Jogos Sérios para Lean Manufacturing: “Jogo: Método 5S”

A crise económica global que se faz sentir leva a que surja uma necessidade de aumentar a competitividade das empresas, através da melhoria de performance dos seus colaboradores. Nesse sentido, Lean Manufacturing é uma área que merece a atenção das empresas e dos seus colaboradores, uma vez que os seus principais objectivos são o aumento da produtividade, a redução dos desperdícios e a optimização dos recursos disponíveis. Uma ferramenta do Lean que merece especial destaque é o Método 5S, que permite aumentar a produtividade através do aumento da organização do posto de trabalho. Uma vez que usar postos de trabalho a mais, de modo a que os colaboradores pratiquem e aprendam a aplicar as regras do 5S, fica dispendioso em tempo de trabalho e custos acrescidos pela paragem da linha produção, surge a necessidade de criação de um Jogo Sério que ajude na aprendizagem destes temas. Um breve estudo do mercado revelou que esta necessidade não está a ser devidamente respondida. Existem algumas entidades que se dedicam ao ensino e partilha deste tipo de conhecimentos, sendo poucas as que têm ferramentas digitais disponíveis. Esta dissertação propõe um Jogo Sério que pretende dar resposta a esta necessidade, permitindo pôr em prática o Método 5S, servindo ainda como ferramenta motivadora, para que o colaborador aprofunde o seu conhecimento na matéria. Esta abordagem prática encoraja o jogador a aprender por tentativa e erro. Informações mostradas ao longo do jogo permitem uma aprendizagem sem haver uma sobrecarga cognitiva. A avaliação do jogo, realizada por um grupo de alunos que frequentam o Mestrado em Engenharia Mecânica, demonstrou que a nossa abordagem é eficiente e resulta na aprendizagem dos conceitos 5S.

Aplicação de metodologias lean na manutenção da simoldes aços

O trabalho presente nesta dissertação incidiu sobre a aplicação das metodologias Lean no âmbito da manutenção de uma empresa metalomecânica de produção de Moldes – Simoldes Aços. No atual enquadramento, com os mercados nacionais e internacionais debaixo de feroz competição, as empresas são obrigadas a estudar métodos e técnicas que permitam eliminar desperdícios, reduzir custos e tempos de produção, ao mesmo tempo que são exigidos maiores níveis de qualidade dos produtos fabricados com vista ao aumento da competitividade. Sendo a Manutenção uma área funcional com um impacto elevado no desempenho da produção, é percebido que o desempenho desta, tem influência direta no comportamento do fluxo produtivo e nos respetivos níveis de eficácia e eficiência. No decorrer do trabalho desta dissertação de mestrado foi realizada uma análise abrangente do estado atual do sector de atividade de manutenção na empresa SIMOLDES SA, o que permitiu identificar as áreas e os pontos a intervir e desenhar as soluções de melhoria na atividade de manutenção. Na fase concludente do trabalho foram implementadas algumas dessas propostas de melhoria, ao passo que outras ficaram agendadas para futura implementação. Na base do trabalho desenvolvido esteve a metodologia Lean, que apresenta um papel relevante na implementação de uma abordagem integrada da função manutenção na manutenção dos objetivos da produção. O presente projeto baseou a sua estratégia de implementação na aplicação da ferramenta do 5S’ em paralelo com o TPM (Total Productive Maintenance). Ambas as ferramentas visam a redução de desperdícios e o aumento da fiabilidade dos processos, pelo aumento da disponibilidade dos equipamentos, da melhoria do desempenho dos processos e da plena integração de todos os colaboradores no processo de fabrico. Com a implementação das melhorias propostas, foram observados melhorias significativas no fluxo das atividades da manutenção, assim como uma maior visibilidade das mesmas em todo o processo produtivo.

