Improving manufacturing performance by standardization of interprocess communication

A number of environmental forces such as increasing value chain network complexity, decreasing product life-cycle cost, and time-to-market requirements or increasing product complexity act upon manufacturing organizations, enhancing the acute need for organizational routines that foster efficient and effective communication between processes. Such organizational routines erode quickly in the absence of common standards for knowledge sharing, that is why successful manufacturing systems benefit from interprocess standardization. The purpose of this paper is to offer a standardization model of interprocess communication that increases manufacturing operational performance (MOP). First, we propose a novel holistic model that makes standardized interprocess communication possible in manufacturing organizations. Second, we propose a model for quantifying the implications of standardizing interprocess communication upon MOP. Finally, as a matter of application, we show the results of its successful implementation in one Japanese manufacturing organization.

Construcción modular ligera energéticamente eficiente

Esta tesis trata sobre la construcción modular ligera, dentro del contexto de la eficiencia energética y de cara a los conceptos de nZEB (near Zero Energy Building) y NZEB (Net Zero Energy Building) que se manejan en el ámbito europeo y específicamente dentro del marco regulador de la Directiva 2010/31 UE. En el contexto de la Unión Europea, el sector de la edificación representa el 40% del total del consumo energético del continente. Asumiendo la necesidad de reducir este consumo se han planteado, desde los organismos de dirección europeos, unos objetivos (objetivos 20-20-20) para hacer más eficiente el parque edificatorio. Estos objetivos, que son vinculantes en términos de legislación, comprometen a todos los estados miembros a conseguir la meta de reducción de consumo y emisiones de GEI (Gases de Efecto Invernadero) antes del año 2020. Estos conceptos de construcción modular ligera (CML) y eficiencia energética no suelen estar asociados por el hecho de que este tipo de construcción no suele estar destinada a un uso intensivo y no cuenta con unos cerramientos con niveles de aislamiento de acuerdo a las normativas locales o códigos de edificación de cada país. El objetivo de nZEB o NZEB, e incluso Energy Plus, según sea el caso, necesariamente (y así queda establecido en las normativas), dependerá no sólo de la mejora de los niveles de aislamiento de los edificios, sino también de la implementación de sistemas de generación renovables, independientemente del tipo de sistema constructivo con el que se trabaje e incluso de la tipología edificatoria. Si bien es cierto que los niveles de industrialización de la sociedad tecnológica actual han alcanzado varias de las fases del proceso constructivo - sobre todo en cuanto a elementos compositivos de los edificios- también lo es el hecho de que las cotas de desarrollo conseguidas en el ámbito de la construcción no llegan al nivel de evolución que se puede apreciar en otros campos de las ingenierías como la aeronáutica o la industria del automóvil. Aunque desde finales del siglo pasado existen modelos y proyectos testimoniales de construcción industrializada ligera (CIL) e incluso ya a principios del siglo XX, ejemplos de construcción modular ligera (CML), como la Casa Voisin, la industrialización de la construcción de edificios no ha sido una constante progresiva con un nivel de comercialización equiparable al de la construcción masiva y pesada. Los términos construcción industrializada, construcción prefabricada, construcción modular y construcción ligera, no siempre hacen referencia a lo mismo y no siempre son sinónimos entre sí. Un edificio puede ser prefabricado y no ser modular ni ligero y tal es el caso, por poner un ejemplo, de la construcción con paneles de hormigón prefabricado. Lo que sí es una constante es que en el caso de la construcción modular ligera, la prefabricación y la industrialización, casi siempre vienen implícitas en muchos ejemplos históricos y actuales. Con relación al concepto de eficiencia energética (nZEB o incluso NZEB), el mismo no suele estar ligado a la construcción modular ligera y/o ligera industrializada; más bien se le ve unido a la idea de cerramientos masivos con gran inercia térmica propios de estándares de diseño como el Passivhaus; y aunque comúnmente a la construcción ligera se le asocian otros conceptos que le restan valor (corta vida útil; función y formas limitadas, fuera de todo orden estético; limitación en los niveles de confort, etc.), los avances que se van alcanzando en materia de tecnologías para el aprovechamiento de la energía y sistemas de generación renovables, pueden conseguir revertir estas ideas y unificar el criterio de eficiencia + construcción modular ligera. Prototipos y proyectos académicos– como el concurso Solar Decathlon que se celebra desde el año 2002 promovido por el DOE (Departamento de Energía de los Estados Unidos), y que cuenta con ediciones europeas como las de los años 2010 y 2012, replantean la idea de la construcción industrializada, modular y ligera dentro del contexto de la eficiencia energética, con prototipos de viviendas de ± 60m2, propuestos por las universidades concursantes, y cuyo objetivo es alcanzar y/o desarrollar el concepto de NZEB (Net Zero Energy Building) o edificio de energía cero. Esta opción constructiva no sólo representa durabilidad, seguridad y estética, sino también, rapidez en la fabricación y montaje, además de altas prestaciones energéticas como se ha podido demostrar en las sucesivas ediciones del Solar Decathlon. Este tipo de iniciativas de desarrollo de tecnologías constructivas, no sólo apuntan a la eficiencia energética sino al concepto global de energía neta, Energía plus o cero emisiones de CO2. El nivel de emisiones por la fabricación y puesta en obra de los materiales de construcción depende, en muchos casos, no solo de la propia naturaleza del material, sino también de la cantidad de recursos utilizados para producir una unidad de medida determinada (kg, m3, m2, ml, etc). En este sentido podría utilizarse, en muchos casos, el argumento válido de que a menos peso, y a menos tamaño, menos emisiones globales de gases de efecto invernadero y menos contaminación. Para el trabajo de investigación de esta tesis se han tomado como referencias válidas para estudio, prototipos tanto de CML (Modular 3D) como de CIL (panelizado y elementos 2D), dado que para los fines de análisis de las prestaciones energéticas de los materiales de cerramiento, ambos sistemas son equiparables. Para poder llegar a la conclusión fundamental de este trabajo de tesis doctoral - que consiste en demostrar la viabilidad tecnológica/ industrial que supone la combinación de la eficiencia energética y la construcción