The effects of material variations in high value manufacturing industries

It has never been easy for manufacturing companies to understand their confidence level in terms of how accurate and to what degree of flexibility parts can be made. This brings uncertainty in finding the most suitable manufacturing method as well as in controlling their product and process verification systems. The aim of this research is to develop a system for capturing the company’s knowledge and expertise and then reflect it into an MRP (Manufacturing Resource Planning) system. A key activity here is measuring manufacturing and machining capabilities to a reasonable confidence level. For this purpose an in-line control measurement system is introduced to the company. Using SPC (Statistical Process Control) not only helps to predict the trend in manufacturing of parts but also minimises the human error in measurement. Gauge R&R (Repeatability and Reproducibility) study identifies problems in measurement systems. Measurement is like any other process in terms of variability. Reducing this variation via an automated machine probing system helps to avoid defects in future products.Developments in aerospace, nuclear, oil and gas industries demand materials with high performance and high temperature resistance under corrosive and oxidising environments. Superalloys were developed in the latter half of the 20th century as high strength materials for such purposes. For the same characteristics superalloys are considered as difficult-to-cut alloys when it comes to formation and machining. Furthermore due to the sensitivity of superalloy applications, in many cases they should be manufactured with tight tolerances. In addition superalloys, specifically Nickel based, have unique features such as low thermal conductivity due to having a high amount of Nickel in their material composition. This causes a high surface temperature on the work-piece at the machining stage which leads to deformation in the final product.Like every process, the material variations have a significant impact on machining quality. The main cause of variations can originate from chemical composition and mechanical hardness. The non-uniform distribution of metal elements is a major source of variation in metallurgical structures. Different heat treatment standards are designed for processing the material to the desired hardness levels based on application. In order to take corrective actions, a study on the material aspects of superalloys has been conducted. In this study samples from different batches of material have been analysed. This involved material preparation for microscopy analysis, and the effect of chemical compositions on hardness (before and after heat treatment). Some of the results are discussed and presented in this paper.

A dynamic feature information model for integrated manufacturing planning and optimization

This paper presents a new, dynamic feature representation method for high value parts consisting of complex and intersecting features. The method first extracts features from the CAD model of a complex part. Then the dynamic status of each feature is established between various operations to be carried out during the whole manufacturing process. Each manufacturing and verification operation can be planned and optimized using the real conditions of a feature, thus enhancing accuracy, traceability and process control. The dynamic feature representation is complementary to the design models used as underlining basis in current CAD/CAM and decision support systems. © 2012 CIRP.

Economical analysis for investment on measuring systems

Metrology processes contribute to entire manufacturing systems that can have a considerable impact on financial investment in coordinate measuring systems. However, there is a lack of generic methodologies to quantify their economical value in today’s industry. To solve this problem, a mathematical model is proposed in this paper by statistical deductive reasoning. This is done through defining the relationships between Process Capability Index, measurement uncertainty and tolerance band. The correctness of the mathematical model is proved by a case study. Finally, several comments and suggestions on evaluating and maximizing the benefits of metrology investment are given.

Linking design and manufacturing domains via web-based and enterprise integration technologies

The manufacturing industry faces many challenges such as reducing time-to-market and cutting costs. In order to meet these increasing demands, effective methods are need to support the early product development stages by bridging the gap of communicating early design ideas and the evaluation of manufacturing performance. This paper introduces methods of linking design and manufacturing domains using disparate technologies. The combined technologies include knowledge management supporting for product lifecycle management systems, Enterprise Resource Planning (ERP) systems, aggregate process planning systems, workflow management and data exchange formats. A case study has been used to demonstrate the use of these technologies, illustrated by adding manufacturing knowledge to generate alternative early process plan which are in turn used by an ERP system to obtain and optimise a rough-cut capacity plan. Copyright © 2010 Inderscience Enterprises Ltd.

