Uma análise de modelos quantitativos aplicados a solução de problemas de Plant - Layout

Este trabalho tem por objetivo reunir e analisar os modelos quantitativos mais comumente usados como suporte às atividades dos especialistas, responsáveis, nas empresas, pela consecução do melhor arranjo. Enfase especial é dispensada à análise dos modelos computacionais que, de fato, constitui a parte central da monografia. Não há qualquer pretensão de originalidade para os conceitos e para o material aqui apresentado.

Addressing the facilities layout design problem through constraint logic programming

One of the most difficult problems that face researchers experimenting with complex systems in real world applications is the Facility Layout Design Problem. It relies with the design and location of production lines, machinery and equipment, inventory storage and shipping facilities. In this work it is intended to address this problem through the use of Constraint Logic Programming (CLP) technology. The use of Genetic Algorithms (GA) as optimisation technique in CLP environment is also an issue addressed. The approach aims the implementation of genetic algorithm operators following the CLP paradigm.

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.

Melhoria do processo produtivo de embalagem numa empresa do ramo automóvel

Este estudo foi desenvolvido no âmbito da Unidade curricular de Dissertação / Projeto / Estágio do Mestrado em Engenharia Mecânica – Ramo de Gestão Industrial do Instituto Superior de Engenharia do Porto, com aplicação em ambiente industrial numa empresa metalomecânica da indústria automóvel. O projeto desenvolveu-se na secção de inspeção e embalagem de produto acabado da empresa IETA S.A., fornecedora de estruturas metálicas, com o objetivo de minimizar as reclamações recebidas por defeitos originados no processo de fabrico. A abordagem a este estudo iniciou-se pelo registo e análise de dados e consequente formulação e implementação de melhorias ao processo de fabrico, com recurso a metodologias e ferramentas Lean. A existência de um problema relacionado com o processo de fabrico em vigor permitiu o conhecimento dos hábitos de trabalho e a apresentação de propostas de melhoria ao layout fabril e ao método de trabalho em vigor na secção. A análise dos problemas existentes possibilitou a identificação de oportunidades de melhoria em outras áreas do processo, revelando-se o poder das ferramentas utilizadas na análise de dados. Este estudo de investigação revelou ser muito enriquecedor e motivador tendo proporcionado a aplicação de conteúdos científicos Lean em ambiente industrial ficando provada a mais-valia da sua implementação. A aplicação das ferramentas e metodologias Lean estudadas permitiram efetuar uma análise cuidada dos dados conduzindo a propostas de melhoria vantajosas e compatíveis com as necessidades da empresa. As propostas apresentadas, apesar de não terem sido todas implementadas, resultaram num impacto positivo no processo de fabrico com uma eliminação expectável de 38% dos defeitos reclamados.

Paperikoneen devestoinnin vaikutukset tehtaan infrastruktuuriin

ässä työssä on analysoitu UPM-Kymmene Oyj Voikkaan tehtaalla tapahtuneiden paperikoneiden 16 ja 17 ja SGW- hiomon pysäyttämisten vaikutuksia tehtaan sisäiseen infrastruktuuriin sekä tehdas- ja osastolayoutien uudelleen järjestelytarpeisiin. Diplomityön tavoitteena oli laatia koko tehdasalueen käsittävä, osastojen, laitosten ja laitteistojen lyhyen ja pitkän tähtäimen sijoitussuunnitelma. Suunnitelmassa on huomioitu vanhan tehtaan puolelle jäävien toimintojen siirto lähemmäs käyntiin jääneitä paperikoneita 11 ja 18 sekä PGW-hiomoa. Suunnitelmassa on myös otettu huomioon tiedossa olevat pitemmän tähtäimen kehityssuunnitelmat. Suunnitelman laatimisella tavoitellaan niin ikään pitkän tähtäimen suunnitelmallisuuden lisäämistä koko tehdasympäristössä. Työn teoriaosassa tarkastellaan tehdassuunnittelua yleensä, esitellään tehdasprojektin eri vaiheet sekä tehdassuunnitteluprojektin oleellisimmat päätöksentekovaiheet. Tarkemman tarkastelun kohteena on, minkä tasoista tilasuunnittelua tehdasprojektin eri vaiheissa tehdään. Kokeellisessa osassa tarkastellaan tutkimuskohteiden vaihtoehtoisia sijoituspaikkoja, vaihtoehtojen toteutuskelpoisuutta ja niiden tarkoituksenmukaisuutta. Loppuyhteenvedossa tehdään johtopäätöksiä tehtaan koko layoutin tarkoituksenmukaisuudesta ja verrataan sitä ns. mallitehtaan periaatteelliseen layoutiin sekä tehdään yhteenvetoa siitä, mitkä ovat tehtaan toiminnan kannalta tärkeimmät muutoskohteet.