Planning and implementing a new assessment strategy using an e-learning platform

One of the most difficult issues of e-Learning is the students’ assessment. Being this an outstanding task regarding theoretical topics, it becomes even more challenging when the topics under evaluation are practical. ISCAP’s Information Systems Department is composed of about twenty teachers who have been for several years using an e-learning environment (at the moment Moodle 2.3) combined with traditional assessment. They are now planning and implementing a new e-learning assessment strategy. This effort was undertaken in order to evaluate a practical topic (the use of spreadsheets to solve management problems) common to shared courses of several undergraduate degree programs. The same team group is already experienced in the assessment of theoretical information systems topics using the b-learning platform. Therefore, this project works as an extension to previous experiences being the team aware of the additional difficulties due to the practical nature of the topics. This paper describes this project and presents two cycles of the action research methodology, used to conduct the research. The first cycle goal was to produce a database of questions. When it was implemented in order to be used with a pilot group of students, several problems were identified. Subsequently, the second cycle consisted in solving the identified problems preparing the database and all the players to a broader scope implementation. For each cycle, all the phases, its drawbacks and achievements are described. This paper suits all those who are or are planning to be in the process of shifting their assessment strategy from a traditional to one supported by an e-learning platform.

A B-learning strategy for Therapeutics at the Bachelor Level

Background Information:The incorporation of distance learning activities by institutions of higher education is considered an important contribution to create new opportunities for teaching at both, initial and continuing training. In Medicine and Nursing, several papers illustrate the adaptation of technological components and teaching methods are prolific, however, when we look at the Pharmaceutical Education area, the examples are scarce. In that sense this project demonstrates the implementation and assessment of a B-Learning Strategy for Therapeutics using a “case based learning” approach. Setting: Academic Pharmacy Methods:This is an exploratory study involving 2nd year students of the Pharmacy Degree at the School of Allied Health Sciences of Oporto. The study population consists of 61 students, divided in groups of 3-4 elements. The b-learning model was implemented during a time period of 8 weeks. Results:A B-learning environment and digital learning objects were successfully created and implemented. Collaboration and assessment techniques were carefully developed to ensure the active participation and fair assessment of all students. Moodle records show a consistent activity of students during the assignments. E-portfolios were also developed using Wikispaces, which promoted reflective writing and clinical reasoning. Conclusions:Our exploratory study suggests that the “case based learning” method can be successfully combined with the technological components to create and maintain a feasible online learning environment for the teaching of therapeutics.

Enterprises' internationalisation strategy: skills in exportation and customs law

Economical development has always been connected to the commercial exchanges between people, due to the necessity to suppress their needs. With the increasing growth of international business and more competitive and demanding markets, exportation has become an important first step to internationalisation. Unlike what happened in the past, companies must be aware that the enrolment in the current global market is risky and requires elaborated technical procedures. Internationalisation should not be treated as an isolated event of business management. The first part of this paper aims to understand the export process and fit it in the current stage of international trade, keeping in mind the framework of export under the customs law. Then, we tried to understand how Portuguese companies should face this process in their internationalisation strategy, and what skills organisations must acquire to be able to export competitively in the current scenario of globalisation. The investigation was based on interviews in companies that, through a process of internationalisation by exportation, have implemented themselves strongly in extern markets. This investigation allowed us to analyse the companies’ motivations to become international, as well as the selection criteria for the export destinations. It was also possible to identify the main obstacles to the internationalisation of Portuguese companies. We concluded that companies that choose exportation as a way to become international acquire specific skills that enable them to become competitive in international trade. However, studies have failed to answer the second initial question about whether the measures implemented by Customs potentiate exports.

Position paper on time and event-triggered communication services in the context of e-manufacturing

Modern factories are complex systems where advances in networking and information technologies are opening new ways towards higher efficiency. Such move is being driven by market rules with ever-increasing competition levels, in search for faster time-to-market, improved process yield, non-stop operations, flexible manufacturing and tighter supply-chain coupling. All these aims present a common requirement, i.e. a realtime flow of information, from the plant-floor up to the management, maintenance, suppliers and clients, to support accurate monitoring and control of the factory. This stresses the importance achieved by the communication infrastructure in modern manufacturing industry. This paper presents the authors view concerning the current trends in modern factory communication systems. It addresses the problems of seamlessly integrating different information flows with diverse requirements, mainly in terms of timeliness. In this aspect, the debate between event-triggered and time-triggered communication is revisited as well as the joint support for both types of traffic. Finally, a view of where factory communication systems are moving to is also presented, showing the impact of open and widely available technologies.

