A case study of concurrent engineering application on the development of parts for the white goods industry in Brazil

This classical way to manage product development processes for massive production seems to be changing: high pressure for cost reduction, higher quality standards, markets reaching for innovation lead to the necessity of new tools for development control. Into this, and learning from the automotive and aerospace industries factories from other segments are starting to understand and apply manufacturing and assembly oriented projects to ease the task of generate goods and from this obtain at least a part of the expected results. This paper is intended to demonstrate the applicability of the concepts of Concurrent Engineering and DFM/DFA (Design for Manufacturing and Assembly) in the development of products and parts for the White Goods industry in Brazil (major appliances as refrigerators, cookers and washing machines), showing one case concerning the development and releasing of a component. Finally is demonstrated in a short term how was reached a solution that could provide cost savings and reduction on the time to delivery using those techniques.

A useful empirical bayesian method to analyse industrial data from saturated factorial designs

The use of saturated two-level designs is very popular, especially in industrial applications where the cost of experiments is too high. Standard classical approaches are not appropriate to analyze data from saturated designs, since we could only get the estimates of the main factor effects and we would not have degrees of freedom to estimate the variance of the error. In this paper, we propose the use of empirical Bayesian procedures to get inferences for data obtained from saturated designs. The proposed methodology is illustrated assuming a simulated data set. © 2013 Growing Science Ltd. All rights reserved.

Ensino de gestão da capacidade e da empresa com o apoio do jogo Mercado Virtual no curso de Mestrado Integrado em Engenharia Industrial e Gestão da UMINHO/Azurém e no Programa de Pós-Graduação em Engenharia de Produção da FEB/Bauru/UNESP

O jogo de empresas Mercado Virtual foi desenvolvido para mediar o processo ensino-aprendizagem na área de tomada decisão e gestão de empresas e tem um banco de dados que armazena as decisões dos alunos. Os dados nele armazenados foram analisados em relação ao balanceamento de capacidade, objetivo de lucro e uso de recursos financeiros da empresa e foram encontradas incoerências entre os conteúdos pertinentes ao modelo e as decisões dos alunos. Elas foram classificadas como lacunas de aprendizado. Com o objetivo de analisar se as mesmas se repetem entre alunos do Programa de Mestrado Engenharia de Produção da UNESP de Bauru e Mestrado Integrado em Engenharia Industrial e Gestão da Uminho de Guimarães, Portugal, foram realizados dois experimentos, um em cada grupo. Para realizá-los utilizou-se o jogo Mercado Virtual e uma planilha de dimensionamento da empresa nos dois locais. A Sala de Estudos, os indicadores e o questionário de pesquisa da opinião foram utilizados somente em Portugal. Os resultados mostraram que o jogo é capaz de evidenciar as diferenças de domínio de conteúdo nos dois grupos e, também, que estas diferenças estão associadas aos projetos dos cursos. Sendo uma pesquisa exploratória, os experimentos foram realizados considerando-se somente os controles do jogo. Por isso, propõe-se a realização de pesquisas adicionais combinando controle sobre algumas das variáveis relacionadas do uso do jogo e atuação sobre aprendizagem dos alunos na forma de entrevistas e pesquisas não estruturadas. Conforme previsto, a pesquisa mostrou que os jogos podem ser utilizados com objetivos de aprendizagem mais amplos, considerando-se a avaliação indireta e cruzada sobre as decisões tomadas pelos alunos, como é o caso dos indicadores. Outra contribuição importante da pesquisa refere-se ao uso de jogos de empresas sob condições pouco controladas, ou seja, não houve...

Binary integer programming formulations for scheduling in market-driven foundries

This paper describes the development and solution of binary integer formulations for production scheduling problems in market-driven foundries. This industrial sector is comprised of small and mid-sized companies with little or no automation, working with diversified production, involving several different metal alloy specifications in small tailor-made product lots. The characteristics and constraints involved in a typical production environment at these industries challenge the formulation of mathematical programming models that can be computationally solved when considering real applications. However, despite the interest on the part of these industries in counting on effective methods for production scheduling, there are few studies available on the subject. The computational tests prove the robustness and feasibility of proposed models in situations analogous to those found in production scheduling at the analyzed industrial sector. (C) 2010 Elsevier Ltd. All rights reserved.