Fast pyrolysis in circulating fluidized bed: feasibility study

Today the limitedness of fossil fuel resources is clearly realized. For this reason there is a strong focus throughout the world on shifting from fossil fuel based energy system to biofuel based energy system. In this respect Finland with its proven excellent forestry capabilities has a great potential to accomplish this goal. It is regarded that one of the most efficient ways of wood biomass utilization is to use it as a feedstock for fast pyrolysis process. By means of this process solid biomass is converted into liquid fuel called bio-oil which can be burnt at power plants, used for hydrogen generation through a catalytic steam reforming process and as a source of valuable chemical compounds. Nowadays different configurations of this process have found their applications in several pilot plants worldwide. However the circulating fluidized bed configuration is regarded as the one with the highest potential to be commercialized. In the current Master’s Thesis a feasibility study of circulating fluidized bed fast pyrolysis process utilizing Scots pine logs as a raw material was conducted. The production capacity of the process is 100 000 tonne/year of bio-oil. The feasibility study is divided into two phases: a process design phase and economic feasibility analysis phase. The process design phase consists of mass and heat balance calculations, equipment sizing, estimation of pressure drops in the pipelines and development of plant layout. This phase resulted in creation of process flow diagrams, equipment list and Microsoft Excel spreadsheet that calculates the process mass and heat balances depending on the bio-oil production capacity which can be set by a user. These documents are presented in the current report as appendices. In the economic feasibility analysis phase there were at first calculated investment and operating costs of the process. Then using these costs there was calculated the price of bio-oil which is required to reach the values of internal rate of return of 5%, 10%, 20%, 30%, 40%, and 50%.

Analysis and modelling of chemical looping combustion process with and without oxygen uncoupling

Effective control and limiting of carbon dioxide (CO₂) emissions in energy production are major challenges of science today. Current research activities include the development of new low-cost carbon capture technologies, and among the proposed concepts, chemical combustion (CLC) and chemical looping with oxygen uncoupling (CLOU) have attracted significant attention allowing intrinsic separation of pure CO₂ from a hydrocarbon fuel combustion process with a comparatively small energy penalty. Both CLC and CLOU utilize the well-established fluidized bed technology, but several technical challenges need to be overcome in order to commercialize the processes. Therefore, development of proper modelling and simulation tools is essential for the design, optimization, and scale-up of chemical looping-based combustion systems. The main objective of this work was to analyze the technological feasibility of CLC and CLOU processes at different scales using a computational modelling approach. A onedimensional fluidized bed model frame was constructed and applied for simulations of CLC and CLOU systems consisting of interconnected fluidized bed reactors. The model is based on the conservation of mass and energy, and semi-empirical correlations are used to describe the hydrodynamics, chemical reactions, and transfer of heat in the reactors. Another objective was to evaluate the viability of chemical looping-based energy production, and a flow sheet model representing a CLC-integrated steam power plant was developed. The 1D model frame was succesfully validated based on the operation of a 150 kWth laboratory-sized CLC unit fed by methane. By following certain scale-up criteria, a conceptual design for a CLC reactor system at a pre-commercial scale of 100 MWth was created, after which the validated model was used to predict the performance of the system. As a result, further understanding of the parameters affecting the operation of a large-scale CLC process was acquired, which will be useful for the practical design work in the future. The integration of the reactor system and steam turbine cycle for power production was studied resulting in a suggested plant layout including a CLC boiler system, a simple heat recovery setup, and an integrated steam cycle with a three pressure level steam turbine. Possible operational regions of a CLOU reactor system fed by bituminous coal were determined via mass, energy, and exergy balance analysis. Finally, the 1D fluidized bed model was modified suitable for CLOU, and the performance of a hypothetical 500 MWth CLOU fuel reactor was evaluated by extensive case simulations.

