Integrated Optimal Product Design and Process Planning for One-of-a-Kind Production

2008 ◽  
Author(s):  
G. Hong ◽  
P. R. Dean ◽  
W. Yang ◽  
Y. L. Tu ◽  
D. Xue
Keyword(s):  
Product Design ◽  
Process Planning ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Product Family ◽  
Manufacturing Processes ◽  
Customer Requirements ◽  
Industrial Case Study ◽  
Optimal Product Design ◽  
Local Company

One-of-a-kind production (OKP) is a new manufacturing paradigm to produce customized products based on requirements of individual customers while maintaining the quality and efficiency of mass production. In this research, an integrated optimal product design and process planning approach is developed to satisfy customer requirements considering design and manufacturing constraints. In this work, a hybrid AND-OR graph is introduced to model the variations of design configurations/parameters and manufacturing processes/parameters in generic product family. Since different design configurations and parameters can be created from the same customer requirements, and each design can be further achieved through alternative manufacturing processes and parameters, co-evolutionary genetic programming and numerical optimization are employed to identify the optimal product design configuration/parameters and manufacturing process/parameters. An industrial case study to identify the optimal design configuration/parameters and manufacturing process/parameters of custom window products in a local company is introduced to demonstrate the effectiveness of the developed method.

Identification of the Optimal Design and its Production Process for One-of-a-Kind Production

2008 ◽  
Vol 44-46 ◽  
pp. 607-617
Author(s):  
G. Hong ◽  
P. Dean ◽  
W. Yang ◽  
Y.L. Tu ◽  
D. Xue
Keyword(s):  
Optimal Design ◽  
Product Design ◽  
Process Parameters ◽  
Mass Production ◽  
Manufacturing Process ◽  
Production Efficiency ◽  
Product Family ◽  
Manufacturing Processes ◽  
Customer Requirements ◽  
Optimal Product Design

One-of-a-kind production (OKP) is a new manufacturing paradigm to produce customized products based on requirements of individual customers while maintaining the quality and efficiency of mass production. In this research, a computer-aided optimal product design and process planning approach is developed to support OKP product design and manufacture to satisfy individual customer requirements with near to mass production efficiency. In this work, a hybrid AND-OR graph is developed to model the variations of design configurations/parameters and manufacturing processes/parameters in generic product family. Since different design configurations and parameters can be created from the same customer requirements, and each design can be further achieved through alternative manufacturing processes and parameters, co-evolutionary genetic programming and numerical optimization are employed to identify the optimal product design configuration/parameters and manufacturing process/parameters. A case study to identify the optimal design configuration/parameters and manufacturing process/parameters of custom window products in an industrial company is introduced to demonstrate the effectiveness of the developed method.

A Customer-Driven Approach to One-of-a-Kind Product Design

2007 ◽  
Author(s):  
Huijun Song ◽  
Deyi Xue ◽  
Yiliu Tu
Keyword(s):  
Product Design ◽  
Technical Level ◽  
Customer Requirements ◽  
Industrial Case Study ◽  
Product Families ◽  
Decomposition Approach ◽  
Function Decomposition ◽  
Optimal Product Design ◽  
Different Levels

This research addresses the issues to identify the optimal product design based on individual customer requirements in one-of-a-kind production (OKP). In this work, a function decomposition approach is introduced for modeling the variations of design functions, configurations, and parameters in generic OKP product families. Requirements of individual customers are modeled at two different levels: function level and technical level. Customized OKP products are created from the generic OKP product families based on customer requirements. The optimal product design is identified from feasible design candidates through optimization. An industrial case study is given to demonstrate the effectiveness of the introduced approach.

Process-Oriented Tolerance Synthesis for Multistage Manufacturing Systems

2000 ◽  
Author(s):  
Yu Ding ◽  
Jionghua Jin ◽  
Dariusz Ceglarek ◽  
Jianjun Shi
Keyword(s):  
Product Design ◽  
Process Design ◽  
Manufacturing Systems ◽  
Minimum Cost ◽  
Manufacturing Processes ◽  
Industrial Case Study ◽  
Multistage Manufacturing ◽  
Process Oriented ◽  
Design Characteristics

Abstract In multistage manufacturing systems, quality of final products is strongly affected not only by product design characteristics but also by key process design characteristics. However, historically, tolerance research has primarily focused on allocating tolerances based on product design characteristics for each component. Currently, there is no analytical approach for multistage manufacturing processes to optimally allocate tolerances to integrate product and process characteristics at minimum cost. One of the major obstacles is that the relationship between tolerances of process and product characteristics is not well understood and modeled. Under this motivation, this paper aims at presenting a framework addressing the process-oriented (rather than product-oriented) tolerancing technique for multistage manufacturing processes. Based on a developed state space model, tolerances of process design characteristics at each fabrication stage are related to the quality of final product. All key elements in the framework are described and then derived for a multistage assembly process. An industrial case study is used to illustrate the proposed approach.

