Economic and Environmental Optimization of Ornamental Stone Block Cutting with a 3D Algorithm

This thesis focuses on finding the optimum block cutting dimensions in terms of the environmental and economic factors by using a 3D algorithm for a limestone quarry in Foggia, Italy. The environmental concerns of quarrying operations are mainly: energy consumption, material waste, and pollution. The main economic concerns are the block recovery, the selling prices, and the production costs. Fractures adversely affect the block recovery ratio. With a fracture model, block production can be optimized. In this research, the waste volume produced by quarrying was minimised to increase the recovery ratio and ensure economic benefits. SlabCutOpt is a software developed at DICAM–University of Bologna for block cutting optimization which tests different cutting angles on the x-y-z planes to offer up alternative cutting methods. The program tests several block sizes and outputs the optimal result for each entry. By using SlabCutOpt, ten different block dimensions were analysed, the results indicated the maximum number of non-intersecting blocks for each dimension. After analysing the outputs, the block named number 1 with the dimensions ‘1mx1mx1m’ had the highest recovery ratio as 43% and the total Relative Money Value (RMV) with a value of 22829. Dimension number 1, also had the lowest waste volume, with a value of 3953.25 m3, for the total bench. For cutting the total bench volume of 6932.25m3, the diamond wire cutter had the lowest dust emission values for the block with the dimension ‘2mx2mx2m’, with a value of 24m3. When compared with the Eco-Label standards, block dimensions having surface area values lower than 15m2, were found to fit the natural resource waste criteria of the label, as the threshold required 25% of minimum recovery [1]. Due to the relativity of production costs, together with the Eco-Label threshold, the research recommends the selection of the blocks with a surface area value between 6m2 and 14m2.

Sviluppo di un sistema per allocazione e scheduling di applicazioni periodiche

In questa tesi, viene illustrato un metodo risolutivo al problema dell’allocazione e schedulazione, su risorse eterogenee con capacità unaria rinnovabile e cumulativa non rinnovabile, di applicazioni multitask periodiche, con periodi in relazione armonica, strutturate in attività indipendenti o sottoposte a vincoli di precedenza e con durate dipendenti dalla specifica risorsa di allocazione. L’obiettivo è quello di fornire un’implementazione del modello in grado di gestire l’allocazione e la schedulazione di istanze (i.e. insieme di applicazioni) variabili, caratterizzate da una serie di parametri. La struttura implementativa, realizzata secondo la Logic-based Benders decomposition, prevede la suddivisione del problema in due moduli. Il primo in grado di generare un’allocazione e realizzato con tecniche di programmazione lineare intera mista, il secondo con lo scopo di controllare l’ammissibilità di tale allocazione attraverso una schedulazione ottima e realizzato mediante tecniche di programmazione a vincoli. Il meccanismo di comunicazione tra i due moduli avviene mediante vincoli lineari, denominati tagli di Benders, che vengono aggiunti dopo ogni iterazione del sistema. L’efficacia del modello sarà valutata confrontando i risultati ottenuti attraverso una serie di test, con i valori forniti da un metodo di allocazione e schedulazione alternativo.

SmartForge: An event-driven architecture for simulator-based process optimization

In the metal industry, and more specifically in the forging one, scrap material is a crucial issue and reducing it would be an important goal to reach. Not only would this help the companies to be more environmentally friendly and more sustainable, but it also would reduce the use of energy and lower costs. At the same time, the techniques for Industry 4.0 and the advancements in Artificial Intelligence (AI), especially in the field of Deep Reinforcement Learning (DRL), may have an important role in helping to achieve this objective. This document presents the thesis work, a contribution to the SmartForge project, that was performed during a semester abroad at Karlstad University (Sweden). This project aims at solving the aforementioned problem with a business case of the company Bharat Forge Kilsta, located in Karlskoga (Sweden). The thesis work includes the design and later development of an event-driven architecture with microservices, to support the processing of data coming from sensors set up in the company's industrial plant, and eventually the implementation of an algorithm with DRL techniques to control the electrical power to use in it.

Modelling, simulation and optimization of maintenance considerations on condition based maintenance

Globalization has increased the pressure on organizations and companies to operate in the most efficient and economic way. This tendency promotes that companies concentrate more and more on their core businesses, outsource less profitable departments and services to reduce costs. By contrast to earlier times, companies are highly specialized and have a low real net output ratio. For being able to provide the consumers with the right products, those companies have to collaborate with other suppliers and form large supply chains. An effect of large supply chains is the deficiency of high stocks and stockholding costs. This fact has lead to the rapid spread of Just-in-Time logistic concepts aimed minimizing stock by simultaneous high availability of products. Those concurring goals, minimizing stock by simultaneous high product availability, claim for high availability of the production systems in the way that an incoming order can immediately processed. Besides of design aspects and the quality of the production system, maintenance has a strong impact on production system availability. In the last decades, there has been many attempts to create maintenance models for availability optimization. Most of them concentrated on the availability aspect only without incorporating further aspects as logistics and profitability of the overall system. However, production system operator’s main intention is to optimize the profitability of the production system and not the availability of the production system. Thus, classic models, limited to represent and optimize maintenance strategies under the light of availability, fail. A novel approach, incorporating all financial impacting processes of and around a production system, is needed. The proposed model is subdivided into three parts, maintenance module, production module and connection module. This subdivision provides easy maintainability and simple extendability. Within those modules, all aspect of production process are modeled. Main part of the work lies in the extended maintenance and failure module that offers a representation of different maintenance strategies but also incorporates the effect of over-maintaining and failed maintenance (maintenance induced failures). Order release and seizing of the production system are modeled in the production part. Due to computational power limitation, it was not possible to run the simulation and the optimization with the fully developed production model. Thus, the production model was reduced to a black-box without higher degree of details.