Multivariate Statistical Process Control and Case-Based Reasoning for situation assessment of Sequencing Batch Reactors

ABSRACT This thesis focuses on the monitoring, fault detection and diagnosis of Wastewater Treatment Plants (WWTP), which are important fields of research for a wide range of engineering disciplines. The main objective is to evaluate and apply a novel artificial intelligent methodology based on situation assessment for monitoring and diagnosis of Sequencing Batch Reactor (SBR) operation. To this end, Multivariate Statistical Process Control (MSPC) in combination with Case-Based Reasoning (CBR) methodology was developed, which was evaluated on three different SBR (pilot and lab-scales) plants and validated on BSM1 plant layout.

Incorporação do lodo da estação de tratamento de água (ETA II) do município de Rio Claro-SP, na argila, para produção de cerâmica vermelha

The slugde from decanters in Water Treatment Plants (WTP) has different composition varying, according to the region, coagulant type and dosages, the plant layout. In this work, the physical characterization of the sludge generated from decenties (ETAII the municipality of Rio Claro, Brazil), the manufacture of bodies of evidence-sludge mixture of clay (with humidity of 8% and concentrations of sludge, 5, 15 and 30%) the testing technology after burning the mixture to a temperature of 950 ° C were investigated. The main aim assess the possibility of its use as raw material in the ceramic red production. For comparison of the obtained results it was used values of the testing technology of bodies of evidence only with clay, prepared under the same conditions. In general, the addition of sludge from ETA made worse the properties of the ceramic body, however, the values obtained from the tests on the concentration of 5% of sludge, still remain within the acceptable limits for the production of red pottery pieces.

Rediseño de productos: de los productos modularizados a la distribución de planta para una familia de productos

Esta investigación pretende evidenciar como el rediseño de un producto, específicamente el rediseño modular, puede generar cambios en la distribución de planta incrementando los niveles de producción de una empresa -- Dicho incremento se logró implementando una nueva metodología, que será ampliamente descrita en este trabajo, y que contempla todo el proceso del rediseño de productos, desde el desensamble hasta la distribución de la planta -- Para esta investigación se utilizaron herramientas conocidas como el Análisis Funcional, la Matriz de Interacción, El Diseño para el Ensamble (DFA), el Diagrama de Operaciones y algunos conceptos de la gestión de plataforma de un producto modular -- Como ejemplo ilustrativo, se rediseñaron dos productos ya existentes, una licuadora SAMURAI modelo FACICLIC negra y un procesador de alimentos HAMILTON BEACH modelo 70740, los cuales sirvieron de base para evidenciar cómo al transformar un producto en uno más modular se mejora significativamente la distribución de planta, logrando un incremento en la producción de éste, al tiempo que se reducen los tiempos de ensamble y se optimiza la disposición de los puestos de trabajo en la planta para conformar el producto final -- Para llevar a cabo esta investigación, fue indispensable crear una nueva ruta metodológica que nos permitiera rediseñar un producto inicial como un producto modularizado y terminar con el rediseño de la distribución de planta de una familia de productos modulares -- Esta nueva ruta metodológica, que hace parte de nuestros resultados de investigación, consta de tres fases -- La primera fase, se basa principalmente en modularizar cada uno de los productos que se quieren integrar dentro de la familia de productos, la segunda fase, logra identificar los módulos comunes entre los productos modularizados para generar la plataforma, y por último, la fase tres genera una nueva distribución de planta para el ensamble de la familia de productos generada -- Esta investigación constata, entre otras cosas, como el rediseño modular de productos es una herramienta fundamental en el planteamiento de una familia de productos en una empresa -- Partiendo de productos que ya pasaron por un proceso de modularización previo, se propuso una métrica que permite definir la similitud entre módulos, considerando la mayor cantidad de sus propiedades, la forma física y la función de cada uno de ellos, complementando así la metodología propuesta por Katja Hölttä en su tesis doctoral -- Finalmente se propuso una distribución de planta que permite un ensamble más eficiente tanto en tiempo como en número de operarios necesarios para la producción, incrementando así la versatilidad y las tasas de producción de la empresa