Process Planning in Manufacturing Systems

2015 ◽  
Vol 760 ◽  
pp. 745-750
Author(s):  
Cristian Tarba ◽  
Sergiu Tonoiu ◽  
Petre Gheorghe Tiriplica ◽  
Ionut Gabriel Ghionea
Keyword(s):  
Product Design ◽  
Process Planning ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Planning Process ◽  
Physical Entity ◽  
Manufacturing Process Planning ◽  
Design And Manufacturing

The process of the product design consists in a plan for the product, its components and subassemblies. To obtain the physical entity building a manufacturing plan is needed. The activity of developing such a manufacturing plan is name process planning. Process planning is the relation between design and manufacturing. Process planning consists in defining the sequence of the steps that should be taken to make the product. Process planning is referring to the engineering and technological issues of how to make it.

How to Establish Digital Thread Using 3D Factory

2019 ◽  
Author(s):  
Holey Ajay ◽  
Alandikar Shashank
Keyword(s):  
Product Design ◽  
Real Time ◽  
Process Planning ◽  
Manufacturing Process ◽  
Shop Floor ◽  
Manufacturing Facility ◽  
Digital Twin ◽  
Manufacturing Process Planning ◽  
Isolated Systems ◽  
Factory Layout

Abstract In a manufacturing assembly line scenario, factory layout is one of the most crucial information used by manufacturing, facility and factory automation engineers for planning purposes. It is important for manufacturing, facility and operations team to work with most up-to-date layout when product, process and operational information on the shop-floor is constantly changing. There are four elements which governs availability of a real-time layout, these are nothing but Product Design, Manufacturing Process Planning, Layout Planning and Shop-floor. The layout must accommodate these changes coming from product design, process updates and shop-floor modifications on real-time basis so that there is no confusion amongst the stakeholders while referring layout data for their planning purpose. If we talk about the impact on the layout because of product design and process design, it is hardly managed real-time due to the isolated systems to manage these data. The integration of product, process and plant (PPP) is becoming crucial to facilitate collaboration and shrink new product introduction lead time where as real-time update from the shop-floor changes is expected in the era of digital transformation. One of the reasons why the integration of product, process and plant (PPP) does not happen is multiple isolated systems used to maintain this data, there are also challenges to feed data back from the shop-floor because of the non-availability of the thread between these objects. The paper is about how factory layout can be developed integrating product, process and plant (PPP) in a single dynamic environment and establish a digital thread between the product design, manufacturing process planning and factory layout to trigger real-time changes and facilitate digital twin of the factory. The methodology adopted here is to develop bill of material for manufacturing resources and align it with the product data management. This approach not only provides ability to maintain change control over resource objects but also helps in configuration management of the resource bill of material. The resources are grouped together as layout structure for the plant with each object required to manufacture the product. The detailed layout developed for the plant while integrating with product and process is used to establish connection with objects on the shop-floor through sensors and IOT (Internet of Things) devices to form digital twin. Such details added in layout which is So far there are no efforts to digitalize every information on the factory floor and able to generate Digital Twin of the factory by connecting physical objects with the digital objects. Paper will elaborate the approach to establish digital thread between PPP and how this can become foundation to drive digital twin of the factory.

scholarly journals Flexible Process Planning Design and Resource Optimization

2021 ◽  
Vol 8 (S1-Feb) ◽  
pp. 38-48
Author(s):  
V Thamaraiselvan ◽  
N Ramakrishnan
Keyword(s):  
Process Planning ◽  
Manufacturing Process ◽  
Flexible Manufacturing ◽  
Capital Investment ◽  
Industrial Revolution ◽  
Manufacturing Processes ◽  
Planning Model ◽  
Human Capabilities ◽  
Flexible Process Planning ◽  
Start Ups

