Distributed process execution in collaborative networks

Processes are a central entity in enterprise collaboration. Collaborative processes need to be executed and coordinated in a distributed Computational platform where computers are connected through heterogeneous networks and systems. Life cycle management of such collaborative processes requires a framework able to handle their diversity based on different computational and communication requirements. This paper proposes a rational for such framework, points out key requirements and proposes it strategy for a supporting technological infrastructure. Beyond the portability of collaborative process definitions among different technological bindings, a framework to handle different life cycle phases of those definitions is presented and discussed. (c) 2007 Elsevier Ltd. All rights reserved.

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.

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.

Is it possible to remove polymeric nanoparticles from aqueous paints during the activated sludge treatment?

The market for emulsion polymers (latexes) is large and growing at the expense of other manufacturing processes that emit higher amounts of volatile organic solvents. The paint industry is not an exception and solvent-borne paints have been gradually substituted by aqueous paints. In their life-cycle, much of the aqueous paint used for architectural or decorative purposes will eventually be discharged into wastewater treatment facilities, where its polymeric nanoparticles (mainly acrylic and styrene-acrylic) can work as xenobiotics to the microbial communities present in activated sludge. It is well established that these materials are biocompatible at macroscopic scale. But is their behaviour the same at nanoscale? What happens to the polymeric nanoparticles during the activated sludge process? Do nanoparticles agregate and are discharged together with the sludge or remain in emulsion? How do microorganisms interact with these nanoparticles? Are nanoparticles degradated by them? Are they adsorbed? Are these nanoparticles toxic to the microbial community? To study the influence of these xenobiotics in the activated sludge process, an emulsion of cross-linked poly(butyl methacrylate) nanoparticles of ca. 50 nm diameter was produced and used as model compound. Activated sludge from a wastewater treatment plant was tested by the OCDE’s respiration inhibition test using several concentrations of PBMA nanoparticles. Particle aggregation was followed by Dynamic Light Scattering and microorganism surfaces were observed by Atomic Force Microscopy. Using sequential batch reactors (SBRs) and continuous reactors, both inoculated with activated sludge, the consumption of carbon, ammonia, nitrite and nitrate was monitored and compared, in the presence and absence of nanoparticles. No particles were detected in all treated waters by Dynamic Light Scattering. This can either mean that microorganisms can efficiently remove all polymer nanoparticles or that nanoparticles tend to aggregate and be naturally removed by precipitation. Nevertheless respiration inhibition tests demonstrated that microorganisms consume more oxygen in the presence of nanoparticles, which suggests a stress situation. It was also observed a slight decrease in the efficiency of nitrification in the presence of nanoparticles. AFM images showed that while the morphology of some organisms remained the same both in the presence and absence of nanoparticles, others assumed a rough surface with hilly like shapes of ca. 50 nm when exposed to nanoparticles. Nanoparticles are thus likely to be either incorporated or adsorbed at the surface of some organisms, increasing the overall respiration rate and decreasing nitrification efficiency. Thus, despite its biocompatibility at macroscopic scale, PBMA is likely to be no longer innocuous at nanoscale.

Optimization of the Pultrusion process

Manufacturing processes need permanently to innovate and optimize because any can be susceptible to continuous improvement. Innovation and commitment to the development of these new solutions resulting from existing expertise and the continuing need to increase productivity, flexibility and ensuring the necessary quality of the manufactured products. To increase flexibility, it is necessary to significantly reduce set-up times and lead time in order to ensure the delivery of products ever faster. This objective can be achieved through a normalization of the pultrusion line elements. Implicitly, there is an increase of productivity by this way. This work is intended to optimize the pultrusion process of structural profiles. We consider all elements of the system from the storehouse of the fibers (rack) to the pultrusion die. Particular attention was devoted to (a) the guidance system of the fibers and webs, (b) the resin container where the fibers are impregnated, (c) standard plates positioning of the fibers towards the entrance to the spinneret and also (d) reviewed the whole process of assembling and fixing the die as well as its the heating system. With the implementation of these new systems was achieved a significant saving of time set-up and were clearly reduced the unit costs of production. Quality assurance was also increased.