A comparison of two distributed large-volume measurement systems:the mobile spatial co-ordinate measuring system and the indoor global positioning system

Advances in the area of industrial metrology have generated new technologies that are capable of measuring components with complex geometry and large dimensions. However, no standard or best-practice guides are available for the majority of such systems. Therefore, these new systems require appropriate testing and verification in order for the users to understand their full potential prior to their deployment in a real manufacturing environment. This is a crucial stage, especially when more than one system can be used for a specific measurement task. In this paper, two relatively new large-volume measurement systems, the mobile spatial co-ordinate measuring system (MScMS) and the indoor global positioning system (iGPS), are reviewed. These two systems utilize different technologies: the MScMS is based on ultrasound and radiofrequency signal transmission and the iGPS uses laser technology. Both systems have components with small dimensions that are distributed around the measuring area to form a network of sensors allowing rapid dimensional measurements to be performed in relation to large-size objects, with typical dimensions of several decametres. The portability, reconfigurability, and ease of installation make these systems attractive for many industries that manufacture large-scale products. In this paper, the major technical aspects of the two systems are briefly described and compared. Initial results of the tests performed to establish the repeatability and reproducibility of these systems are also presented. © IMechE 2009.

Assessing the impact of management concerns in e-business requirements planning in manufacturing organizations

This paper describes the application of a model, initially developed for determining the e-business requirements of a manufacturing organization, to assess the impact of management concerns on the functions generated. The model has been tested on 13 case studies in small, medium and large organizations. This research shows that the incorporation of concerns for generating the requirements for e-business functions improves the results, because they expose issues that are of relevance to the decision making process relating to e-business. Running the model with both and without concerns, and then presenting the reasons for major variances, can expose the issues and enable them to be studied in detail at the individual function/ reason level. © IFIP International Federation for Information Processing 2013.

Do manufacturing firms need informality in ERP post-implementation? A study of Chinese manufacturing sites

Purpose - Enterprise resource planning (ERP) systems are limited due to their operation around a fixed design production process and a fixed lead time to production plan and purchasing plan. The purpose of this paper is to define the concept of informality and to describe the notion of a system combining informality and ERP systems, based on empirical research from four manufacturing case studies. Design/methodology/approach - The case studies present a range of applications of ERP and are analysed in terms of the three characteristics of informality, namely, organisation structure, communication method and leadership approach. Findings - The findings suggest that systems consisting of informality in combination with ERP systems can elicit knowledge fromfrontlineworkers leading to timely improvements in the system. This is achieved by allowing users to modify work procedures or production orders, and to support collaborative working among all employees. However it was found that informality is not required for manufacturers with a relatively stable environment who can deal with uncertainty with a proactive strategy. Research limitations/implications - This study was carried out in China, with four companies as unit of analysis. Future work can help to extend this study across countries. Originality/value - The use of Four dimensions of informality that relate to manufacturers implementing ERP are defined as "technology in practice", "user flexibility", "trusted human networks" and "positive reaction to uncertainty". This is a new construct not applied before to ERP implementations.

A reliability centered maintenance decision system for a discrete part manufacturing facility

This thesis develops and validates the framework of a specialized maintenance decision support system for a discrete part manufacturing facility. Its construction utilizes a modular approach based on the fundamental philosophy of Reliability Centered Maintenance (RCM). The proposed architecture uniquely integrates System Decomposition, System Evaluation, Failure Analysis, Logic Tree Analysis, and Maintenance Planning modules. It presents an ideal solution to the unique maintenance inadequacies of modern discrete part manufacturing systems. Well established techniques are incorporated as building blocks of the system's modules. These include Failure Mode Effect and Criticality Analysis (FMECA), Logic Tree Analysis (LTA), Theory of Constraints (TOC), and an Expert System (ES). A Maintenance Information System (MIS) performs the system's support functions. Validation was performed by field testing of the system at a Miami based manufacturing facility. Such a maintenance support system potentially reduces downtime losses and contributes to higher product quality output. Ultimately improved profitability is the final outcome. ^

A theory of constraints service systems improvement method: Case of the airline turnaround problem

