygen deficit and blood lactate accumulation during a 6-minute cycle ergometer test. Six recreational cyclists completed three 6-minute cycling tests using fast-start, even-pacing and slow-fast pacing conditions. Cycle ergometer performance was measured as the mean power output produced for each cycling test. Energy system contribution during each cycling trial was estimated using a modified accumulated oxygen deficit (AOD) method. Blood lactate concentration was analysed from blood sampled using a catheter in a forearm vein prior to exercise, at 2 minutes, 4 minutes and 6 minutes during exercise, and at 2 minutes, 5 minutes and 10 minutes post-exercise. There was no significant difference between the pacing conditions for mean power output (P=0.09), peak V̇O₂ (P=0.92), total V̇O₂ (P=0.76), AOD (P=0.91), the time-course of V̇O₂ (P=0.22) or blood lactate accumulation (P=0.07). There was, however, a significant difference between the three pacing conditions in the oxygen deficit measured over time (P=0.02). These changes in the time-course of oxygen deficit during cycling trials did not, however, significantly affect the mean power output produced by each pacing condition.

Effect of creatine supplementation on housekeeping genes in human skeletal muscle using real-time RT-PCR

The present study examined the validity and reliability of measuring the expression of various genes in human skeletal muscle using quantitative real-time RT-PCR on a GeneAmp 5700 sequence detection system with SYBR Green 1 chemistry. In addition, the validity of using some of these genes as endogenous controls (i.e., housekeeping genes) when human skeletal muscle was exposed to elevated total creatine levels and exercise was also examined. For all except 28S, linear relationships between the logarithm of the starting RNA concentrations and the cycle threshold (C_T) values were established for ß-actin, ß2-microglobulin (ß₂M), cyclophilin (CYC), and glyceraldehyde-3-phosphate dehydrogenase (GAPDH). We found a linear response between C_T values and the logarithm of a given amount of starting cDNA for all the genes tested. The overall intra-assay coefficient of variance for these genes was 1.3% and 21% for raw C_T values and the linear value of 2^-C_T, respectively. Interassay variability was 2.3% for raw C_T values and 34% for the linear value of 2^-C_T. We also examined the expression of various housekeeping genes in human skeletal muscle at days 0, 1, and 5 following oral supplementation with either creatine or a placebo employing a double-blind crossover study design. Treatments were separated by a 5-wk washout period. Immediately following each muscle sampling, subjects performed two 30-s all-out bouts on a cycle ergometer. Creatine supplementation increased (P < 0.05) muscle total creatine content above placebo levels; however, there were no changes (P > 0.05) in C_T values across the supplementation periods for any of the genes. Nevertheless, 95% confidence intervals showed that GAPDH was variable, whereas ß-actin, ß₂M, and CYC were the least varying genes. Normalization of the data to these housekeeping genes revealed variable behavior for ß₂M with more stable expressions for both ß-actin and CYC. We conclude that, using real-time RT-PCR, ß-actin or CYC may be used as housekeeping genes to study gene expression in human muscle in experiments employing short-term creatine supplementation combined with high-intensity exercise.

Hybrid life-cycle inventory for road construction and use

Life-cycle assessment (LCA) is a technique that is used worldwide by clients and their design team to assess the impact of
their projects on the environment. The main advantage of LCA is in supporting decision making with quantitative data. LCA inventories
can be either fully developed or streamlined. Fully developed LCAs are time-consuming and costly to prepare. Streamlined LCAs can be
used as an effective decision-making tool when considering environmental performance during the design process, but with a loss of
inventory completeness. Acknowledging the advantages and disadvantages of both types of LCA, this paper proposes a hybrid LCA
method that uses input-output data to fill in those gaps routinely left in conventional LCA inventories.

Value analysis of just-in-time demolition approach

The recent deconstruction approach for demolition projects promotes reusing and recycling materials. However, the demolition project is interrupted and slowed down while the project team wait for the waste exchange process. Wasted materials generated from the demolition project have to be stored on demolition site or extra depository. Cost and time might be lost for the inventory of wasted materials and products. Just-in-Time (JIT) is a matured method widely used in manufacture industry as well as construction industry. It is utilised to reduce the inventory of both raw materials and final products. It is also used to shorten production cycle and improve the quality of the products. The JIT philosophy can be applied into demolition project so that the inventory of wasted materials can be eliminated and the project time can be shortened. To implement JIT demolition, the waste exchange process can be performed before the wasted materials are generated from the project. Material owners and demanders can virtually plan for waste handling before the demolition project is physically implemented. As a result, waste materials can be sent to demanders through transportation right after they are produced from the project. Applying JIT philosophy in demolition projects can effectively reduce the inventory of wasted materials and the amount of demolition waste to be sent to landfills. Therefore the cost and time of the project are reduced, and the quality of final delivered materials is improved.