Manufacturing processes undergo various transformations based on technological advancements and industry expectations. At initial times, during the period of first Industrial revolution, products were getting manufactured using human capabilities and skills. Then, electrically-driven motors, machines and conveyors were used. Now in the fourth Industrial revolution, Industries are equipped with automation, robots and cyber-physical systems. But adopting such technologies requires a high capital investment which cannot be accommodated by some start-ups. In this research paper, a case of a start-up which manufactures straws and vessel scrubbers in an eco-friendly manner as an initiative towards sustainability has been discussed. The key product of the company is biodegradable straws which are manufactured from coconut leaves through a set of processes. The scope of the research is to develop a labour-intensive process planning model. Managing contemporary issues is a big task for the company because of the dynamic nature of the environment. In this case, the demand for straws changes based on customer preference and accordingly, the manufacturing processes need to be revised. Hence, developing a rigid planning model is not an effective solution, so that, flexible manufacturing process needs to be developed. There is always a scope of improvement towards betterment and optimization in a manufacturing process. It is not necessary that the improvements should lead to drastic results. Japanese manufactures who bring the Toyota Production System (TPS) believe that small improvements in a continual basis will fetch better results in terms of quality, efficiency and lead time reduction. Once the model is developed, areas of improvement to optimize the resources are found out and iterations of process planning model were carried over to improve the efficiency. Through the study, it is found that the development of a flexible process plan is required to compete with the changing business scenarios.

Computational Geometric Solutions for Efficient Additive Manufacturing Process Planning

2014 ◽  
Author(s):  
Anoop Verma ◽  
Rahul Rai
Keyword(s):  
Additive Manufacturing ◽  
Real Time ◽  
Process Planning ◽  
Manufacturing Process ◽  
Manufacturing Processes ◽  
Planning Decisions ◽  
Manufacturing Process Planning ◽  
Build Time ◽  
Time Accuracy ◽  
Geometric Solutions

Additive manufacturing processes are capable of printing parts with any shape and complexity. The parts fabricated with additive manufacturing processes requires minimum human intervention. Process planning decisions play an important role in making sure the fabricated parts meets the desired specification, including the build time and cost. A quick and unified approach to quantify the manufacturing build time, accuracy, and cost in real time is lacking. In the present research, a generic and near real-time framework for unified additive manufacturing process planning is presented. We have developed computational geometric solutions to estimate tight upper bound of manufacturing process planning decisions that can be analyzed in almost real time. Results of developed computational approach are compared against the optimized process plans to ensure its applicability. Case studies comprising of numerous parts with varying shape, and application area is also outlined.

Study on Models of Planning and Scheduling in IT Manufacturing Processes

2010 ◽  
Vol 20-23 ◽  
pp. 28-33
Author(s):  
Da Wei Liu ◽  
Hong Bin Liu
Keyword(s):  
Process Planning ◽  
Manufacturing Process ◽  
Manufacturing System ◽  
Manufacturing Processes ◽  
Key Factors ◽  
Integration Model ◽  
Planning And Scheduling ◽  
Process Plans ◽  
Manufacturing Process Planning

Traditionally, Models of IT manufacturing process planning and scheduling were carried out in a sequential way, where scheduling was done after process plans had been delivered. Since the two functions are usually complementary, it is necessary to integrate them correctly so that performance of an IT manufacturing system can be improved efficiently. In the thesis, a new integration model focused on key factors has been developed to facilitate the integration and optimization. The practice of the models show that the proposed approaches are promising and very effective methods for the integration of process planning and scheduling in IT manufacturing processes.

Rules of Precedence as Basis to Generate Manufacturing Routes and Process Planning

2012 ◽  
Vol 502 ◽  
pp. 115-120
Author(s):  
O.L. Agostinho ◽  
A. Batocchio ◽  
I. Bento da Silva
Keyword(s):  
Machine Tool ◽  
Process Planning ◽  
Manufacturing Process ◽  
Cutting Tool ◽  
Work Piece ◽  
Manufacturing Processes ◽  
Data Bases ◽  
Logical Approach ◽  
Structured Knowledge ◽  
Tool Cutting

This paper presents a methodology to generate manufacturing routes and operations using rules of precedence to provide logical approach in their dimensioning and chaining. The rules of precedence order and prioritize the knowledge of various manufacturing processes, taking into account the theories of machining, forging, assembly, and heat treatments; also, utilizes the theories of accumulation of tolerance and process capability, between others. The proposed methodology requires development of manufacturing data bases of manufacturing process , tolerances and capabilities, deviations of the machine tool cutting tool fixture device and work piece . The rules of precedence make viable the generation of manufacturing routings and operations, through the usage of structured knowledge, instead of tacit one .This approach allows the structured development of manufacturing routes, which can be deployed to engineers working in the areas of manufacturing engineering.

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