This dissertation develops a process improvement method for service operations based on the Theory of Constraints (TOC), a management philosophy that has been shown to be effective in manufacturing for decreasing WIP and improving throughput. While TOC has enjoyed much attention and success in the manufacturing arena, its application to services in general has been limited. The contribution to industry and knowledge is a method for improving global performance measures based on TOC principles. The method proposed in this dissertation will be tested using discrete event simulation based on the scenario of the service factory of airline turnaround operations. To evaluate the method, a simulation model of aircraft turn operations of a U.S. based carrier was made and validated using actual data from airline operations. The model was then adjusted to reflect an application of the Theory of Constraints for determining how to deploy the scarce resource of ramp workers. The results indicate that, given slight modifications to TOC terminology and the development of a method for constraint identification, the Theory of Constraints can be applied with success to services. Bottlenecks in services must be defined as those processes for which the process rates and amount of work remaining are such that completing the process will not be possible without an increase in the process rate. The bottleneck ratio is used to determine to what degree a process is a constraint. Simulation results also suggest that redefining performance measures to reflect a global business perspective of reducing costs related to specific flights versus the operational local optimum approach of turning all aircraft quickly results in significant savings to the company. Savings to the annual operating costs of the airline were simulated to equal 30% of possible current expenses for misconnecting passengers with a modest increase in utilization of the workers through a more efficient heuristic of deploying them to the highest priority tasks. This dissertation contributes to the literature on service operations by describing a dynamic, adaptive dispatch approach to manage service factory operations similar to airline turnaround operations using the management philosophy of the Theory of Constraints.

Scheduling medical application workloads on virtualized computing systems

This dissertation presents and evaluates a methodology for scheduling medical application workloads in virtualized computing environments. Such environments are being widely adopted by providers of "cloud computing" services. In the context of provisioning resources for medical applications, such environments allow users to deploy applications on distributed computing resources while keeping their data secure. Furthermore, higher level services that further abstract the infrastructure-related issues can be built on top of such infrastructures. For example, a medical imaging service can allow medical professionals to process their data in the cloud, easing them from the burden of having to deploy and manage these resources themselves. In this work, we focus on issues related to scheduling scientific workloads on virtualized environments. We build upon the knowledge base of traditional parallel job scheduling to address the specific case of medical applications while harnessing the benefits afforded by virtualization technology. To this end, we provide the following contributions: (1) An in-depth analysis of the execution characteristics of the target applications when run in virtualized environments. (2) A performance prediction methodology applicable to the target environment. (3) A scheduling algorithm that harnesses application knowledge and virtualization-related benefits to provide strong scheduling performance and quality of service guarantees. In the process of addressing these pertinent issues for our target user base (i.e. medical professionals and researchers), we provide insight that benefits a large community of scientific application users in industry and academia. Our execution time prediction and scheduling methodologies are implemented and evaluated on a real system running popular scientific applications. We find that we are able to predict the execution time of a number of these applications with an average error of 15%. Our scheduling methodology, which is tested with medical image processing workloads, is compared to that of two baseline scheduling solutions and we find that it outperforms them in terms of both the number of jobs processed and resource utilization by 20–30%, without violating any deadlines. We conclude that our solution is a viable approach to supporting the computational needs of medical users, even if the cloud computing paradigm is not widely adopted in its current form.

Systems Engineering Perspective of the Cruise Industry

The maturation of the cruise industry has led to increased competition which demands more efficient operations. Systems engineering, a discipline that studies complex organizations of material, people, and information, is traditionally only applied in the manufacturing sector; however, it can make significant contributions to service industries such as the cruise industry. The author describes this type of engineering, explores how it can be applied to the cruise industry, and presents two case studies demonstrating applications to the cruise industry luggage delivery process and the information technology help desk process. The results show that this approach can make the processes more productive and enhance profitability for the cruise lines.