Análise e melhoria de layout de processo na indústria de beneficiamento de couro

A aplicação de técnicas de estudo de sistemas em ambientes industriais com grande concorrência, é cada vez mais significativa devido às modificações e flexibilidade de produção exigidas. A aplicação de técnicas de análise e ajustes de layouts são algumas destas técnicas que podem trazer resultados competitivos positivos. O presente trabalho descreve os tipos de layouts existentes, com suas aplicações, vantagens e desvantagens com a finalidade de analisar e propor melhorias em layouts de processo na indústria coureira. O trabalho enfoca ainda os principais pontos a serem considerados quando da criação de um novo layout ou do ajuste e/ou melhoria de um existente. Para tal, foi realizado um estudo de caso utilizando a técnica de Melhoria de Layout de Silveira (1998), com a aplicação do Planejamento Sistemático de Layout em um layout de processo do setor da Secagem, característico em uma indústria beneficiadora de couro. Os resultados obtidos traduzem o re-arranjo de seus postos de trabalho com redução do fluxo de material de acordo com a aproximação de postos com relações de afinidade. Essa alteração possibilitou uma melhor organização espacial dos postos de trabalho e um melhor controle da produção, através da separação natural dos lotes. A metodologia adotada pode ser utilizada como ferramenta de melhoria nos demais setores, tanto da própria empresa, como do mercado coureiro em geral.

An interdisciplinary approach to designing and evaluating a hybrid solar-biomass power plant

Purpose: Energy security is a major concern for India and many rural areas remain un-electrified. Thus, innovations in sustainable technologies to provide energy services are required. Biomass and solar energy in particular are resources that are widely available and underutilised in India. This paper aims to provide an overview of a methodology that was developed for designing and assessing the feasibility of a hybrid solar-biomass power plant in Gujarat. Design/methodology/approach: The methodology described is a combination of engineering and business management studies used to evaluate and design solar thermal collectors for specific applications and locations. For the scenario of a hybrid plant, the methodology involved: the analytical hierarchy process, for solar thermal technology selection; a cost-exergy approach, for design optimisation; quality function deployment, for designing and evaluating a novel collector - termed the elevation linear Fresnel reflector (ELFR); and case study simulations, for analysing alternative hybrid plant configurations. Findings: The paper recommended that for a hybrid plant in Gujarat, a linear Fresnel reflector of 14,000 m2 aperture is integrated with a 3 tonne per hour biomass boiler, generating 815 MWh per annum of electricity for nearby villages and 12,450 tonnes of ice per annum for local fisheries and food industries. However, at the expense of a 0.3 ¢/kWh increase in levelised energy costs, the ELFR can increase savings of biomass (100 t/a) and land (9 ha/a). Research limitations/implications: The research reviewed in this paper is primarily theoretical and further work will need to be undertaken to specify plant details such as piping layout, pump sizing and structure, and assess plant performance during real operational conditions. Originality/value: The paper considers the methodology adopted proved to be a powerful tool for integrating technology selection, optimisation, design and evaluation and promotes interdisciplinary methods for improving sustainable engineering design and energy management. © Emerald Group Publishing Limited.

A Modified Acidic Approach For Dna Extraction From Plant Species Containing High Levels Of Secondary Metabolites.

Purified genomic DNA can be difficult to obtain from some plant species because of the presence of impurities such as polysaccharides, which are often co-extracted with DNA. In this study, we developed a fast, simple, and low-cost protocol for extracting DNA from plants containing high levels of secondary metabolites. This protocol does not require the use of volatile toxic reagents such as mercaptoethanol, chloroform, or phenol and allows the extraction of high-quality DNA from wild and cultivated tropical species.

Apoplastic And Intracellular Plant Sugars Regulate Developmental Transitions In Witches' Broom Disease Of Cacao.

Witches' broom disease (WBD) of cacao differs from other typical hemibiotrophic plant diseases by its unusually long biotrophic phase. Plant carbon sources have been proposed to regulate WBD developmental transitions; however, nothing is known about their availability at the plant-fungus interface, the apoplastic fluid of cacao. Data are provided supporting a role for the dynamics of soluble carbon in the apoplastic fluid in prompting the end of the biotrophic phase of infection. Carbon depletion and the consequent fungal sensing of starvation were identified as key signalling factors at the apoplast. MpNEP2, a fungal effector of host necrosis, was found to be up-regulated in an autophagic-like response to carbon starvation in vitro. In addition, the in vivo artificial manipulation of carbon availability in the apoplastic fluid considerably modulated both its expression and plant necrosis rate. Strikingly, infected cacao tissues accumulated intracellular hexoses, and showed stunted photosynthesis and the up-regulation of senescence markers immediately prior to the transition to the necrotrophic phase. These opposite findings of carbon depletion and accumulation in different host cell compartments are discussed within the frame of WBD development. A model is suggested to explain phase transition as a synergic outcome of fungal-related factors released upon sensing of extracellular carbon starvation, and an early senescence of infected tissues probably triggered by intracellular sugar accumulation.