Design of Flexible Production Systems

Design of Flexible Production Systems
Author: Tullio Tolio
Publisher: Springer Science & Business Media
Total Pages: 308
Release: 2008-12-11
Genre: Technology & Engineering
ISBN: 3540854142

In the last decade, the production of mechanical components to be assembled in final products produced in high volumes (e.g. cars, mopeds, industrial vehicles, etc.) has undergone deep changes due to the overall modifications in the way companies compete. Companies must consider competitive factors such as short lead times, tight product tolerances, frequent market changes and cost reduction. Anyway, companies often have to define production objectives as trade-offs among these critical factors since it can be difficult to improve all of them. Even if system flexibility is often considered a fundamental requirement for firms, it is not always a desirable characteristic of a system because it requires relevant investment cost which can jeopardize the profitability of the firm. Dedicated systems are not able to adapt to changes of the product characteristics while flexible systems offer more flexibility than what is needed, thus increasing investment and operative costs. Production contexts characterized by mid to high demand volume of well identified families of products in continuous evolution do not require the highest level of flexibility; therefore, manufacturing system flexibility must be rationalized and it is necessary to find out the best trade-off between productivity and flexibility by designing manufacturing systems endowed with the right level of flexibility required by the production problem. This new class of production systems can be named Focused Flexibility Manufacturing Systems-FFMSs. The flexibility degree in FFMSs is related to their ability to cope with volume, mix and technological changes, and it must take into account both present and future changes. The required level of system flexibility impacts on the architecture of the system and the explicit design of flexibility often leads to hybrid systems, i.e. automated integrated systems in which parts can be processed by both general purpose and dedicated machines. This is a key issue of FFMSs and results from the matching of flexibility and productivity that respectively characterize FMSs and Dedicated Manufacturing Systems (DMSs). The market share of the EU in the machine tool sector is 44%; the introduction of focused flexibility would be particularly important for machine tool builders whose competitive advantage is based on the ability of customizing their systems on the basis of needs of their customers. In fact, even if current production contexts frequently present situations which would fit well with the FFMS approach, tradition and know-how of machine tool builders play a crucial role. Firms often agree with the focused flexibility vision, nevertheless they decide not to pay the risk and efforts related to the design of this new system architecture. This is due also to the lack of well-structured design approaches which can help machine tool builders to configure innovative systems. Therefore, the FFMS topic is studied through the book chapters following a shared mission: "To define methodologies and tools to design production systems with a minimum level of flexibility needed to face, during their lifecycle, the product and process evolution both in the technological and demand aspects. The goal is to find out the optimal trade-off between flexibility and productivity". The book framework follows the architecture which has been developed to address the FFMS Design problem. This architecture is both broad and detailed, since it pays attention to all the relevant levels in a firm hierarchy which are involved in the system design. Moreover, the architecture is innovative because it models both the point of view of the machine tool builder and the point of view of the system user. The architecture starts analyzing Manufacturing Strategy issues and generating the possible demand scenario to be faced. Technological aspects play a key role while solving process plan problems for the products in the part family. Strategic and technological data becomes input when a machine tool builder performs system configuration. The resulting system configurations are possible solutions that a system user considers when planning its system capacity. All the steps of the architecture are deeply studied, developing methods and tools to address each subproblem. Particular attention is paid to the methodologies adopted to face the different subproblems: mathematical programming, stochastic programming, simulation techniques and inverse kinematics have been used. The whole architecture provides a general approach to implement the right degree of flexibility and it allows to study how different aspects and decisions taken in a firm impact on each other. The work presented in the book is innovative because it gives links among different research fields, such as Manufacturing Strategy, Process Plan, System Design, Capacity Planning and Performance Evaluation; moreover, it helps to formalize and rationalize a critical area such as manufacturing system flexibility. The addressed problem is relevant at an academic level but, also, at an industrial level. A great deal of industrial sectors need to address the problem of designing systems with the right degree of flexibility; for instance, automotive, white goods, electrical and electronic goods industries, etc. Attention to industrial issues is confirmed by empirical studies and real case analyses which are presented within the book chapters.