A capacity sharing and stealing strategy for open real-time systems

This paper focuses on the scheduling of tasks with hard and soft real-time constraints in open and dynamic real-time systems. It starts by presenting a capacity sharing and stealing (CSS) strategy that supports the coexistence of guaranteed and non-guaranteed bandwidth servers to efficiently handle soft-tasks’ overloads by making additional capacity available from two sources: (i) reclaiming unused reserved capacity when jobs complete in less than their budgeted execution time and (ii) stealing reserved capacity from inactive non-isolated servers used to schedule best-effort jobs. CSS is then combined with the concept of bandwidth inheritance to efficiently exchange reserved bandwidth among sets of inter-dependent tasks which share resources and exhibit precedence constraints, assuming no previous information on critical sections and computation times is available. The proposed Capacity Exchange Protocol (CXP) has a better performance and a lower overhead when compared against other available solutions and introduces a novel approach to integrate precedence constraints among tasks of open real-time systems.

Flexible manufacturing field trial

Within the European project R-Fieldbus (http://www.hurray.isep.ipp.pt/activities/rfieldbus/), an industrial manufacturing field trial was developed. This field trial was conceived as a demonstration test bed for the technologies developed during the project. Because the R-Fieldbus field trial included prototype hardware devices, the purpose of this equipment changed and since the conclusion of the project, several new technologies also emerged, therefore an update of the field trial was required. This document describes an update of the manufacturing field trial. The purpose of this update, the changes and improvements introduced are described in the document. Additionally, this document also provides a reliable source of documentation for the equipment, configuration and software components of the manufacturing field trial.

Bifacial dye-sensitized solar cells: a strategy to enhance overall efficiency based on transparent polyaniline electrode

Dye-sensitized solar cell (DSSC) is a promising solution to global energy and environmental problems because of its clean, low-cost, high efficiency, good durability, and easy fabrication. However, enhancing the efficiency of the DSSC still is an important issue. Here we devise a bifacial DSSC based on a transparent polyaniline (PANI) counter electrode (CE). Owing to the sunlight irradiation simultaneously from the front and the rear sides, more dye molecules are excited and more carriers are generated, which results in the enhancement of short-circuit current density and therefore overall conversion efficiency. The photoelectric properties of PANI can be improved by modifying with 4-aminothiophenol (4-ATP). The bifacial DSSC with 4-ATP/PANI CE achieves a light-to-electric energy conversion efficiency of 8.35%, which is increased by ,24.6% compared to the DSSC irradiated from the front only. This new concept along with promising results provides a new approach for enhancing the photovoltaic performances of solar cells.

Development of a platform for lean manufacturing simulation games

More than ever, the economic globalization is creating the need to increase business competitiveness. Lean manufacturing is a management philosophy oriented to the elimination of activities that do not create any type of value and are thus considered a waste. One of the main differences from other management philosophies is the shop-floor focus and the operators' involvement. Therefore, the training of all organization levels is crucial for the success of lean manufacturing. Universities should also participate actively in this process by developing students' lean management skills and promoting a better and faster integration of students into their future organizations. This paper proposes a single realistic manufacturing platform, involving production and assembly operations, to learn by playing many of the lean tools such as VSM, 5S, SMED, poke-yoke, line balance, TPM, Mizusumashi, plant layout, and JIT/kanban. This simulation game was built in tight cooperation with experienced lean companies under the international program “Lean Learning Academy,”http://www.leanlearningacademy.eu/ and its main aim is to make bachelor and master courses in applied sciences more attractive by integrating classic lectures with a simulated production environment that could result in more motivated students and higher study yields. The simulation game results show that our approach is efficient in providing a realistic platform for the effective learning of lean principles, tools, and mindset, which can be easily included in course classes of less than two hours.

Lean learning academy: an innovative framework for lean manufacturing training

Worldwide competitiveness poses enormous challenges on managers, demanding a continuous quest to increase rationality in the use of resources. As a management philosophy, Lean Manufacturing focuses on the elimination of activities that do not create any type of value and therefore are considered waste. For companies to successfully implement the Lean Manufacturing philosophy it is crucial that the human resources of the organization have the necessary training, for which proper tools are required. At the same time, higher education institutions need innovative tools to increase the attractiveness of engineering curricula and develop a higher level of knowledge among students, improving their employability. This paper describes how Lean Learning Academy, an international collaboration project between five EU universities and five companies, from SME to Multinational/Global companies, developed and applied an innovative training programme for Engineers on Lean Manufacturing, a successful alternative to the traditional teaching methods in engineering courses.