An automated approach for performance deviation analysis of evolving software systems

A manutenção e evolução de sistemas de software tornou-se uma tarefa bastante crítica ao longo dos últimos anos devido à diversidade e alta demanda de funcionalidades, dispositivos e usuários. Entender e analisar como novas mudanças impactam os atributos de qualidade da arquitetura de tais sistemas é um pré-requisito essencial para evitar a deterioração de sua qualidade durante sua evolução. Esta tese propõe uma abordagem automatizada para a análise de variação do atributo de qualidade de desempenho em termos de tempo de execução (tempo de resposta). Ela é implementada por um framework que adota técnicas de análise dinâmica e mineração de repositório de software para fornecer uma forma automatizada de revelar fontes potenciais – commits e issues – de variação de desempenho em cenários durante a evolução de sistemas de software. A abordagem define quatro fases: (i) preparação – escolher os cenários e preparar os releases alvos; (ii) análise dinâmica – determinar o desempenho de cenários e métodos calculando seus tempos de execução; (iii) análise de variação – processar e comparar os resultados da análise dinâmica para releases diferentes; e (iv) mineração de repositório – identificar issues e commits associados com a variação de desempenho detectada. Estudos empíricos foram realizados para avaliar a abordagem de diferentes perspectivas. Um estudo exploratório analisou a viabilidade de se aplicar a abordagem em sistemas de diferentes domínios para identificar automaticamente elementos de código fonte com variação de desempenho e as mudanças que afetaram tais elementos durante uma evolução. Esse estudo analisou três sistemas: (i) SIGAA – um sistema web para gerência acadêmica; (ii) ArgoUML – uma ferramenta de modelagem UML; e (iii) Netty – um framework para aplicações de rede. Outro estudo realizou uma análise evolucionária ao aplicar a abordagem em múltiplos releases do Netty, e dos frameworks web Wicket e Jetty. Nesse estudo foram analisados 21 releases (sete de cada sistema), totalizando 57 cenários. Em resumo, foram encontrados 14 cenários com variação significante de desempenho para Netty, 13 para Wicket e 9 para Jetty. Adicionalmente, foi obtido feedback de oito desenvolvedores desses sistemas através de um formulário online. Finalmente, no último estudo, um modelo de regressão para desempenho foi desenvolvido visando indicar propriedades de commits que são mais prováveis a causar degradação de desempenho. No geral, 997 commits foram minerados, sendo 103 recuperados de elementos de código fonte degradados e 19 de otimizados, enquanto 875 não tiveram impacto no tempo de execução. O número de dias antes de disponibilizar o release e o dia da semana se mostraram como as variáveis mais relevantes dos commits que degradam desempenho no nosso modelo. A área de característica de operação do receptor (ROC – Receiver Operating Characteristic) do modelo de regressão é 60%, o que significa que usar o modelo para decidir se um commit causará degradação ou não é 10% melhor do que uma decisão aleatória.

An automated approach for performance deviation analysis of evolving software systems

A manutenção e evolução de sistemas de software tornou-se uma tarefa bastante crítica ao longo dos últimos anos devido à diversidade e alta demanda de funcionalidades, dispositivos e usuários. Entender e analisar como novas mudanças impactam os atributos de qualidade da arquitetura de tais sistemas é um pré-requisito essencial para evitar a deterioração de sua qualidade durante sua evolução. Esta tese propõe uma abordagem automatizada para a análise de variação do atributo de qualidade de desempenho em termos de tempo de execução (tempo de resposta). Ela é implementada por um framework que adota técnicas de análise dinâmica e mineração de repositório de software para fornecer uma forma automatizada de revelar fontes potenciais – commits e issues – de variação de desempenho em cenários durante a evolução de sistemas de software. A abordagem define quatro fases: (i) preparação – escolher os cenários e preparar os releases alvos; (ii) análise dinâmica – determinar o desempenho de cenários e métodos calculando seus tempos de execução; (iii) análise de variação – processar e comparar os resultados da análise dinâmica para releases diferentes; e (iv) mineração de repositório – identificar issues e commits associados com a variação de desempenho detectada. Estudos empíricos foram realizados para avaliar a abordagem de diferentes perspectivas. Um estudo exploratório analisou a viabilidade de se aplicar a abordagem em sistemas de diferentes domínios para identificar automaticamente elementos de código fonte com variação de desempenho e as mudanças que afetaram tais elementos durante uma evolução. Esse estudo analisou três sistemas: (i) SIGAA – um sistema web para gerência acadêmica; (ii) ArgoUML – uma ferramenta de modelagem UML; e (iii) Netty – um framework para aplicações de rede. Outro estudo realizou uma análise evolucionária ao aplicar a abordagem em múltiplos releases do Netty, e dos frameworks web Wicket e Jetty. Nesse estudo foram analisados 21 releases (sete de cada sistema), totalizando 57 cenários. Em resumo, foram encontrados 14 cenários com variação significante de desempenho para Netty, 13 para Wicket e 9 para Jetty. Adicionalmente, foi obtido feedback de oito desenvolvedores desses sistemas através de um formulário online. Finalmente, no último estudo, um modelo de regressão para desempenho foi desenvolvido visando indicar propriedades de commits que são mais prováveis a causar degradação de desempenho. No geral, 997 commits foram minerados, sendo 103 recuperados de elementos de código fonte degradados e 19 de otimizados, enquanto 875 não tiveram impacto no tempo de execução. O número de dias antes de disponibilizar o release e o dia da semana se mostraram como as variáveis mais relevantes dos commits que degradam desempenho no nosso modelo. A área de característica de operação do receptor (ROC – Receiver Operating Characteristic) do modelo de regressão é 60%, o que significa que usar o modelo para decidir se um commit causará degradação ou não é 10% melhor do que uma decisão aleatória.

