Simulation-based support tool for operator performance in batch manufacturing

In industry, the workload and utilization of shop floor operators is often misunderstood. In this paper, we will present several real case studies, using Discrete Event Simulation (DES) models, which allow us to better understand operators in a batch manufacturing environment. The first study investigates labour in a machining plant consisting of multiple identical CNC machines that batch produce parts. The second study investigates labour in an eight station, gravity die casting rotary table. The results from these studies have shown that there can be potential improvements made by the production planners in the current labour configuration. In the first case study, a matrix is produced that estimates what the operator's utilization levels will be for various configurations. From this, the preferred operator to machine ratio over a range of cycle times is presented. In the second study, the results have shown that by reducing the casting cycle time, the operator would be overloaded. A discrete event simulation of these two cases highlighted areas that were misunderstood by plant management, and provided them with a useful decision support tool for production planning.

Unifying manufacturing simulation models using HLA

The increasing use of simulation in manufacturing has seen an increase in simulation models created using many simulation package. This use of different simulators can create simulation islands in a manufacturing factory, making it difficult to get a true simulated overview of the factory. At present, there are only a few cases where manufacturing simulations have been linked to enable multiple simulation models to run as one. This research expands upon these cases. For this paper the topic of discussion is the research in connecting different 'Commercial Off The Shelf' simulators together to allow flow of all information through the connected models using high level architecture.

A decision support tool for resource allocation in batch manufacturing

A decision support tool for production planning is discussed in this paper to perform the job of machine grouping and labour allocation within a machining line. The production plans within the industrial partner have been historically inefficient because the relationship between the cycle times, the machine group size, and the operator's utilisation hasn't been properly understood. Starting with a simulation model, a rule-base has been generated to predict the operator's utilisation for a range of production settings. The resource allocation problem is then solved by breaking the problem into a series of smaller sized tasks. The objective is to minimise the number of operators and the difference between the maximum and minimum cycle times of machines within each group. The results from this decision support tool is presented for the particular case study.

Productivity growth and efficiency change in Malaysian manufacturing: recent evidence from disaggregated data

This paper estimates productivity growth in Malaysian manufacturing over the period 1983-1999. Malmquist productivity Indices (MPIs) have been computed using non parametric Data Envelopment Analysis (DEA) type linear programming, which show productivity growth sourced from efficiency change and growth in technology. Unlike previous studies, this study identifies the sources of productivity growth in Malaysian manufacturing industries at the five digit breakdown of Malaysian Standard Industrial Classification (MSIC) thereby revealing more industry specific efficiency and technical growth patterns. Results indicated that a high majority of the industries operated with low levels of technical efficiency with little or no improvement over time. Growth estimates revealed that two third of the industries (76 out of total 114 categories) experienced average annual productivity improvement ranging from 0.1% to 7.8%. Average annual technical progress was recorded by 95 industry categories while technical efficiency improvement was achieved by 53 industries. Overall yearly average indicated relatively low productivity growth from the mid 1990’s onwards caused by either efficiency decline or technical regress. Summary results for industries showed that some of the high rates of productivity growth have been recorded in glass and glass products (7.3%), Petroleum and coal (7.2%), industrial chemicals (4.9%) contributed from both efficiency improvement and technical progress ranging from 0.8% to 5.4% and from 1.7% to 4.1%, respectively. These results are expected to have some implications for ongoing and future strategic policy reform in Malaysian manufacturing generating a more sustainable growth for specific industry categories.

Input usage, output mix and industry deregulation: an analysis of the Australian dairy manufacturing industry

In this paper we estimate a Translog output distance function for a balanced panel of state level data for the Australian dairy processing sector. We estimate a fixed effects specification employing Bayesian methods, with and without the imposition of monotonicity and curvature restrictions. Our results indicate that Tasmania and Victoria are the most technically efficient states with New South Wales being the least efficient. The imposition of theoretical restrictions marginally affects the results especially with respect to estimates of technical change and industry deregulation. Importantly, our bias estimates show changes in both input use and output mix that result from deregulation. Specifically, we find that deregulation has positively biased the production of butter, cheese and powders.

Manufacturing influence on the delamination fracture behavior of the T800H/3900-2 carbon fiber reinforced polymer composites

'Torayca' T800H/3900-2 is the first material qualified on Boeing Material Specification (BMS 8-276) which utilizes the thermoplastic-particulate interlayer toughening technology. Two manufacturing processes, the autoclave process and the fast heating rated Quickstep™ process, were employed to cure this material. The Quickstep process is a unique composite production technology which utilizes the fast heat transfer rate of fluid to heat and cure polymer composite components. The manufacturing influence on the mode I delamination fracture toughness of laminates was investigated by performing double cantilever beam tests. The composite specimens fabricated by two processes exhibited dissimilar delamination resistance curves (R-curves) under mode I loading. The initial value of fracture toughness GIC-INIT was 564 J/m2 for the autoclave specimens and 527 J/m2 for the Quickstep specimens. However, the average propagation fracture toughness GIC-PROP was 783 J/m2 for the Quickstep specimens, which was 2.6 times of that for the autoclave specimens. The mechanism of fracture occurred during delamination was studied under scanning electron microscope (SEM). Three types of fracture were observed: the interlayer fracture, the interface fracture, and the intralaminar fracture. These three types of fracture played different roles in affecting the delamination resistance curves during the crack growth. More fiber bridging was found in the process of delamination for the Quickstep specimens. Better fiber/matrix adhesion was found in the Quickstep specimens by conducting indentation-debond tests.