The challenge of reconciling working time demands and life transitions : a policy proposal

Labour markets, like all market institutions, exhibit structural and dynamic characteristics. Both the structural and dynamic characteristics of labour markets inevitably change and evolve over time in response to a host of exogenous and endogenous factors. In the case of the Australian labour market, structural changes are reflected in significant shifts in the industry and occupational composition of employment, the decline of full-time work and the concomitant rise in part-time and atypical forms of employment, demographic changes in the labour force, as well as changes in social and individual preferences. Dynamic shifts can be found in cyclical pattern of employment and wages growth, the growth in labour mobility, and transitions between various labour market states.
The starting point for this paper is that these structural and dynamic changes have given rise to an increase in the likelihood that individuals will experience a transition between various labour market states, and a greater diversity in the range of transitions they may experience over their working life. This acceleration in the rate of transition generates ‘transition costs’ for both employers and employees, as well the likelihood of mismatch between employer and employee working time preferences. As a consequence, existing labour market policy regimes, based on the traditional model of labour market participation over the life course may not provide adequate protection for most workers today.
Gunther Schmid (1998) and others have proposed institutional reforms which promote ‘transitional labour markets’. Transitional labour market institutions are those that allow individuals (and firms) to successfully adjust to critical events. While transitional labour market institutions may consist of traditional ‘active labour market policy’ mechanisms, Schmid and others have proposed a range of innovative policy responses which allow individuals (and firms) to adjust the intensity of their abour market participation over the life cycle. In this paper we use the general approach of advocated by the transitional labour market concept to do three things. First, we investigate the processes by which the nature of labour market transitions has changed over time. Second, we review the range of policy options available to government to smooth labour market dysfunctions associated with labour market transitions, with the objective of ensuring labour markets operate more efficiently and more equitably. Third, we focus on one possible way in which an existing labour market institution, Long Service Leave (LSL), could be reformed to make way for a more comprehensive transitional labour market institution in the form of a ‘working time bank’.

Strawberries any-time, any-day, any-where : a strategic marketing analysis

While the number of Australian strawberry producers has declined by 40% over the past decade the value of production has increased by 58%. Such changes reflect structural changes occurring within an increasingly competitive industry. This paper discusses a study that was conducted to develop a marketing strategy that was conducted in order to reposition an industry so that it may grow in the face of a maturing product life cycle.

To establish a benchmark position, an industry analysis based on the Five Forces model was first undertaken. This analysis was followed by a consumer analysis which consisted of (a) a series of focus group discussions and (b) a comprehensive consumer marketing research survey. The findings of this survey enabled a series of market segments to be identified and profiled. Based on these results a strategic marketing communication campaign aimed at increasing strawberry consumption was developed and implemented.

New cutting-planes for the time-and/or precedence-constrained ATSP and directed VRP

In this paper, we introduce five classes of new valid cutting planes for the precedence-constrained (PC) and/or time-window-constrained (TW) Asymmetric Travelling Salesman Problems (ATSPs) and directed Vehicle Routing Problems (VRPs). We show that all five classes of new inequalities are facet-defining for the directed VRP-TW, under reasonable conditions and the assumption that vehicles are identical. Similar proofs can be developed for the VRP-PC. As ATSP-TW and PC-ATSP can be formulated as directed identical-vehicle VRP-TW and PC-VRP, respectively, this provides a link to study the polyhedral combinatorics for the ATSP-TW and PC-ATSP. The first four classes of these new cutting planes are cycle-breaking inequalities that are lifted from the well-known D^-_k and D⁺_k inequalities (see Grötschel and Padberg in Polyhedral theory. The traveling salesman problem: a guided tour of combinatorial optimization, Wiley, New York, 1985). The last class of new cutting planes, the TW ₂ inequalities, are infeasible-path elimination inequalities. Separation of these constraints will also be discussed. We also present prelimanry numerical results to demonstrate the strengh of these new cutting planes.