modular ligera - se parte del estudio del estado de la técnica ( desde la selección de los materiales y los posibles procesos de industrialización en fábrica, hasta su puesta en obra, funcionamiento y uso, bajo los conceptos de consumo cero, cero emisiones de carbono y plus energético). Además -y con un estado de la técnica que identifica la situación actual- se llevan a cabo pruebas y ensayos con un prototipo a escala natural y células de ensayo, para comprobar el comportamiento de los elementos compositivos de los mismos, frente a unas condicionantes climáticas determinadas. Este tipo de resultados se contrastan con los obtenidos mediante simulaciones informáticas basadas en los mismos parámetros y realizadas en su mayoría mediante métodos simplificados de cálculos, validados por los organismos competentes en materia de eficiencia energética en la edificación en España y de acuerdo a la normativa vigente. ABSTRACT This thesis discusses lightweight modular construction within the context of energy efficiency in nZEB (near Zero Energy Building) and NZEB (Net Zero Energy Building) both used in Europe and, specifically, within the limits of the regulatory framework of the EU Directive 2010/31. In the European Union the building sector represents 40% of the total energy consumption of the continent. Due to the need to reduce this consumption, European decision-making institutions have proposed aims (20-20-20 aims) to render building equipment more efficient. These aims are bound by law and oblige all member States to endeavour to reduce consumption and GEI emissions before the year 2020. Lightweight modular construction concepts and energy efficiency are not generally associated because this type of building is not normally meant for intensive use and does not have closures with insulation levels which fit the local regulations or building codes of each country. The objective of nZEB or NZEB and even Energy Plus, depending on each case, will necessarily be associated (as established in the guidelines) not only with the improvement of insulation levels in buildings, but also with the implementation of renewable systems of generation, independent of the type of building system used and of the building typology. Although it is true that the levels of industrialisation in the technological society today have reached several of the building process phases - particularly in the composite elements of buildings - it is also true that the quotas of development achieved in the area of construction have not reached the evolutionary levelfound in other fields of engineering, such as aeronautics or the automobile industry. Although there have been models and testimonial projects of lightweight industrialised building since the end of last century, even going back as far as the beginning of the XX century with examples of lightweight modular construction such as the Voisin House, industrialisation in the building industry has not been constant nor is its comercialisation comparable to massive and heavy construction. The terms industrialised building, prefabricated building, modular building and lightweight building, do not always refer to the same thing and they are not always synonymous. A building can be prefabricated yet not be modular or lightweight. To give an example, this is the case of building with prefabricated concrete panels. What is constant is that, in the case of lightweight modular construction, prefabrication and industrialisation are almost always implicit in many historical and contemporary examples. Energy efficiency (nZEB or even NZEB) is not normally linked to lightweight modular construction and/or industrialised lightweight; rather, it is united to the idea of massive closureswith high thermal inertia typical of design standards such as the Passive House; and although other concepts that subtract value from it are generally associated with lightweight building (short useful life, limited forms and function, inappropriate toany aesthetic pattern; limitation in comfort levels, etc.), the advances being achieved in technology for benefitting from energy and renewable systems of generation may well reverse these ideas and unify the criteria of efficiency + lightweight modular construction. Academic prototypes and projects - such as the Solar Decathlon competition organised by the US Department of Energy and celebrated since 2002, with its corresponding European events such as those held in 2010 and 2012, place a different slant on the idea of industrialised, modular and lightweight building within the context of energy efficiency, with prototypes of homes measuring approximately 60m2, proposed by university competitors, whose aim is to reach and/or develop the NZEB concept, or the zero energy building. This building option does not only signify durability, security and aesthetics, but also fast manufacture and assembly. It also has high energy benefits, as has been demonstrated in successive events of the Solar Decathlon. This type of initiative for the development of building technologies, does not only aim at energy efficiency, but also at the global concept of net energy, Energy Plus and zero CO2 emissions. The level of emissions in the manufacture and introduction of building materials in many cases depends not only on the inherent nature of the material, but also on the quantity of resources used to produce a specific unit of measurement (kg, m3, m2, ml, etc.). Thus in many cases itcould be validly arguedthat with less weight and smaller size, there will be fewer global emissions of greenhouse effect gases and less contamination. For the research carried out in this thesis prototypes such as the CML (3D Module) and CIL (panelled and elements) have been used as valid study references, becauseboth systems are comparablefor the purpose of analysing the energy benefits of closure materials. So as to reach a basic conclusion in this doctoral thesis - that sets out to demonstrate the technological/industrial viability of the combination of energy efficiency and lightweight modular construction - the departure point is the study of the state of the technique (from the selection of materials and the possible processes of industrialisation in manufacture, to their use on site, functioning and use, respecting the concepts of zero consumption, zero emissions of carbon and Energy Plus). Moreover, with the state of the technique identifying the current situation, tests and practices have been carried out with a natural scale prototype and test cells so as to verify the behaviour of the composite elements of these in certain climatic conditions. These types of result are contrasted with those obtained through computer simulation based on the same parameters and done, principally, using simplified methods of calculation, validated by institutions competent in energy efficiency in Spanish building and in line with the rules in force.

