Joint Maintenance and Energy Management in Manufacturing Systems: Prospect Discussion, Challenge Analysis, and a Case Study

2016 ◽  
Author(s):  
Xufeng Yao ◽  
Zeyi Sun ◽  
Dong Wei ◽  
Lingyun Wang
Keyword(s):  
Energy Management ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Energy Control ◽  
Research Directions ◽  
Equipment Reliability ◽  
Automotive Assembly ◽  
Potential Benefits ◽  
Joint Maintenance

The maintenance in manufacturing systems has been widely studied to improve equipment reliability, increase the productivity, and reduce operational cost. Recently, with the increasing concerns on climate change and environmental protection, the energy related performance of manufacturing system has also draw wide attention from both academia and industry. One common decision of maintenance and energy management can be the identification of the machines that could be shut down in the manufacturing system for either maintenance or energy saving purpose. Thus, the idea of implementing maintenance and energy control simultaneously has emerged. Some existing cases about the joint maintenance and energy control in manufacturing systems can be found in literature. In this paper, we further analyze the existing opportunities for joint energy and maintenance decision making in manufacturing systems. A few research directions towards this goal are proposed and discussed. The corresponding research challenges are also analyzed. A numerical case based on a section of an automotive assembly line is used to illustrate the potential benefits of the proposed approach.

Joint Maintenance and Energy Management of Sustainable Manufacturing Systems

2015 ◽  
Author(s):  
Xufeng Yao ◽  
Zeyi Sun ◽  
Lin Li ◽  
Hua Shao
Keyword(s):  
Decision Making ◽  
Energy Management ◽  
Energy Cost ◽  
Manufacturing Systems ◽  
Sustainable Manufacturing ◽  
Manufacturing Plants ◽  
Machine Reliability ◽  
Automotive Assembly ◽  
Maintenance Decision ◽  
Joint Maintenance

The expenses associated with maintenance activities and energy consumption account for a large portion of the total operation cost in manufacturing plants. Therefore, effective methods that can be used for smart maintenance decision-making and energy management to reduce the costs of these two sections and improve the competitiveness of manufacturing enterprise are of high interests to industry. Many efforts focusing on maintenance decision-making and energy management have been dedicated. However, most of the existing research focusing on these two topics has been conducted separately, very little work has been done from a joint perspective that considers the benefits from both manufacturing machine reliability improvement and energy cost reduction. In this paper, a joint maintenance and energy management method is proposed to identify the maintenance actions considering energy cost as well as other equipment health metrics. A numerical case based on a section of an automotive assembly line is used to illustrate the potential benefits of the proposed approach.

An integrated fuzzy-based multi-criteria decision-making approach for the selection of an effective manufacturing system

2018 ◽  
Vol 25 (1) ◽  
pp. 280-296 ◽  
Author(s):  
Ram Prakash ◽  
Sandeep Singhal ◽  
Ashish Agarwal
Keyword(s):  
Decision Making ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Research Work ◽  
Sustainable Growth ◽  
Multi Criteria Decision Making ◽  
Content Type ◽  
Manufacturing Company ◽  
Selection Of

Purpose The research paper presents analysis and prioritization of barriers influencing the improvement in the effectiveness of manufacturing system. The purpose of this paper is to develop an integrated fuzzy-based multi-criteria decision-making (F-MCDM) framework to assist management of the case company in the selection of most effective manufacturing system. The framework helps in prioritizing the manufacturing systems on the basis of their effectiveness affected by the barriers. Design/methodology/approach In this paper, on the basis of experts’ opinion, five barriers have been identified in a brain-storming session. The problem of prioritization of manufacturing system is a multi-criteria decision-making (MCDM) problem and hence is solved by using the F-MCDM approach using dominance matrix. Findings Manufacturing systems’ effectiveness for Indian industries is influenced by barriers. The prioritization of manufacturing systems depends on qualitative factor decision-making criteria. Among the manufacturing systems, leagile manufacturing system is given the highest priority followed by lean manufacturing system, agile manufacturing system, flexible manufacturing system and cellular manufacturing system. Research limitations/implications The selection of an appropriate manufacturing system plays a vital role for sustainable growth of the manufacturing company. In the present work, barriers which influence the effectiveness of manufacturing system have been identified. On the basis of degree of influence of barriers on the effectiveness of the manufacturing system, five alternative manufacturing systems are prioritized. The framework will help the management of the case company to take reasonable decision for the adoption of the appropriate manufacturing system. Practical implications The results of the research work are very useful for the manufacturing companies interested in analyzing the alternative manufacturing systems on the basis of their effectiveness and their sensitivity toward various barriers. The management of Indian manufacturing company will take decision to adopt a manufacturing system whose effectiveness is least sensitive toward barriers. Effectiveness of such manufacturing system will improve with time without having retardation due to barriers. With improved effectiveness of the manufacturing system, the manufacturing company would be able to survive with global competition. The result of the present work is based on the inputs from the case company and may vary for the other manufacturing company. In the present work, only five alternative manufacturing systems and five barriers have been considered. To obtain the better result, MCDM approach with more number of alternative manufacturing systems and barriers might be considered. Originality/value The research work is based on the fuzzy analytic hierarchy process framework and on the case study conducted by the authors. The work carried out is original in nature and based on the real-life case study.