A Knowledge-based Approach for the Planning and Design of Flexible Manufacturing Systems

A Knowledge-based Approach for the Planning and Design of Flexible Manufacturing Systems
Author: Iftikhar Hussain
Publisher:
Total Pages: 328
Release: 1998
Genre:
ISBN:

The increasing global competition has led the manufacturing enterprises to adopt FMS to respond to producing a variety of products in low quantities, low costs, high quality and short lead times. The benefits associated with FMS can only be realised if the systems are planned and designed properly. In this research work, two KB computer models are developed for the planning and design of an FMS. An expert system shell AM is used for the development and implementation of the methodology. A Knowledge Based Flexible Manufacturing System Planning (KBFMSP) Model is developed to address the planning issues of an FMS such as demand information, part types information, machine information, MHS information and LAN information. The planning stage is primarily used for finding a potential demand for the system, characteristics and process plan of the part types to be manufactured, machines (Turning and Milling centres) selection, MHS (AGV-robot based and conveyor-robot based) and selecting a computer communication network architecture. Production rules are used in the planning methodology which, by using a forward chaining strategy, arrive at a decision. After successful execution of the rules, the control of the programme then moves to the design stage. At the design stage, a Knowledge Based Flexible Manufacturing System Design (KBFMSD) Model is developed to address the detailed design issues of the FMS such as required number of machines, a suitable MHS, machines and MHS layout and financial assessment. A hybrid (knowledge base plus analytical) methodology is incorporated in the KBFMSD Model to help calculate the key design factors and to assist in arriving at a completed FMS design. The viability of the FMS design is checked by using various financial assessment criteria such as Break Even Analysis, Net Present Value (NPV), Internal Rate of Return (IRR) and the Pay Back Period methods. Finally, the planning and design models are tested, verified and validated by using industrial and published case studies information. The results indicate that the KB methodology developed for the integrated planning and design of FMS is a viable technique and produces realistic and consistent results.

Manufacturing Systems Control Design

Manufacturing Systems Control Design
Author: Stjepan Bogdan
Publisher: Springer Science & Business Media
Total Pages: 312
Release: 2006-08-02
Genre: Technology & Engineering
ISBN: 1846283345

This book covers all the steps from identification of operations and resources to the transformation of virtual models into real-world algorithms. The matrix-based approach presented here is a solution to the real-time application of control in discrete event systems and flexible manufacturing systems (FMS), and offers a sound practical basis for the design of controllers for manufacturing systems.

Modeling, Simulation, and Control of Flexible Manufacturing Systems

Modeling, Simulation, and Control of Flexible Manufacturing Systems
Author: MengChu Zhou
Publisher: World Scientific
Total Pages: 432
Release: 1999
Genre: Technology & Engineering
ISBN: 9789810230296

One critical barrier leading to successful implementation of flexible manufacturing and related automated systems is the ever-increasing complexity of their modeling, analysis, simulation, and control. Research and development over the last three decades has provided new theory and graphical tools based on Petri nets and related concepts for the design of such systems. The purpose of this book is to introduce a set of Petri-net-based tools and methods to address a variety of problems associated with the design and implementation of flexible manufacturing systems (FMSs), with several implementation examples.There are three ways this book will directly benefit readers. First, the book will allow engineers and managers who are responsible for the design and implementation of modern manufacturing systems to evaluate Petri nets for applications in their work. Second, it will provide sufficient breadth and depth to allow development of Petri-net-based industrial applications. Third, it will allow the basic Petri net material to be taught to industrial practitioners, students, and academic researchers much more efficiently. This will foster further research and applications of Petri nets in aiding the successful implementation of advanced manufacturing systems.

Hybrid Control Systems in Manufacturing

Hybrid Control Systems in Manufacturing
Author: A. Villa
Publisher: CRC Press
Total Pages: 260
Release: 1991
Genre: Computers
ISBN: 9782881247675

Whenever a control strategy for a manufacturing system is designed, the aim of the designer is to obtain a solution which is both optimal, and involves and handles all constraints induced by the industrial application environment. The hybrid control system approach presented here aims to be a methodology for designing control laws showing a good balance of sub-optimality properties and of knowledge-based capabilities of handling real constraints. Book club price, $48. Annotation copyrighted by Book News, Inc., Portland, OR

Manufacturing Systems Control Design

Manufacturing Systems Control Design
Author: Stjepan Bogdan
Publisher: Springer
Total Pages: 298
Release: 2009-10-12
Genre: Technology & Engineering
ISBN: 9781848008816

This book covers all the steps from identification of operations and resources to the transformation of virtual models into real-world algorithms. The matrix-based approach presented here is a solution to the real-time application of control in discrete event systems and flexible manufacturing systems (FMS), and offers a sound practical basis for the design of controllers for manufacturing systems.