Evaluation of the kinetics of xylose formation from dilute sulfuric acid hydrolysis of forest residues of Eucalyptus grandis

Dilute acid hydrolysis studies were performed on forest residues of Eucalyptus grandis, in a cylindrical reactor of stainless steel. The kinetics of this hydrolysis reaction was investigated employing 0.65% sulfuric acid, a residue/acid solution ratio of 1/9 (w/w), temperatures of 130, 140, 150, and 160 degrees C, and reaction times in the range 20-100 min. The results showed that, under the optimized conditions of acid hydrolysis employed in this study, the variables temperature and reaction time had a strong influence on hemicellulose removal and a small influence on the degree of lignin and cellulose removal. The highest xylose extraction yield was 87.6% attained at 160 degrees C, after 70 min reaction time, simultaneously with the formation of decomposition products, namely 2.8% acetic acid, 0.6% furfural, and 0.06% 5-hydroxymethylfurfural. A similar xylose extraction yield (82.8%) was observed at 150 degrees C after 100 min, with the formation of 3.2% acetic acid, 1.0% furfural, and 0.07% 5-hydroxymethylfurfural. The kinetic parameters determined at 130, 140, 150, and 160 degrees C for degradation of xylan present in the hemicellulose of the eucalyptus forest residue during the formation of xylose were the first-order reaction rate constants (k) for each temperature, 1.22 x 10(-4), 2.12 x 10(-4), 5.43 x 10(-4), and 9.05 x 10(-4) s(-1), respectively, and an activation energy (E-a) of 101.3 kJ mol(-1).

Banana Peel Applied to the Solid Phase Extraction of Copper and Lead from River Water: Preconcentration of Metal Ions with a Fruit Waste

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Red Mud from Brazil: Thermal Behavior and Physical Properties

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Variable speed refrigeration system with HPF input rectifier stage

This paper is based on the analysis and implementation of a new drive system applied to refrigeration systems, complying with the restrictions imposed by the IEC standards (Harmonic/Flicker/EMI-Electromagnetic Interference restrictions), in order to obtain high efficiency, high power factor, reduced harmonic distortion in the input current and reduced electromagnetic interference, with excellent performance in temperature control of a refrigeration prototype system (automatic control, precision and high dynamic response). The proposal is replace the single-phase motor by a three-phase motor, in the conventional refrigeration system. In this way, a proper control technique can be applied, using a closed-loop (feedback control), that will allow an accurate adjustment of the desirable temperature. The proposed refrigeration prototype uses a 0.5Hp three-phase motor and an open (Belt-Drive) Bitzer IY type compressor. The input rectifier stage's features include the reduction in the input current ripple, the reduction in the output voltage ripple, the use of low stress devices, low volume for the EMI input filter, high input power factor (PF), and low total harmonic distortion (THD) in the input current, in compliance with the IEC61000-3-2 standards. The digital controller for the output three-phase inverter stage has been developed using a conventional voltage-frequency control (scalar V/f control), and a simplified stator oriented Vector control, in order to verify the feasibility and performance of the proposed digital controls for continuous temperature control applied at the refrigerator prototype. ©2008 IEEE.

Swarm control designs applied to a micro-electro-mechanical gyroscope system (MEMS)

This paper analyzes the non-linear dynamics of a MEMS Gyroscope system, modeled with a proof mass constrained to move in a plane with two resonant modes, which are nominally orthogonal. The two modes are ideally coupled only by the rotation of the gyro about the plane's normal vector. We demonstrated that this model has an unstable behavior. Control problems consist of attempts to stabilize a system to an equilibrium point, a periodic orbit, or more general, about a given reference trajectory. We also developed a particle swarm optimization technique for reducing the oscillatory movement of the nonlinear system to a periodic orbit. © 2010 Springer-Verlag.

Methodology proposal for acquisition of biotelemetric data in a real time

This work presents a methodological proposal for acquisition of biometric data through telemetry basing its development on a research-action and a case study. Nowadays, the qualified professionals of physical evaluation have to use specific devices to obtain biometric signals and data. These devices in the most of the time are high cost and difficult to use and handling. Therefore, the methodological proposal was elaborate in order to develop, conceptually, a bio telemetric device which could acquire the desirable biometric signals: oxymetry, biometrics, corporal temperature and pedometry which are essential for the area of physical evaluation. It was researched the existent biometrics sensors, the possible ways for the remote transmission of signals and the computer systems available so that the acquisition of data could be possible. This methodological proposal of remote acquisition of biometrical signals is structured in four modules: Acquisitor of biometrics data; Converser and transmitter of biometric signals; Receiver and Processor of biometrics signals and Generator of Interpretative Graphs. The modules aim the obtention of interpretative graphics of human biometric signals. In order to validate this proposal a functional prototype was developed and it is presented in the development of this work.