Comparison of Different Scenarios Using Computer Simulation to Improve the Manufacturing System Productivity: Case Study

2013 ◽  
Vol 845 ◽  
pp. 770-774 ◽  
Author(s):  
Seyed Mojib Zahraee ◽  
Milad Hatami ◽  
J.M. Rohani ◽  
H. Mihanzadeh ◽  
Mohammadreza Haghighi
Keyword(s):  
Computer Simulation ◽  
Production Line ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Manufacturing System ◽  
Waiting Times ◽  
Manufacturing Companies ◽  
System Productivity ◽  
High Resource

In the manufacturing industry, managers and engineers are seeking to find methods in order to eliminate the common problems in manufacturing systems such as bottlenecks and waiting times. This is because that all of these kinds of problems impose extra cost to the companies. In addition, manufacturing companies are striving to sustain their competitiveness by improving productivity, efficiency and quality of manufacturing industry for instance high throughput and high resource utilization. The paper concentrates on the application of computer simulation to analysis manufacturing system in order to improve the productivity. Therefore, this study introduces a color manufacturing line as a case study and the basic application of arena 13.9 software. The goal of this paper is to improve the productivity and efficiency of the production line by using computer simulation. To achieve this goal, first the basic model of the current situation of production line was simulated. Second, three different alternatives were simulated and modified to find the best scenario based on the maximum productivity and minimum total cost.

Modelling and Design of Closed-Loop Manufacturing Systems

2013 ◽  
Vol 378 ◽  
pp. 367-374 ◽  
Author(s):  
Andrey A. Kutin ◽  
Mikhail Turkin
Keyword(s):  
Analytical Method ◽  
Flexible Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Flexible Manufacturing System ◽  
Closed Loop ◽  
Production Systems ◽  
Finite Buffers ◽  
Unreliable Machines

This paper introduces an analytical method for evaluating the performance of closed loop manufacturing systems with unreliable machines and finite buffers. The method involves transforming an arbitrary loop into one without thresholds and then evaluating the transformed loop using a new set of decomposition equations. It is more accurate than existing methods and is effective for a wider range of cases. The convergence reliability, and speed of the method are also discussed. In addition, observations are made on the behavior of closed loop production systems under various conditions. Finally, the method is used in a case study to design a flexible manufacturing system for production of aerospace parts.

Effects Analysis of Internal Buffers in Serial Manufacturing Systems for Optimal Throughput

2019 ◽  
Author(s):  
Jad Imseitif ◽  
Herman Tang
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
Discrete Event ◽  
System Throughput ◽  
Assembly Lines ◽  
Event Simulation ◽  
Study Results ◽  
Automotive Assembly ◽  
Negative Impacts ◽  
Internal Buffer

Abstract Buffers can improve the efficiency of manufacturing systems by accommodating the negative impacts of machine stoppage and maximize the system throughput. Buffers are often designed and integrated into manufacturing systems. This study investigates the effects of small internal buffers on the throughput of serial manufacturing systems using discrete-event simulation (DES). For a serial manufacturing system, its internal buffer can be designed as an idle station or a small conveyor. In the study, typical automotive assembly lines are used as serial manufacturing systems. In addition, the capacity of a small internal buffer and two small buffers are studied for optimal throughput. The study results provide a general approach on where to assign small internal buffers in serial manufacturing systems and what the effects of such buffers and their configurations are.

Digital Twin of manufacturing systems: a case study on increasing the efficiency of reconfiguration

2020 ◽  
Vol 68 (6) ◽  
pp. 435-444 ◽  
Author(s):  
Behrang Ashtari Talkhestani ◽  
Michael Weyrich
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
Added Value ◽  
Future Research ◽  
System Availability ◽  
Qualitative And Quantitative ◽  
Digital Twin ◽  
System A ◽  
Set Up

AbstractThe added value of a Digital Twin for reconfiguring manufacturing systems promises an increase in system availability, a reduction in set-up and conversion times and enables the manufacturing of customer-specific products. To evaluate this claim, this paper selects an architecture of the Digital Twin and realizes it on the basis of an application scenario for a cyber-physical manufacturing system. A case study is used to test the reconfiguration of a manufacturing system by comparing two different methods, one without and one with use of the Digital Twin. In this paper, the process steps of both reconfigurations are described and discussed in detail and a qualitative and quantitative evaluation of the reconfiguration results is presented. Finally, this paper gives an outlook on future research on intelligent automation of manufacturing systems using the Digital Twin.

