Rationales of holonic manufacturing systems in leather industry

This paper presents an insight into leather manufacturing processes, depicting peculiarities and challenges faced by leather industry. An analysis of this industry reveals the need for a new approach to optimize the productivity of leather processing operations, ensure consistent quality of leather, mitigate the adverse health effects in tannery workers exposed to chemicals and comply with environmental regulation. Holonic manufacturing systems (HMS) paradigm represent a bottom-up distributed approach that provides stability, adaptability, efficient use of resources and a plug and operate functionality to the manufacturing system. A vision of how HMS might operate in a tannery is illustrated presenting the rationales behind its application in this industry. © 2013 Springer-Verlag.

A global assessment of manufacturing: Economic development, energy use, carbon emissions, and the potential for energy efficiency and materials recycling

We present in two parts an assessment of global manufacturing. In the first part, we review economic development, pollution, and carbon emissions from a country perspective, tracking the rise of China and other developing countries. The results show not only a rise in the economic fortunes of the newly industrializing nations, but also a significant rise in global pollution, particularly air pollution and CO2 emissions largely from coal use, which alter and even reverse previous global trends. In the second part, we change perspective and quantitatively evaluate two important technical strategies to reduce pollution and carbon emissions: energy efficiency and materials recycling. We subdivide the manufacturing sector on the basis of the five major subsectors that dominate energy use and carbon emissions: (a) iron and steel, (b) cement, (c) plastics, (d) paper, and (e) aluminum. The analysis identifies technical constraints on these strategies, but by combined and aggressive action, industry should be able to balance increases in demand with these technical improvements. The result would be high but relatively flat energy use and carbon emissions. The review closes by demonstrating the consequences of extrapolating trends in production and carbon emissions and suggesting two options for further environmental improvements, materials efficiency, and demand reduction. © 2013 by Annual Reviews. All rights reserved.

Model-based control of thermoacoustic instabilities in partially premixed lean combustion - A design case study

Self-excited oscillation is becoming a major issue in low-emission, lean partially premixed combustion systems, and active control has been shown to be a feasible method to suppress such instabilities. A number of robust control methods are employed to obtain a feedback controller and it is observed that the robustness to system uncertainty is significantly better for a low complexity controller in spite of the norms being similar. Moreover, we demonstrate that closed-loop stability for such a complex system can be proved via use of the integral quadratic constraint method. Open- and closed-loop nonlinear simulations are provided. © 2013 Copyright Taylor and Francis Group, LLC.

Steering manufacturing firms towards service business model innovation

Increasingly, manufacturing firms are turning to services as a new way of creating and capturing value. Despite its potential benefits, many new product-service providers struggle to deploy service activities effectively, not least because they fail to refect the presence of service activities in their performance management systems. This article reports the results of an in-depth case study, which examines how manufacturers can steer the transition towards services. It shows that manufacturing firms need to emphasize two separate but related dimensions of the market performance of service activities: "service adoption," refecting the proportion of customers who purchase the manufacturer's services; and "service coverage," signaling the range of service elements or the comprehensiveness of the service contract that customers opt for. These two indicators, refecting service market performance, should be supplemented with a "complementarity index" designed to disclose whether the relationship between products and services is reinforcing or substitutive. When combined, these indicators allow manufacturing firms to deploy a service-based business model in an integrated and sustainable manner. © 2013 by The Regents of the University of California. All rights reserved.

Computations of turbulent lean premixed combustion using conditional moment closure

Conditional Moment Closure (CMC) is a suitable method for predicting scalars such as carbon monoxide with slow chemical time scales in turbulent combustion. Although this method has been successfully applied to non-premixed combustion, its application to lean premixed combustion is rare. In this study the CMC method is used to compute piloted lean premixed combustion in a distributed combustion regime. The conditional scalar dissipation rate of the conditioning scalar, the progress variable, is closed using an algebraic model and turbulence is modelled using the standard k-e{open} model. The conditional mean reaction rate is closed using a first order CMC closure with the GRI-3.0 chemical mechanism to represent the chemical kinetics of methane oxidation. The PDF of the progress variable is obtained using a presumed shape with the Beta function. The computed results are compared with the experimental measurements and earlier computations using the transported PDF approach. The results show reasonable agreement with the experimental measurements and are consistent with the transported PDF computations. When the compounded effects of shear-turbulence and flame are strong, second order closures may be required for the CMC. © 2013 Copyright Taylor and Francis Group, LLC.