Manufacturing DNA microarrays of high spot homogeneity and reduced background signal

Analyses on DNA microarrays depend considerably on spot quality and a low background signal of the glass support. By using betaine as an additive to a spotting solution made of saline sodium citrate, both the binding efficiency of spotted PCR products and the homogeneity of the DNA spots is improved significantly on aminated surfaces such as glass slides coated with the widely used poly-l-lysine or aminosilane. In addition, non-specific background signal is markedly diminished. Concomitantly, during the arraying procedure, the betaine reduces evaporation from the microtitre dish wells, which hold the PCR products. Subsequent blocking of the chip surface with succinic anhydride was improved considerably in the presence of the non-polar, non-aqueous solvent 1,2-dichloroethane and the acylating catalyst N-methylimidazole. This procedure prevents the overall background signal that occurs with the frequently applied aqueous solvent 1-methyl-2-pyrrolidone in borate buffer because of DNA that re-dissolves from spots during the blocking process, only to bind again across the entire glass surface.

Potential use of additivity of mutational effects in simplifying protein engineering.

The problem of rationally engineering protein molecules can be simplified where effects of mutations on protein function are additive. Crystal structures of single and double mutants in the hydrophobic core of gene V protein indicate that structural and functional effects of core mutations are additive when the regions structurally influenced by the mutations do not substantially overlap. These regions of influence can provide a simple basis for identifying sets of mutations that will show additive effects.

A Regulatory Compliance Plan for Decommissioning a Sodium Phosphate Manufacturing Plant

Sodium phosphates are a class of chemicals that have been widely employed in commercial and consumer applications. However, declining use of these chemicals due to environmental concerns has lead to restructuring within the industry that has caused, and is likely to continue to cause, reduction of sodium phosphate production capacity. Closure of a sodium phosphate manufacturing plant necessitates decommissioning and decontamination activities that are subject to a variety of federal, state, and local regulations. A compliance plan was developed to provide a blueprint for ensuring that all federal regulatory requirements are met, however, site dependent state and local requirements were excluded. The compliance plan provides a framework that addresses project team formation and project planning, regulatory requirements, identification of affected processing equipment, plant pre-shutdown activities, waste stream identification and waste management facilities, safety, training, and emergency preparedness planning, and project decommissioning remedial actions. This regulatory compliance plan will enable sodium phosphate plant operators to complete decontamination and decommissioning work in a timely, efficient, compliant, and cost effective manner.