Optimization of Linear Layout Problem in Flexible Manufacturing System Using Evolutionary Algorithms - Case Study

2015 ◽  
Vol 766-767 ◽  
pp. 896-901
Author(s):  
M. Saravanan ◽  
S. Ganesh Kumar ◽  
V. Srinivasa Raman
Keyword(s):  
Flexible Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Flexible Manufacturing System ◽  
Transportation Cost ◽  
Sheep Flock ◽  
Layout Problem ◽  
Proposed Model ◽  
Better Than

Linear layout is the commonly major preferred arrangement of the flexible manufacturing systems (FMS). The proposed enhanced sheep flock heredity algorithm to solving the unequal area linear layout problem through the real case study problem. The proposed model is to minimize the transportation cost with non-overlapping. Computational results show that proposed sheep flock heredity algorithm (SFHA) can obtain better than particle swarm optimization (PSO) and existing method.

Energy Management in Manufacturing Systems

2011 ◽  
Author(s):  
Qing Chang ◽  
Guoxian Xiao ◽  
Lin Li ◽  
Stephan Biller
Keyword(s):  
Energy Consumption ◽  
Energy Saving ◽  
Energy Management ◽  
Production System ◽  
Manufacturing Systems ◽  
Production Management ◽  
Production Efficiency ◽  
Manufacturing System ◽  
Energy Savings ◽  
Energy System

Conventionally, improving production efficiency, flexibility and responsiveness has been the primary research focus of production management, while energy consumption has received relatively little attention. Energy consumption plays a more and more important role in manufacturing environment. This is mainly driven by energy cost and environmental concerns. When the energy system becomes complicated and coupled with ongoing production, it is very difficult to hunt the “hidden treasure” which affects the overall benefit of a manufacturing system. This paper provides a systematic method for energy management in a production system. We start from dynamic production transient analysis and provide quantitative analysis for energy saving opportunity in a system. Furthermore, energy saving is integrated into production system which includes downtime and throughput to provide integrated energy management framework for a production system. A case study is conducted to demonstrate its potential on energy savings in a multi-stage manufacturing system.

Case Study: The Methodology of Lean Manufacturing Implementation

2013 ◽  
Vol 393 ◽  
pp. 3-8 ◽  
Author(s):  
Nurul Hayati Abdul Halim ◽  
Ahmed Jaffar ◽  
Yusoff Noriah ◽  
Ahmad Adnan Naufal
Keyword(s):  
Continuous Flow ◽  
Lean Manufacturing ◽  
Manufacturing System ◽  
Evaluation Methods ◽  
Time Study ◽  
Step Process ◽  
Assembly Area ◽  
Automotive Assembly ◽  
Significant Achievement

This paper presents a review on the actual implementation of Lean Manufacturing (LM) techniques at a manufacturing area. It focuses on the execution of flow from the beginning until the end of the implementation, types of analyses and tools applied, evaluation methods and how the company benefited from the implementation. The on-site study was conducted at an automotive assembly area, XYZ Sendirian Berhad. LM, using a set of tools, such as time study, single minute exchange of dies (SMED), standardized work, continuous flow manufacturing system (CFMS) and 5-Why analysis were successfully implemented. The flow of implementation activities was designed by referring to Toyotas 8-Step process. The results of this study showed a significant achievement in waste identification and elimination at the case study area. This successfully proves that the Toyota 8-Steps process could work well in any environment, provided the systematic and appropriate methods and tools are used. At the same time, it could also helps to organize and optimize the effectiveness of LM establishment to the company.

Evaluation System for Energy Consumption and Productivity in Manufacturing System Simulation

2012 ◽  
Vol 6 (3) ◽  
pp. 279-288 ◽  
Author(s):  
Hironori Hibino ◽  
◽  
Toru Sakuma ◽  
Makoto Yamaguchi
Keyword(s):  
Energy Consumption ◽  
Evaluation System ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
System Simulation ◽  
Unified Modeling Language ◽  
State Transitions ◽  
Dynamic Changes ◽  
Unified Modeling

Industries need to design and improve their manufacturing systems while considering energy consumption and productivity concurrently. Manufacturing system simulation is often used to evaluate productivity when manufacturing systems are designed or improved. However, it is difficult to use simulation to evaluate energy consumption when designing and improving manufacturing systems. The purpose of our research is to establish a system for the concurrent evaluation of energy consumption and productivity in manufacturing system simulation. In this paper, first, requirements for a simulation to evaluate energy consumption and productivity are analyzed. Second, an evaluation system is proposed in consideration of the requirements. A Unified Modeling Language (UML) model that defines facility state transitions and relationships between the facility state and energy consumption is proposed. A manufacturing system simulation implemented in the proposed UML model is also proposed and developed. The proposed simulation is also implemented in a function to concurrently generate information on production throughput and energy consumption along a time progression. A system that provides a function to visually evaluate dynamic changes in the energy consumption per unit of production throughput along a time progression is also proposed and developed. Finally, a case study for semiconductor manufacturing systems is carried out to confirm the efficiency of our proposed evaluation system.

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