Modelling and simulation for manufacturing systems : challenges and benefits

Computer modelling and simulation is an indispensable tool of the information age, used extensively in design, analysis, operations, decision-making, optimization, and education and training. Manufacturing, production and design relies upon simulation to develop efficient production systems and factories that produce quality products. Computer simulation allows scientists and engineers to understand and predict three-dimensional and time-dependent phenomena in science and engineering discipline. This talk will focus on challenges associated with modelling and simulation in the manufacturing sector and through a number of case studies highlights the benefits gained through the use of such technologies.

Factories of the future : a system of systems engineering perspective

Factories of the Future will be distinguished by intelligent machines, automation, human factors integration and knowledge management. Modelling and simulation is recognised as a key enabling technology essential to economic, social and environmental sustainability of future manufacturing systems. This talk will explore the history, recent achievements and directions in modelling and simulation for 21st century factories and supply chains. A systems science approach is employed, from stakeholder engagement through participative modelling to self-tuning and self-assembling simulations. Our contributions lower the cost of the application of modelling and simulation to manufacturing processes, enabling real time planning, dynamic risk analysis, dashboards and 3D visualisation. This realisation of the virtual factory integrates human factors and decisions into the core technology platform. The implications to future manufacturing enterprises are explored through a series of case studies from aerospace, mining and small and medium manufacturing enterprises.

Additive manufacturing in the cycling industry: mainstream or gimmick?

INTRODUCTION. Additive manufacturing (AM) for various industries has been trailed, prototyped and used in limited production runs (Gibson, 2015). But considering additive manufacturing with metallic materials has been around for over 15 years the penetration into an industry such as cycling that values customisation and progressive design techniques has been quite limited. This case study looks at the potential of and why additive manufacturing has not progressed from concept development and prototyping into production and mainstream. Selective Laser Melting (SLM) additive manufacturing systems mainly use Stainless Steel 316 (SS316) and Titanium 6Al.4V (Ti64) as a baseline material; both these materials are extremely common in the custom and high volume bike industries. For the purposes of this article we will focus on smaller custom bike manufacturers who are typically more agile and open to high levels of customisation in their products. The study finds that whilst a high number of companies will experiment and prototype with additive manufacturing there is little evidence that the design and development process translates to ongoing production for sale to the consumer, this could be due to knowledge of design and fabrication techniques.

Benchmark generation algorithm for stochastic mixed model assembly shop simulation and optimization

The Operations Research (OR) community have defined many deterministic manufacturing control problems mainly focused on scheduling. Well-defined benchmark problems provide a mechanism for communication of the effectiveness of different optimization algorithms. Manufacturing problems within industry are stochastic and complex. Common features of these problems include: variable demand, machine part specific breakdown patterns, part machine specific process durations, continuous production, Finished Goods Inventory (FGI) buffers, bottleneck machines and limited production capacity. Discrete Event Simulation (DES) is a commonly used tool for studying manufacturing systems of realistic complexity. There are few reports of detail-rich benchmark problems for use within the simulation optimization community that are as complex as those faced by production managers. This work details an algorithm that can be used to create single and multistage production control problems. The reported software implementation of the algorithm generates text files in eXtensible Markup Language (XML) format that are easily edited and understood as well as being cross-platform compatible. The distribution and acceptance of benchmark problems generated with the algorithm would enable researchers working on simulation and optimization of manufacturing problems to effectively communicate results to benefit the field in general.

Using information flow model to specify the Kanban-controlled shopfloor control system

The implementation of Kanban-based production control systems may be difficult in make-to-order environments such as job shops. The flexible manufacturing approach constitutes a promising solution to adapt the Kanban method to such environments. This paper presents an information flow modelling approach for specifying the operational planning and control functions of the Kanban-controlled shopfloor control system (KSCS) in a flexible manufacturing environment. By decomposing the KSCS control functionalities, we have created the system information flow model through the data flow diagrams of Structured Systems Analysis Methodology. The data flow diagrams serve effective system specifications for communicating the system operations to participants of different disciplines as well as the system model for the design and development of KSCS.

Extending robust industrial optimisation using simulation and reinforcement learning

Traditional optimisation methods are incapable of capturing the complexity of today's dynamic manufacturing systems. A new methodology, integrating simulation models and intelligent learning agents, was successfully applied to identify solutions to a fundamental scheduling problem. The robustness of this approach was then demonstrated through a series of real-world industrial applications.

Managing realtime information flow between distributed discrete event simulation models

Investigates the creation of a method for the connection and communication of commercial off the shelf discrete-event simulation packages for simulation models of manufacturing systems. Through this research a method to connect different commercial off the shelf discrete-event simulation packages was successfully developed facilitating parallel development of models and the creation of extremely large models.