Laminar propagation of lean premixed flames ignited in stratified mixture

Combustion in stratified mixtures is envisaged in practical energy systems such as direct-injection spark-ignited (DISI) car engines, gas turbines, for reducing CO2 and pollutant emissions while protecting their efficiency. The mixture gradients change the fundamental properties of the flame, especially by a difference in temperature and composition between the burnt gases and those of a flame consuming a homogeneous mixture. This paper presents an investigation of the properties of the flame propagating in a lean homogeneous mixture after ignition in a richer mixture according to the magnitude of the stratification. Three magnitudes of stratification are investigated. The local flame burning velocity is determined by an original PIV algorithm developed previously. The local equivalence ratio in the fresh gases is measured from anisole PLIF. From the simultaneous PIV-PLIF measurements, the flame burning velocities conditioned on the local stretch rate and equivalence ratio in fresh gases are measured. The flame propagating through the homogeneous lean mixture has properties depending on the ignition conditions in the stratified layer. The flame propagating in the lean mixture is back-supported longer for ignition under the richer condition. The change of stretch sensitivity and burning velocity of the flame in the lean mixture is measured over time for the three magnitudes of mixture stratification investigated. The ignition in richer mixtures compensates for the nonequidiffusion effect of lean propane flame and sustains its robustness to stretch. The flame propagation in the lean homogeneous mixture is enhanced by ignition in a richer stratified layer, as much by their robustness to stretch as by an increase in the flame speed or the burning velocity. The decay time of this influence of the stratification, called memory effect, is determined. © 2013 The Combustion Institute.

Manufacturing dish shaped rings on radial-axial ring rolling mills

Ring rolling is an established method to produce seamless rings of different cross-sectional geometries. For dish shaped rings, there are applications in different areas such as offshore, aeronautics or the energy sector. At the moment, dish shaped rings are produced by machining of rings with rectangular shaped cross section, by (open die) hollow forging on a conical mandrel or by using shaped ring rolling tools. These ways of manufacturing have the disadvantage of high material waste, additional costs for special tools, long process time and limited or inflexible geometries. Therefore, the manufacturing of dish shaped rings on conventional radial-axial ring rolling mills would expand the range of products for ring producers. The aim of this study is to investigate the feasibility of an alternative to the current manufacturing processes, without requiring additional tooling and material costs. Therefore, the intended formation of dish shaped rings-previously regarded as a form error-is investigated. Based on an analysis of geometrical requirements and metal flow mechanisms, a rolling strategy is presented, causing dishing and ring climbing by a large height reduction of the ring. Using this rolling strategy dish shaped rings with dishing angles up to 18° were achieved. In addition to the experiments finite element method (FEM)-simulations of the process have been successfully conducted, in order to analyze the local strain evolution. However, when the contact between ring and main roll is lost in the process the ring starts to oscillate around the mandrel and neither dishing nor ring climbing is observed. © 2013 German Academic Society for Production Engineering (WGP).

UbiDM: A new paradigm for product design and manufacturing via ubiquitous computing technology

Since ubiquitous technology was introduced in the early 1980s, it has rapidly developed, and been applied to various domains mainly for the improvement of human life. In this article, the authors propose that ubiquitous computing technology can be effectively used for the design and manufacturing of a product by proposing a new paradigm, called UbiDM (Design and Manufacture via Ubiquitous Computing Technology). The key aspect of UbiDM is the utilisation of the entire product lifecycle information obtained via ubiquitous computing technology for the design and manufacture of the product. The new paradigm can solve many of the problems that have not been properly handled by previous manufacturing paradigms. Specifically, it will address the concept of UbiDM by the following aspects: (1) why there is a need for UbiDM; (2) the essence of UbiDM; (3) enabling technologies; (4) application area; (5) worldwide RD status; and (6) the societal impacts of UbiDM.

Manufacturing excellent engineers: Skill development in a Masters programme

An MPhil programme, delivered by the Engineering Department at the University of Cambridge, claims to be excellent at preparing graduates for manufacturing industry careers. The course uses a combination of different educational experiences, including industry-based assignments, industrial visits and practical exercises. This research explores how problem solving skills are developed during the first module, Induction, which is designed to enable students to undertake their first industrial assignment. From the literature, four conditions necessary for skill development were identified: Provision of a skill description, making explicit key components A number of different experiences with a range of contextual variables A teaching process which includes regular feedback and student reflection Students motivated to learn. These were used to construct a skill development framework (SDF). Using a case study research design, multiple types of evidence were collected to test for the above conditions using both classroom observation and questionnaire methods. The results confirmed the presence of the SDF conditions at different levels, with reflection aspects considered the weakest. Conflicting results were obtained regarding the students' self-awareness of skill levels. A plausible explanation is a change in the students' frame of reference. This initial study set out to develop a better understanding of the process of skill development. Whilst the SDF appears reasonable, there is a need for further work in three broad areas of defining skills, assessing skills and developing reflection skills.

Lean product development in practice: Insights from 4 companies

This paper aims to elucidate practitioners' understanding and implementation of Lean in Product Development (LPD). We report on a workshop held in the UK during 2012. Managers and engineers from four organizations discussed their understanding of LPD and their ideas and practice regarding management and assessment of value and waste. The study resulted in a set of insights into current practice and lean thinking from the industry perspective. Building on this, the paper introduces a balanced value and waste model that can be used by practitioners as a checklist to identify issues that need to be considered when applying LPD. The main results indicate that organizations tend to focus on waste elimination rather than value enhancement in LPD. Moreover, the lean metrics that were discussed by the workshop participants do not link the strategic level with the operational one, and poorly reflect the value and waste generated in the process. Future directions for research are explored, and include the importance of a balanced approach considering both value and waste when applying LPD, and the need to link lean metrics with value and waste levels.