Editorial Preface

This special volume of Procedia Engineering contains papers presented at the 12th Global Congress on Manufacturing and Management (GCMM - 2014), held during 8-10 December 2014 at VIT University, Vellore, India. A total of 258 papers were presented during the conference, covering the entire spectrum of Materials Processing, Manufacturing Engineering, Industrial Engineering and Management. Materials and Manufacturing field is undergoing a rapid transformation due to unexpected challenges arising from the current approach to optimization and continuous performance improvement in manufacturing processes, production of large products and development of new materials. The 12th edition of the conference has earmarked the objective to offer a common platform for professionals, researchers and educators from industry, research centers and academia to present and discuss recent advances in the field of Manufacturing Engineering.

Development and characterisation of a new bioink for additive tissue manufacturing

Additive manufacturing forms a potential route towards economically viable production of cellular constructs for tissue engineering. Hydrogels are a suitable class of materials for cell delivery and 3D culture, but are generally unsuitable as construction materials. Gelatine-methacrylamide is an example of such a hydrogel system widely used in the field of tissue engineering, e.g. for cartilage and cardiovascular applications. Here we show that by the addition of gellan gum to gelatine-methacrylamide and tailoring salt concentrations, rheological properties such as pseudo-plasticity and yield stress can be optimised towards gel dispensing for additive manufacturing processes. In the hydrogel formulation, salt is partly substituted by mannose to obtain isotonicity and prevent a reduction in cell viability. With this, the potential of this new bioink for additive tissue manufacturing purposes is demonstrated.

From Polymorph Screening to Dissolution Testing - Solid Phase Analysis during Pharmaceutical Development and Manufacturing

Solid materials can exist in different physical structures without a change in chemical composition. This phenomenon, known as polymorphism, has several implications on pharmaceutical development and manufacturing. Various solid forms of a drug can possess different physical and chemical properties, which may affect processing characteristics and stability, as well as the performance of a drug in the human body. Therefore, knowledge and control of the solid forms is fundamental to maintain safety and high quality of pharmaceuticals. During manufacture, harsh conditions can give rise to unexpected solid phase transformations and therefore change the behavior of the drug. Traditionally, pharmaceutical production has relied on time-consuming off-line analysis of production batches and finished products. This has led to poor understanding of processes and drug products. Therefore, new powerful methods that enable real time monitoring of pharmaceuticals during manufacturing processes are greatly needed. The aim of this thesis was to apply spectroscopic techniques to solid phase analysis within different stages of drug development and manufacturing, and thus, provide a molecular level insight into the behavior of active pharmaceutical ingredients (APIs) during processing. Applications to polymorph screening and different unit operations were developed and studied. A new approach to dissolution testing, which involves simultaneous measurement of drug concentration in the dissolution medium and in-situ solid phase analysis of the dissolving sample, was introduced and studied. Solid phase analysis was successfully performed during different stages, enabling a molecular level insight into the occurring phenomena. Near-infrared (NIR) spectroscopy was utilized in screening of polymorphs and processing-induced transformations (PITs). Polymorph screening was also studied with NIR and Raman spectroscopy in tandem. Quantitative solid phase analysis during fluidized bed drying was performed with in-line NIR and Raman spectroscopy and partial least squares (PLS) regression, and different dehydration mechanisms were studied using in-situ spectroscopy and partial least squares discriminant analysis (PLS-DA). In-situ solid phase analysis with Raman spectroscopy during dissolution testing enabled analysis of dissolution as a whole, and provided a scientific explanation for changes in the dissolution rate. It was concluded that the methods applied and studied provide better process understanding and knowledge of the drug products, and therefore, a way to achieve better quality.

Modular distributed manufacturing systems and the implications for integrated control

Driven by the need for more responsive manufacturing processes and as a consequence of increasing complexity in products and production systems, this short paper introduces a number of developments in the area of modular, distributed manufacturing systems. Requirements for the development of such systems are addressed and, in particular, the relevance to current and future integrated control systems is examined. One of the key issues for integrated control systems in the future is the need to provide support for distributed decision-making in addition to existing distributed control capabilities.

Rationales of holonic manufacturing systems in leather industry

This paper presents an insight into leather manufacturing processes, depicting peculiarities and challenges faced by leather industry. An analysis of this industry reveals the need for a new approach to optimize the productivity of leather processing operations, ensure consistent quality of leather, mitigate the adverse health effects in tannery workers exposed to chemicals and comply with environmental regulation. Holonic manufacturing systems (HMS) paradigm represent a bottom-up distributed approach that provides stability, adaptability, efficient use of resources and a plug and operate functionality to the manufacturing system. A vision of how HMS might operate in a tannery is illustrated presenting the rationales behind its application in this industry. © 2013 Springer-Verlag.