A new paradigm: cloud agile manufacturing

Cloud Agile Manufacturing is a new paradigm proposed in this article. The main objective of Cloud Agile Manufacturing is to offer industrial production systems as a service. Thus users can access any functionality available in the cloud of manufacturing (process design, production, management, business integration, factories virtualization, etc.) without knowledge — or at least without having to be experts — in managing the required resources. The proposal takes advantage of many of the benefits that can offer technologies and models like: Business Process Management (BPM), Cloud Computing, Service Oriented Architectures (SOA) and Ontologies. To develop the proposal has been taken as a starting point the Semantic Industrial Machinery as a Service (SIMaaS) proposed in previous work. This proposal facilitates the effective integration of industrial machinery in a computing environment, offering it as a network service. The work also includes an analysis of the benefits and disadvantages of the proposal.

Cloud agile manufacturing

This paper proposes a new manufacturing paradigm, we call Cloud Agile Manufacturing, and whose principal objective is to offer industrial production systems as a service. Thus users can access any functionality available in the cloud of manufacturing (process design, production, management, business integration, factories virtualization, etc.) without knowledge — or at least without having to be experts — in managing the required resources. The proposal takes advantage of many of the benefits that can offer technologies and models like: Business Process Management (BPM), Cloud Computing, Service Oriented Architectures (SOA) and Ontologies. To develop the proposal has been taken as a starting point the Semantic Industrial Machinery as a Service (SIMaaS) proposed in previous work. This proposal facilitates the effective integration of industrial machinery in a computing environment, offering it as a network service. The work also includes an analysis of the benefits and disadvantages of the proposal.

3D Maps Representation Using GNG

Current RGB-D sensors provide a big amount of valuable information for mobile robotics tasks like 3D map reconstruction, but the storage and processing of the incremental data provided by the different sensors through time quickly become unmanageable. In this work, we focus on 3D maps representation and propose the use of the Growing Neural Gas (GNG) network as a model to represent 3D input data. GNG method is able to represent the input data with a desired amount of neurons or resolution while preserving the topology of the input space. Experiments show how GNG method yields a better input space adaptation than other state-of-the-art 3D map representation methods.

Optimal Design of a Hybrid Membrane System Combining Reverse and Forward Osmosis for Seawater Desalination

In this work we study Forward Osmosis (FO) as an emerging desalination technology, and its capability to replace totally or partially Reverse Osmosis (RO) in order to reduce the great amount of energy required in the current desalination plants. For this purpose, we propose a superstructure that includes both membrane based desalination technologies, allowing the selection of only one of the technologies or a combination of both of them seeking for the optimal configuration of the network. The optimization problem is solved for a seawater desalination plant with a given fresh water production. The results obtained show that the optimal solution combines both desalination technologies to reduce not only the energy consumption but also the total cost of the desalination process in comparison with the same plant but operating only with RO.

Discontinuity spacing analysis in rock masses using 3D point clouds

The complete characterization of rock masses implies the acquisition of information of both, the materials which compose the rock mass and the discontinuities which divide the outcrop. Recent advances in the use of remote sensing techniques – such as Light Detection and Ranging (LiDAR) – allow the accurate and dense acquisition of 3D information that can be used for the characterization of discontinuities. This work presents a novel methodology which allows the calculation of the normal spacing of persistent and non-persistent discontinuity sets using 3D point cloud datasets considering the three dimensional relationships between clusters. This approach requires that the 3D dataset has been previously classified. This implies that discontinuity sets are previously extracted, every single point is labeled with its corresponding discontinuity set and every exposed planar surface is analytically calculated. Then, for each discontinuity set the method calculates the normal spacing between an exposed plane and its nearest one considering 3D space relationship. This link between planes is obtained calculating for every point its nearest point member of the same discontinuity set, which provides its nearest plane. This allows calculating the normal spacing for every plane. Finally, the normal spacing is calculated as the mean value of all the normal spacings for each discontinuity set. The methodology is validated through three cases of study using synthetic data and 3D laser scanning datasets. The first case illustrates the fundamentals and the performance of the proposed methodology. The second and the third cases of study correspond to two rock slopes for which datasets were acquired using a 3D laser scanner. The second case study has shown that results obtained from the traditional and the proposed approaches are reasonably similar. Nevertheless, a discrepancy between both approaches has been found when the exposed planes members of a discontinuity set were hard to identify and when the planes pairing was difficult to establish during the fieldwork campaign. The third case study also has evidenced that when the number of identified exposed planes is high, the calculated normal spacing using the proposed approach is minor than those using the traditional approach.