MASS CONSERVATION ENHANCEMENT OF FREE BOUNDARY FLOWS IN COMPOSITES MANUFACTURING

Undesirable void formation during the injection phase of the liquid composite molding process can be understood as a consequence of the non-uniformity of the flow front progression, caused by the dual porosity of the fiber perform. Therefore the best examination of the void formation physics can be provided by a mesolevel analysis, where the characteristic dimension is given by the fiber tow diameter. In mesolevel analysis, liquid impregnation along two different scales; inside fiber tows and within the spaces between them; must be considered and the coupling between these flow regimes must be addressed. In such case, it is extremely important to account correctly for the surface tension effects, which can be modeled as capillary pressure applied at the flow front. When continues Galerkin method is used, exploiting elements with velocity components and pressure as nodal variables, strong numerical implementation of such boundary conditions leads to ill-posing of the problem, in terms of the weak classical as well as stabilized formulation. As a consequence, there is an error in mass conservation accumulated especially along the free flow front. This article presents a numerical procedure, which was formulated and implemented in the existing Free Boundary Program in order to significantly reduce this error.

Mass Conservation Enhancement of Free Boundary Mesolevel Flows during LCM Processes of Composites Manufacturing

Undesirable void formation during the injection phase of the liquid composite moulding process can be understood as a consequence of the non-uniformity of the flow front progression, caused by the dual porosity of the fibre perform. Therefore the best examination of the void formation physics can be provided by a mesolevel analysis, where the characteristic dimension is given by the fibre tow diameter. In mesolevel analysis, liquid impregnation along two different scales; inside fibre tows and within the open spaces between them; must be considered and the coupling between these flow regimes must be addressed. In such case, it is extremely important to account correctly for the surface tension effects, which can be modelled as capillary pressure applied at the flow front. Numerical implementation of such boundary conditions leads to ill-posing of the problem, in terms of the weak classical as well as stabilized formulation. As a consequence, there is an error in mass conservation accumulated especially along the free flow front. This contribution presents a numerical procedure, which was formulated and implemented in the existing Free Boundary Program in order to significantly reduce this error.

Aplicação da metodologia SMED numa linha de envernizamento/pintura de revestimentos de cortiça

O presente trabalho visa a redução do tempo de mudança de produção e consequente aumento de produtividade de uma linha de envernizamento/pintura integrada na empresa Amorim Revestimentos SA, unidade S. Paio de Oleiros, que se dedica à produção de pisos flutuantes. Esta necessidade surgiu pelo facto desta linha de produção ser um ponto de estrangulamento do processo produtivo no departamento em que está inserida, devido principalmente à diminuição do tamanho de lotes e aumento da variedade de artigos a produzir. O trabalho envolveu as várias etapas da ferramenta SMED às quais está inerente a aplicação da técnica 5S às máquinas e ferramentas garantindo, assim, o posto de trabalho arrumado, limpo, seguro e com tudo pronto a ser utilizado. Aplicou-se a ferramenta SMED a dois tipos de mudança de acabamento e à mudança de rolo de pintura. Após a implementação desta ferramenta verificou-se uma redução de tempos de 37% (48 para 30 minutos) na mudança de pintura e acabamento de verniz, reduziu-se 25% (32 para 24 minutos) na mudança só de pintura e 13% (46 para 40 minutos) na mudança de rolo de pintura. Estes resultados foram alcançados através da redução do tempo das tarefas externas e internas e transformação das tarefas internas em externas consequentes da aplicação de um conjunto de ações de melhorias. Também foi fundamental a alteração do método de trabalho e a organização geral do posto de trabalho, no que diz respeito à repartição equilibrada das tarefas pelos dois operadores, alteração do sequenciamento das tarefas e aplicação da técnica 5S. As soluções encontradas estão sendo monitorizadas através do registo efectuado pelos operadores e realização de auditorias internas para garantir a perpetuação dos resultados.