CO2 laser manufacturing of miniaturised lenses for lab-on-a-chip systems

This article describes the manufacturing and characterisation of plano-convex miniaturised lenses using a CO2 laser engraving process in PMMA substrates. The technique allows for lenses to be fabricated rapidly and in a reproducible manner at depths of over 200 µm and for lens diameters of more than 3 mm. Experimental characterisation of the lens focal lengths shows good correlation with theory. The plano-convex lenses have been successfully embedded into capillary microfluidic systems alongside planar microlenses, allowing for a significant reduction of ancillary optics without a loss of detection sensitivity when performing fluorescence measurements. Such technology provides a significant step forward towards the portability of fluorescence- or luminescence-based systems for biological/chemical analysis.

Improved manufacturing quality and bonding of laser machined microfluidic systems

Laser micro-machining offers a versatile tool for the rapid manufacturing of polymeric microfluidics systems, with a typical turn-around-time in the order of minutes. However, the chaotic nature of the thermal evaporative ablation process can yield a significant number of defects in the surface of the manufactured microchannels, in the form of residual condensed material. In this work we have investigated the use of solvent evaporation by which to not only laminate bond the laser machined structures but to remove a significant number of the defect formed by the condensation of residual polymer. Results are presented of the surface profiling of the bonded channel structures and demonstrations of the bonding of the microchips to produce autonomous capillary microchannels.

The propagation of technology management taxonomies for evaluating investments in information systems

To provide managers with a critical insight into the management of new technology, this paper uses a case study research strategy to examine the technology management experiences of a leading UK manufacturing organization during its adoption of a vendor-supplied Manufacturing Resource Planning information system.

Modeling and simulation for large scale production systems

Computer modeling and simulation provide a foundation upon which industrial processes and systems can be transformed and innovation dramatically accelerated. Computer modeling and simulation is also an indispensable tool of the information age, used extensively in design, analysis, operations, decision-making, optimization, and education and training. Manufacturing, production and design relies upon simulation to develop efficient production systems and factories that produce quality products. Simulation in industry has yet to meet its full potential. The development of models is very time consuming, particularly for geometries of complex engineering systems such as manufacturing plants, automobiles, aircraft and ships. Computer simulation allows scientists and engineers to understand and predict three-dimensional and time-dependent phenomena in science and engineering discipline. This talk will focus on challenges associated with modeling and simulation in the manufacturing sector and through a number of case studies highlight the benefits gained through the use of such technologies.

Evaluation of cold forming lubricants for fastener manufacturing

Investigates the significance and interactive effects of lubricant type, workpiece surface texture and deformation rate under bulk metal, deformation conditions. A novel test rig was developed in conjunction with statistical test techniques. The result of this work identified a cold forming lubrication system with potential economic and environmental advantages over traditional lubrication systems.

Haptics and virtual reality in modern manufacturing

Product assembly is one of the most studied processes in modern manufacturing. In recent years a number of computer-based virtual reality systems have been proposed, developed and adopted by the manufacturing industries. Such systems have major advantages over conventional training practices for product assembly. Significant cost savings can be realized due to shorter training-scenario development times and reuse of existing engineering math models. In addition, the time span from the product design to full production can be shortened due to non-reliance on actual components and subsystems for training. Such training systems are effective if the knowledge required to be transferred is just process sequence such as assembly sequence. However, knowledge transfer for procedural and cognitive learning as well as skills development is very limited, due to the lack of user interactivity and immersion.

This talk will focus on a research technology platform where haptics and virtual reality are integrated to create an effective environment for production assembly operators’ training. In this system virtual reality provides the grounds for realistic visualization, as well as immersion, whereas haptics enforces physical constraints within the virtual world generating the feelings of realistic interaction, making it accessible for formal learning and better understanding during task performance.

The developed research technology platform imitates real physical training scenarios by providing comprehensive user interaction, constrained within the physical limitations of the real world. Through the utilization of a haptics device, providing realistic force feedback, users are able to engage in product assembly training with a stronger sense of ‘reality’.

Analysing business processes to manage and resolve strategic issues in a manufacturing business

This paper demonstrates the value of applying heuristics to knowledge systems of business processes in a manufacturing company to resolve strategic issues and enable the attainment of strategic business goals. The manufacturing company was losing market share through not being able to get its new products to market quickly enough. The research illustrates the ‘location’ and use of information systems in a manufacturing context. The researchers collected the specific business process knowledge in the company and developed a knowledge management system and then applied heuristics to the ‘AS IS’ manufacturing process to determine better models of manufacturing that would enable faster to market product development and thus enable better strategic alignment between company expectations and realisation of market share. The paper highlights the strategic use of information systems as a means of directly solving business problems.