Manufacturing dish shaped rings on radial-axial ring rolling mills

Ring rolling is an established method to produce seamless rings of different cross-sectional geometries. For dish shaped rings, there are applications in different areas such as offshore, aeronautics or the energy sector. At the moment, dish shaped rings are produced by machining of rings with rectangular shaped cross section, by (open die) hollow forging on a conical mandrel or by using shaped ring rolling tools. These ways of manufacturing have the disadvantage of high material waste, additional costs for special tools, long process time and limited or inflexible geometries. Therefore, the manufacturing of dish shaped rings on conventional radial-axial ring rolling mills would expand the range of products for ring producers. The aim of this study is to investigate the feasibility of an alternative to the current manufacturing processes, without requiring additional tooling and material costs. Therefore, the intended formation of dish shaped rings-previously regarded as a form error-is investigated. Based on an analysis of geometrical requirements and metal flow mechanisms, a rolling strategy is presented, causing dishing and ring climbing by a large height reduction of the ring. Using this rolling strategy dish shaped rings with dishing angles up to 18° were achieved. In addition to the experiments finite element method (FEM)-simulations of the process have been successfully conducted, in order to analyze the local strain evolution. However, when the contact between ring and main roll is lost in the process the ring starts to oscillate around the mandrel and neither dishing nor ring climbing is observed. © 2013 German Academic Society for Production Engineering (WGP).

Re-engineering Manufacturing for Sustainability

This edited volume presents the proceedings of the 20th CIRP LCE Conference, which cover various areas in life cycle engineering such as life cycle design, end-of-life management, manufacturing processes, manufacturing systems, methods and ...

基于多Agent制造过程的建模方法

分析了制造系统与制造过程之间的关系;论证了从过程的角度对制造进行建模更恰当;结合Agent和π演算的特点,给出Agent制造系统描述模型及基于π演算的单个Agent的BDI模型,并指出Agent和π演算结合的制造过程模型有利于进行优化目标在不同制造过程层次的分解,不论从方法的角度还是实现的角度,都适合复杂系统建模。Agent和π演算相结合可以有效分析并解决离散事件的建模与仿真中的问题。

Optimisation of granola breakfast cereal manufacturing process by wet granulation and pneumatic conveying

This study has considered the optimisation of granola breakfast cereal manufacturing processes by wet granulation and pneumatic conveying. Granola is an aggregated food product used as a breakfast cereal and in cereal bars. Processing of granola involves mixing the dry ingredients (typically oats, nuts, etc.) followed by the addition of a binder which can contain honey, water and/or oil. In this work, the design and operation of two parallel wet granulation processes to produce aggregate granola products were incorporated: a) a high shear mixing granulation process followed by drying/toasting in an oven. b) a continuous fluidised bed followed by drying/toasting in an oven. In high shear granulation the influence of process parameters on key granule aggregate quality attributes such as granule size distribution and textural properties of granola were investigated. The experimental results show that the impeller rotational speed is the single most important process parameter which influences granola physical and textural properties. After that binder addition rate and wet massing time also show significant impacts on granule properties. Increasing the impeller speed and wet massing time increases the median granule size while also presenting a positive correlation with density. The combination of high impeller speed and low binder addition rate resulted in granules with the highest levels of hardness and crispness. In the fluidised bed granulation process the effect of nozzle air pressure and binder spray rate on key aggregate quality attributes were studied. The experimental results show that a decrease in nozzle air pressure leads to larger in mean granule size. The combination of lowest nozzle air pressure and lowest binder spray rate results in granules with the highest levels of hardness and crispness. Overall, the high shear granulation process led to larger, denser, less porous and stronger (less likely to break) aggregates than the fluidised bed process. The study also examined the particle breakage of granola during pneumatic conveying produced by both the high shear granulation and the fluidised bed granulation process. Products were pneumatically conveyed in a purpose built conveying rig designed to mimic product conveying and packaging. Three different conveying rig configurations were employed; a straight pipe, a rig consisting two 45° bends and one with 90° bend. Particle breakage increases with applied pressure drop, and a 90° bend pipe results in more attrition for all conveying velocities relative to other pipe geometry. Additionally for the granules produced in the high shear granulator; those produced at the highest impeller speed, while being the largest also have the lowest levels of proportional breakage while smaller granules produced at the lowest impeller speed have the highest levels of breakage. This effect clearly shows the importance of shear history (during granule production) on breakage during subsequent processing. In terms of the fluidised bed granulation, there was no single operating parameter that was deemed to have a significant effect on breakage during subsequent conveying. Finally, a simple power law breakage model based on process input parameters was developed for both manufacturing processes. It was found suitable for predicting the breakage of granola breakfast cereal at various applied air velocities using a number of pipe configurations, taking into account shear histories.