A sensor classification strategy for robotic manipulators

In practice the robotic manipulators present some degree of unwanted vibrations. The advent of lightweight arm manipulators, mainly in the aerospace industry, where weight is an important issue, leads to the problem of intense vibrations. On the other hand, robots interacting with the environment often generate impacts that propagate through the mechanical structure and produce also vibrations. In order to analyze these phenomena a robot signal acquisition system was developed. The manipulator motion produces vibrations, either from the structural modes or from endeffector impacts. The instrumentation system acquires signals from several sensors that capture the joint positions, mass accelerations, forces and moments, and electrical currents in the motors. Afterwards, an analysis package, running off-line, reads the data recorded by the acquisition system and extracts the signal characteristics. Due to the multiplicity of sensors, the data obtained can be redundant because the same type of information may be seen by two or more sensors. Because of the price of the sensors, this aspect can be considered in order to reduce the cost of the system. On the other hand, the placement of the sensors is an important issue in order to obtain the suitable signals of the vibration phenomenon. Moreover, the study of these issues can help in the design optimization of the acquisition system. In this line of thought a sensor classification scheme is presented. Several authors have addressed the subject of the sensor classification scheme. White (White, 1987) presents a flexible and comprehensive categorizing scheme that is useful for describing and comparing sensors. The author organizes the sensors according to several aspects: measurands, technological aspects, detection means, conversion phenomena, sensor materials and fields of application. Michahelles and Schiele (Michahelles & Schiele, 2003) systematize the use of sensor technology. They identified several dimensions of sensing that represent the sensing goals for physical interaction. A conceptual framework is introduced that allows categorizing existing sensors and evaluates their utility in various applications. This framework not only guides application designers for choosing meaningful sensor subsets, but also can inspire new systems and leads to the evaluation of existing applications. Today’s technology offers a wide variety of sensors. In order to use all the data from the diversity of sensors a framework of integration is needed. Sensor fusion, fuzzy logic, and neural networks are often mentioned when dealing with problem of combing information from several sensors to get a more general picture of a given situation. The study of data fusion has been receiving considerable attention (Esteban et al., 2005; Luo & Kay, 1990). A survey of the state of the art in sensor fusion for robotics can be found in (Hackett & Shah, 1990). Henderson and Shilcrat (Henderson & Shilcrat, 1984) introduced the concept of logic sensor that defines an abstract specification of the sensors to integrate in a multisensor system. The recent developments of micro electro mechanical sensors (MEMS) with unwired communication capabilities allow a sensor network with interesting capacity. This technology was applied in several applications (Arampatzis & Manesis, 2005), including robotics. Cheekiralla and Engels (Cheekiralla & Engels, 2005) propose a classification of the unwired sensor networks according to its functionalities and properties. This paper presents a development of a sensor classification scheme based on the frequency spectrum of the signals and on a statistical metrics. Bearing these ideas in mind, this paper is organized as follows. Section 2 describes briefly the robotic system enhanced with the instrumentation setup. Section 3 presents the experimental results. Finally, section 4 draws the main conclusions and points out future work.

A sensor classification strategy for robotic manipulators using multidimensional scaling technique

This paper analyzes the signals captured during impacts and vibrations of a mechanical manipulator. To test the impacts, a flexible beam is clamped to the end-effector of a manipulator that is programmed in a way such that the rod moves against a rigid surface. Eighteen signals are captured and theirs correlation are calculated. A sensor classification scheme based on the multidimensional scaling technique is presented.

Solving nonlinear equations by a tabu search strategy

Solving systems of nonlinear equations is a problem of particular importance since they emerge through the mathematical modeling of real problems that arise naturally in many branches of engineering and in the physical sciences. The problem can be naturally reformulated as a global optimization problem. In this paper, we show that a metaheuristic, called Directed Tabu Search (DTS) [16], is able to converge to the solutions of a set of problems for which the fsolve function of MATLAB® failed to converge. We also show the effect of the dimension of the problem in the performance of the DTS.

A system verification strategy based on the BST infrastructure

A good verification strategy should bring near the simulation and real functioning environments. In this paper we describe a system-level co-verification strategy that uses a common flow for functional simulation, timing simulation and functional debug. This last step requires using a BST infrastructure, now widely available on commercial devices, specially on FPGAs with medium/large pin-counts.