A process-based control for evolvable production systems

Dissertação apresentada na Faculdade de Ciências e Tecnologia da Universidade Nova de Lisboa para a obtenção do grau de Mestre em Engenharia Electrotécnica e de Computadores

Evaluating vehicle painting plans in an automobile assembly plant using an integrated AHP-PROMETHEE approach

The painting activity is one of the most complex and important activities in automobile manufacturing. The inherent complexity of the painting activity and the frequent need for repainting usually turn the painting process into a bottleneck in automobile assembly plants, which is reflected in higher operating costs and longer overall cycle times. One possible approach for optimizing the performance of the paint shop is to improve the efficiency of the color planning. This can be accomplished by evaluating the relative merits of a set of vehicle painting plans. Since this problem has a multicriteria nature, we resort to the multicriteria decision analysis (MCDA) methodology to tackle it. A recent trend in the MCDA field is the development of hybrid approaches that are used to achieve operational synergies between different methods. Here we apply, for the first time, an integrated approach that combines the strengths of the analytic hierarchy process (AHP) and the Preference Ranking Organization METHod for Enrichment Evaluations (PROMETHEE), aided by Geometrical Analysis for Interactive Aid (GAIA), to the problem of assessing alternative vehicle painting plans. The management of the assembly plant found the results of value and is currently using them in order to schedule the painting activities such that an enhancement of the operational efficiency of the paint shop is obtained. This efficiency gain has allowed the management to bid for a new automobile model to be assembled at this specific plant.

Safety function analysis in an industrial production process

Dissertação para obtenção do Grau de Mestre em Engenharia e Gestão Industrial

Thermal conditions affecting heat transfer in FDM/FFE: a contribution towards the numerical modelling of the process

The performance of parts produced by Free Form Extrusion (FFE), an increasingly popular additive manufacturing technique, depends mainly on their dimensional accuracy, surface quality and mechanical performance. These attributes are strongly influenced by the evolution of the filament temperature and deformation during deposition and solidification. Consequently, the availability of adequate process modelling software would offer a powerful tool to support efficient process set-up and optimisation. This work examines the contribution to the overall heat transfer of various thermal phenomena developing during the manufacturing sequence, including convection and radiation with the environment, conduction with support and between adjacent filaments, radiation between adjacent filaments and convection with entrapped air. The magnitude of the mechanical deformation is also studied. Once this exercise is completed, it is possible to select the material properties, process variables and thermal phenomena that should be taken in for effective numerical modelling of FFE.

The role of automatic shape and position recognitionin streamlining manufacturing

The main features of most components consist of simple basic functional geometries: planes, cylinders, spheres and cones. Shape and position recognition of these geometries is essential for dimensional characterization of components, and represent an important contribution in the life cycle of the product, concerning in particular the manufacturing and inspection processes of the final product. This work aims to establish an algorithm to automatically recognize such geometries, without operator intervention. Using differential geometry large volumes of data can be treated and the basic functional geometries to be dealt recognized. The original data can be obtained by rapid acquisition methods, such as 3D survey or photography, and then converted into Cartesian coordinates. The satisfaction of intrinsic decision conditions allows different geometries to be fast identified, without operator intervention. Since inspection is generally a time consuming task, this method reduces operator intervention in the process. The algorithm was first tested using geometric data generated in MATLAB and then through a set of data points acquired by measuring with a coordinate measuring machine and a 3D scan on real physical surfaces. Comparison time spent in measuring is presented to show the advantage of the method. The results validated the suitability and potential of the algorithm hereby proposed

Aplicação de princípios e técnicas de Lean Manufacturing para melhoria do desempenho de linhas de montagem

Dissertação de mestrado integrado em Engenharia e Gestão Industrial

Development of procedures for the design, optimization and manufacturing of customized orthopaedic and trauma implants: Geometrical/anatomical modelling from 3D medical imaging

Tese de Doutoramento (Programa Doutoral em Engenharia Biomédica)