Manufacturing knowledge verification in design support systems

This paper identifies the need for a verification methodology for manufacturing knowledge in design support systems; and proposes a suitable methodology based on the concept of ontological commitment and the PSL ontology (ISO/CD18629). The use of the verification procedures within an overall system development methodology is examined, and an understanding of how various categories of manufacturing knowledge (typical to design support systems) map onto the PSL ontology is developed. This work is also supported by case study material from industrial situations, including the casting and machining of metallic components. The PSL ontology was found to support the verification of most categories of manufacturing knowledge, and was shown to be particularly suited to process planning representations. Additional concepts and verification procedures were however needed to verify relationships between products and manufacturing processes. Suitable representational concepts and verification procedures were therefore developed, and integrated into the proposed knowledge verification methodology.

Manufacturing at double the speed

The speed of manufacturing processes today depends on a trade-off between the physical processes of production, the wider system that allows these processes to operate and the co-ordination of a supply chain in the pursuit of meeting customer needs. Could the speed of this activity be doubled? This paper explores this hypothetical question, starting with examination of a diverse set of case studies spanning the activities of manufacturing. This reveals that the constraints on increasing manufacturing speed have some common themes, and several of these are examined in more detail, to identify absolute limits to performance. The physical processes of production are constrained by factors such as machine stiffness, actuator acceleration, heat transfer and the delivery of fluids, and for each of these, a simplified model is used to analyse the gap between current and limiting performance. The wider systems of production require the co-ordination of resources and push at the limits of human biophysical and cognitive limits. Evidence about these is explored and related to current practice. Out of this discussion, five promising innovations are explored to show examples of how manufacturing speed is increasing—with line arrays of point actuators, parallel tools, tailored application of precision, hybridisation and task taxonomies. The paper addresses a broad question which could be pursued by a wider community and in greater depth, but even this first examination suggests the possibility of unanticipated innovations in current manufacturing practices.

A Structured Approach to Simulate Manufacturing System In Virtual Environment

Nowadays, the realization of the Virtual Factory (VF) is the strategic goal of many manufacturing enterprises for the coming years. The industrial scenario is characterized by the dynamics of innovations increment and the product life cycle became shorter. Furthermore products and the corresponding manufacturing processes get more and more complex. Therefore, companies need new methods for the planning of manufacturing systems.
To date, the efforts have focused on the creation of an integrated environment to design and manage the manufacturing process of a new product. The future goal is to integrate Virtual Reality (VR) tools into the Product Lifecycle Management of the manufacturing industries.
In order to realize this goal the authors have conducted a study to perform VF simulation steps for a supplier of Industrial Automation Systems and have provided a structured approach focusing on interaction between simulation software and VR hardware tools in order to simulate both robotic and
manual work cells.
The first results of the study in progress have been carried out in the VR Laboratory of the Competence Regional Centre for the qualification of the Transportation Systems that has been founded by Campania Region.

Innovative manufacturing process for hybrid pultruded products based on cork and polymeric pre-shapes

Pultruded products are being targeted by a growing demand due to its excellent mechanical properties and low chemical reactivity, ensuring a low level of maintenance operations and allowing an easier assembly operation process than equivalent steel bars. In order to improve the mechanical drawing process and solve some acoustic and thermal insulation problems, pultruded pipes of glass fibre reinforced plastics (GFRF) can be filled with special products that increase their performance regarding the issues previously referred. The great challenge of this work was drawing a new equipment able to produce pultruded pipes filled with cork or polymeric pre-shaped bars as a continuous process. The project was carried out successfully and the new equipment was built and integrated in the pultrusion equipment already existing, allowing to obtain news products with higher added-value in the market, covering some needs previously identified in the field of civil construction.

Towards intelligent manufacturing

This article describes the application of an Artificial Intelligence Planner in a robotized assembly cell that can be integrated to a Flexible Manufacturing System. The objective is to allow different products to be automatically assembled in a single production line with no pre-established assembly plans. The planner function is to generate action plans to the robot, in real time, from two input information: the initial state (disposition of parts of the product in line) and the final state (configuration of the assembled product). Copyright © 2007 IFAC.

Modelagem do resfriamento para a zona termicamente afetada pela soldagem de tubos de aço carbono

Because the high consumption of welded pipe for exploration and conduction oil and gas, optimization of manufacturing processes is necessary to obtain better productivity, efficiency and cost reduction. The objective of this study is to analyze the forms of heat transfer during the welding of pipes using longitudinal submerged arc process them to propose a model for the temperature distribution in the welded region. For this analysis are addressed as the heat transfer modes operate in the specified welding process and the necessary considerations for the mathematical model were obtained. The calculations were performed and the simulations needed to obtain the temperature distribution in the tube were carried out. Therefore, the practice was satisfactory and the results showed a range of temperatures along the pipe for a particular model and the future suggestions for improvement of this work