3D numerical modelling of acoustic horns using the method of fundamental solutions

In the present work, a three-dimensional (3D) formulation based on the method of fundamental solutions (MFS) is applied to the study of acoustic horns. The implemented model follows and extends previous works that only considered two-dimensional and axisymmetric horn configurations. The more realistic case of 3D acoustic horns with symmetry regarding two orthogonal planes is addressed. The use of the domain decomposition technique with two interconnected sub-regions along a continuity boundary is proposed, allowing for the computation of the sound pressure generated by an acoustic horn installed on a rigid screen. In order to reduce the model discretization requirements for these cases, Green’s functions derived with the image source methodology are adopted, automatically accounting for the presence of symmetry conditions. A strategy for the calculation of an optimal position of the virtual sources used by the MFS to define the solution is also used, leading to improved reliability and flexibility of the proposed method. The responses obtained by the developed model are compared to reference solutions, computed by well-established models based on the boundary element method. Additionally, numerically calculated acoustic parameters, such as directivity and beamwidth, are compared with those evaluated experimentally.

3D teaching: the ideal complement for professionals in design and construction

Today, the requirement of professional skills to university students is constantly increasing in our society. In our opinion, the content offered in official degrees need to be nourished with different variables, enriching their global professional knowledge in a parallel way; that is why, in recent years, there is a great multiplicity of complementary courses at university. One of the most socially demanded technical requirements within the architectural, design or engineering field is the management of 3D drawing software, becoming an indispensable reality in these sectors. Thus, this specific training becomes essential over two-dimension traditional design, because the inclusion of great possibilities of spatial development that go beyond conventional orthographic projections (plans, sections or elevations), allowing modelling and rotation of the selected items from multiple angles and perspectives. Therefore, this paper analyzes the teaching methodology of a complementary course for those technicians in the construction industry interested in computer-aided design, using modelling (SketchupMake) and rendering programs (Kerkythea). The course is developed from the technician point of view, by learning computer management and its application to professional development from a more general to a more specific view through practical examples. The proposed methodology is based on the development of real examples in different professional environments such as rehabilitation, new constructions, opening projects or architectural design. This multidisciplinary contribution improves criticism of students in different areas, encouraging new learning strategies and the independent development of three-dimensional solutions. Thus, the practical implementation of new situations, even suggested by the students themselves, ensures active participation, saving time during the design process and the increase of effectiveness when generating elements which may be represented, moved or virtually tested. In conclusion, this teaching-learning methodology improves the skills and competencies of students to face the growing professional demands of society. After finishing the course, technicians not only improved their expertise in the field of drawing but they also enhanced their capacity for spatial vision; both essential qualities in these sectors that can be applied to their professional development with great success.

Datasets and results of the research [Discontinuity spacing analysis in rock masses using 3D point clouds]

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Characterization of rock slopes through slope mass rating using 3D point clouds

Rock mass classification systems are widely used tools for assessing the stability of rock slopes. Their calculation requires the prior quantification of several parameters during conventional fieldwork campaigns, such as the orientation of the discontinuity sets, the main properties of the existing discontinuities and the geo-mechanical characterization of the intact rock mass, which can be time-consuming and an often risky task. Conversely, the use of relatively new remote sensing data for modelling the rock mass surface by means of 3D point clouds is changing the current investigation strategies in different rock slope engineering applications. In this paper, the main practical issues affecting the application of Slope Mass Rating (SMR) for the characterization of rock slopes from 3D point clouds are reviewed, using three case studies from an end-user point of view. To this end, the SMR adjustment factors, which were calculated from different sources of information and processes, using the different softwares, are compared with those calculated using conventional fieldwork data. In the presented analysis, special attention is paid to the differences between the SMR indexes derived from the 3D point cloud and conventional field work approaches, the main factors that determine the quality of the data and some recognized practical issues. Finally, the reliability of Slope Mass Rating for the characterization of rocky slopes is highlighted.

Visual perception for the 3D recognition of geometric pieces in robotic manipulation

During grasping and intelligent robotic manipulation tasks, the camera position relative to the scene changes dramatically because the robot is moving to adapt its path and correctly grasp objects. This is because the camera is mounted at the robot effector. For this reason, in this type of environment, a visual recognition system must be implemented to recognize and “automatically and autonomously” obtain the positions of objects in the scene. Furthermore, in industrial environments, all objects that are manipulated by robots are made of the same material and cannot be differentiated by features such as texture or color. In this work, first, a study and analysis of 3D recognition descriptors has been completed for application in these environments. Second, a visual recognition system designed from specific distributed client-server architecture has been proposed to be applied in the recognition process of industrial objects without these appearance features. Our system has been implemented to overcome problems of recognition when the objects can only be recognized by geometric shape and the simplicity of shapes could create ambiguity. Finally, some real tests are performed and illustrated to verify the satisfactory performance of the proposed system.