Subtractive and additive manufacturing technology in moulding industry

This report is a review of additive and subtractive manufacturing techniques. This approach (additive manufacturing) has resided largely in the prototyping realm, where the methods of producing complex freeform solid objects directly from a computer model without part-specific tooling or knowledge. But these technologies are evolving steadily and are beginning to encompass related systems of material addition, subtraction, assembly, and insertion of components made by other processes. Furthermore, these various additive processes are starting to evolve into rapid manufacturing techniques for mass-customized products, away from narrowly defined rapid prototyping. Taking this idea far enough down the line, and several years hence, a radical restructuring of manufacturing could take place. Manufacturing itself would move from a resource base to a knowledge base and from mass production of single use products to mass customized, high value, life cycle products, majority of research and development was focused on advanced development of existing technologies by improving processing performance, materials, modelling and simulation tools, and design tools to enable the transition from prototyping to manufacturing of end use parts.

Studying Recommender Systems to Enhance Distributed Computing Schedulers

<p>Distributed Computing frameworks belong to a class of programming models that allow developers to</p><p> launch workloads on large clusters of machines. Due to the dramatic increase in the volume of</p><p> data gathered by ubiquitous computing devices, data analytic workloads have become a common</p><p> case among distributed computing applications, making Data Science an entire field of</p><p> Computer Science. We argue that Data Scientist's concern lays in three main components: a dataset,</p><p> a sequence of operations they wish to apply on this dataset, and some constraint they may have</p><p> related to their work (performances, QoS, budget, etc). However, it is actually extremely</p><p> difficult, without domain expertise, to perform data science. One need to select the right amount</p><p> and type of resources, pick up a framework, and configure it. Also, users are often running their</p><p> application in shared environments, ruled by schedulers expecting them to specify precisely their resource</p><p> needs. Inherent to the distributed and concurrent nature of the cited frameworks, monitoring and </p><p> profiling are hard, high dimensional problems that block users from making the right</p><p> configuration choices and determining the right amount of resources they need. Paradoxically, the </p><p> system is gathering a large amount of monitoring data at runtime, which remains unused.</p><p> In the ideal abstraction we envision for data scientists, the system is adaptive, able to exploit</p><p> monitoring data to learn about workloads, and process user requests into a tailored execution</p><p> context. In this work, we study different techniques that have been used to make steps toward</p><p> such system awareness, and explore a new way to do so by implementing machine learning</p><p> techniques to recommend a specific subset of system configurations for Apache Spark applications.</p><p> Furthermore, we present an in depth study of Apache Spark executors configuration, which highlight</p><p> the complexity in choosing the best one for a given workload.</p>