Achieving greater feedback and flexibility using online pre-laboratory exercises with non-major chemistry students

Compulsory online pre-laboratory exercises were required of non-major, first-year university chemistry students in response to poor student preparation for laboratory sessions. The online pre-laboratory exercises were designed to be straightforward, endeavoring to help students maximize the benefits of the introductory laboratory class. Diagrams and pictures were included in the exercises to improve descriptions. Students were allowed multiple attempts with immediate feedback provided to help them learn from their mistakes. The study is a descriptive account of students' perceptions of the impact of online pre-laboratory exercises on their learning. Students recognized the value of the exercises in improving their organization, their preparedness for the laboratory class, and their understanding of the chemistry concepts of the weekly experiments. The increased flexibility of doing pre-laboratory exercises online and the increased feedback to students were two important aspects of this project that nearly all students recognized as being beneficial to their learning.

New models for learning flexibility: νegotiated choices for both academics and students

‘Flexible learning’ represents a need associated with ‘lifelong learning’ and the equipping of graduates to actively engage in a ‘knowledge society’. While the precise meaning of each of these terms is not easy to discern, notions of flexible learning have progressed an evolutionary path that concentrates on students as though they are the only stakeholder group in the higher education environment that would benefit from choice. Academic discourse also presumes that all cultural groups making up the increasingly diverse student population aspire to engage in student-centred learning as a precursor to involvement in a knowledge economy. In this environment academics have been encouraged to embrace online teaching and promote a more student-centred learning approach when the natural inclination and talent of many academics may make this style of pedagogy so challenging that learning outcomes are compromised. We question this ‘one size fits all’ mentality and suggest a model that empowers both the students and academics by allowing them the ability to choose the approach that suits their educational philosophy and preferred learning/teaching approach. The model represents an innovation in flexibility that recognises initial embedded learning foundation abilities and reaches both teachers and learners by utilising their own frames of reference.

The effect of cure cycle heating rate on the fibre/matrix interface

Development of civil aerospace composites is key to future “greener” aircraft. Aircraft manufacturers must improve efficiency of their product and manufacturing processes to remain viable. The aerospace industry is undergoing a materials revolution in the design and manufacture of composite airframes. The Airbus A350 and Boeing 787 (both due to enter service in the latter part of this decade) will push utilisation levels of  composite materials beyond 50% of the total airframe by weight. This  change requires massive investment in materials technology, manufacturing capability and skills development. The Quickstep process provides the ability to rapidly cure aerospace standard composite materials whilst providing enhanced mechanical properties. Utilising fluid to transfer heat to the   composite component during the curing process allows far higher heat rates than with conventional cure techniques. The rapid heat-up rates reduce the viscosity of the resin system greatly to provide a longer processing window introducing greater flexibility and removing the need for high pressure during cure. Interlaminar fracture toughness (Mode I) and Interfacial Shear Strength of aerospace standard materials cured using Quickstep have been    compared to autoclave cured laminates. Results suggest an improvement in fibre-matrix adhesion.

The origin of ring strain and conformational flexibility in Tri- and Tetrasiloxane Rings and their heavier group 14 congeners

Never change a winning team. Since the appearance of the first volume in 1994 this series has become a well respected forum, and like its highly successful predecessors, this sixth volume again brings together leading experts from academia and industry to provide a comprehensive and critical survey of the frontiers of current industrial and university research. - Synthesis and characterization of new organosilicon compounds - Applications in polymer and materials science - Summary of the latest research results The result is a unique compendium with two volumes of first-hand information, vital for all experts working in this field.

Comparison of the flexibility of eight-membered tetrasiloxane and stannasiloxane rings: a crystallographic and computational study

The syntheses and crystal structures of the eight-membered cyclo-stannasiloxanes cyclo-[t-Bu(OH)Si(OSnt-Bu₂O)₂Si(OH)t-Bu] (1) and cyclo-{t-Bu₂Si[OSn(CH₂SiMe₃)₂O]₂Sit-Bu₂} (2) as well as the synthesis of the six-membered cyclo-stannasiloxane cyclo-{t-Bu₂Si[OSn(CH₂SiMe₃)₂]₂O} (3) are reported. Compound 1 crystallizes as its trans isomer, but the cis isomer dominates in solution. In agreement with the experimentally obtained results, ab initio and DFT calculations on the model compounds cyclo-(H₂SiO)₄ (4), cyclo-[H₂Si(OSnH₂)OSiH₂] (5), cyclo-O(H₂SiOSnH₂)₂O (6), and cyclo-[H₂Si(OSiH₂)OSnH₂] (7) indicate that the energetic preference to adopt puckered structures increases and the ring flexibility decreases with an increasing number of tin atoms in the ring. The rich diversity of puckered conformations is attributed to the steric demand of the different organic substituents.