Geometric modeling from the medical images in the CAD system to support prosthesis design

This paper presents an individual designing prosthesis for surgical use and proposes a methodology for such design through mathematical extrapolation of data from digital images obtained via tomography of individual patient's bones. Individually tailored prosthesis designed to fit particular patient requirements as accurately as possible should result in more successful reconstruction, enable better planning before surgery and consequently fewer complications during surgery. Fast and accurate design and manufacture of personalized prosthesis for surgical use in bone replacement or reconstruction is potentially feasible through the application and integration of several different existing technologies, which are each at different stages of maturity. Initial case study experiments have been undertaken to validate the research concepts by making dimensional comparisons between a bone and a virtual model produced using the proposed methodology and a future research directions are discussed.

Preliminary results concerning the VSS X- chart with unknow in-control parameters

The VSS X- chart is known to perform better than the traditional X- control chart in detecting small to moderate mean shifts in the process. Many researchers have used this chart in order to detect a process mean shift under the assumption of known parameters. However, in practice, the process parameters are rarely known and are usually estimated from an in-control Phase I data set. In this paper, we evaluate the (run length) performances of the VSS X- control chart when the process parameters are estimated and we compare them in the case where the process parameters are assumed known. We draw the conclusion that these performances are quite different when the shift and the number of samples used during the phase I are small. ©2010 IEEE.

Different methods of cutting fluid application on turning of a difficult-to-machine steel

Different methods of cutting fluid application are used on turning of a difficult-tomachine steel (SAE EV-8). A semi-synthetic cutting fluid was applied using a conventional method, minimum quantity of cutting fluid (MQCF), and pulverization. By the minimum quantity method was also applied a lubricant of vegetable oil (MQL). Thereafter, a cutting fluid jet under high pressure (3.0 MPa) was singly applied in the following regions: chip-tool interface; top surface of the chip; and tool-workpiece contact. Two other methods were used: an interflow between conventional application and chip-tool interface jet and, finally, three jets simultaneously applied. In order to carry out these tests, it was necessary to set up a high pressure system using a piston pump for generating a cutting fluid jet, a Venturi for fluid application (MQCF and MQL), and a nozzle for cutting fluid pulverization. The output variables analyzed included tool life, surface roughness, cutting tool temperature, cutting force, chip form, chip compression rate and machined specimen microstructure. It can be observed that the tool life increases and the cutting force decreases with the application of cutting fluid jet, mainly when it is directed to the chip-tool interface. Excluding the methods involving jet fluid, the conventional method seems to be more efficient than other methods of low pressure. © (2013) Trans Tech Publications, Switzerland.

A priori reformulations for joint rolling-horizon scheduling of materials processing and lot-sizing problem

In many production processes, a key material is prepared and then transformed into different final products. The lot sizing decisions concern not only the production of final products, but also that of material preparation in order to take account of their sequence-dependent setup costs and times. The amount of research in recent years indicates the relevance of this problem in various industrial settings. In this paper, facility location reformulation and strengthening constraints are newly applied to a previous lot-sizing model in order to improve solution quality and computing time. Three alternative metaheuristics are used to fix the setup variables, resulting in much improved performance over previous research, especially regarding the use of the metaheuristics for larger instances. © 2013 Elsevier Ltd. All rights reserved.

A single chart with supplementary runs rules for monitoring the mean vector and the covariance matrix of multivariate processes

The MRMAX chart is a single chart based on the standardized sample means and sample ranges for monitoring the mean vector and the covariance matrix of multivariate processes. User's familiarity with the computation of these statistics is a point in favor of the MRMAX chart. As a single chart, the recently proposed MRMAX chart is very appropriate for supplementary runs rules. In this article, we compare the supplemented MRMAX chart and the synthetic MRMAX chart with the standard MRMAX chart. The supplementary and the synthetic runs rules enhance the performance of the MRMAX chart. © 2013 Elsevier Ltd.