scholarly journals A Systematic Approach to Quality Oriented Product Sequencing for Multistage Manufacturing Systems

2016 ◽  
Vol 2016 ◽  
pp. 1-9
Author(s):  
Faping Zhang ◽  
Shahid Ikramullah Butt
Keyword(s):  
Manufacturing Systems ◽  
Variation Method ◽  
System Quality ◽  
Quality Performance ◽  
Part Quality ◽  
Multistage Manufacturing ◽  
Product Manufacturing ◽  
Complex Engineering ◽  
Product Sequence ◽  
Inspection Data

Product sequencing is one way to reduce cost and improve product quality for multistage manufacturing systems (MMS). However, systematically evaluating the influence of product sequence on quality performance for MMS is still a challenge. By considering the rate of incoming conforming product, manufacturing system quality transition between batch to batch, and quality propagation along stages, this paper investigates the appropriate batch policies and product sequencing for MMS so that satisfied quality performance can be achieved. A model to analyze the relationship between the product sequencing and quality performance is conducted just by using the quality inspection data and the complex engineering knowledge used in the variation method is avoided. Based on Markov Chain processes methodology, quality performance is modeled as a function of transition states jointly determined by multistage condition, product sequencing, incoming part quality, and propagation of the rate of conforming products among multistage. Quality related batch strategies are discussed for optimal quality performance. Two kinds of quality efficiency are put forward to facilitate the modeling and the discussion. The results of the model will lead to guidelines for quality management in multistage manufacturing systems.

Quality Evaluation of Multistage Manufacturing Systems by Jointly Considering the Incoming Part Quality and System Conditions

2013 ◽  
Author(s):  
Faping Zhang ◽  
Jingjing Li ◽  
Yan Yan ◽  
Jiping Lu ◽  
Shuiyuan Tang
Keyword(s):  
Product Quality ◽  
Manufacturing Systems ◽  
Quality Evaluation ◽  
System Quality ◽  
Quality Model ◽  
Quality Performance ◽  
Part Quality ◽  
Multistage Manufacturing ◽  
Good Product ◽  
Good Product Quality

The quality performance of a multistage manufacturing systems (MMS) is jointly affected by incoming part quality, system condition unreliability due to batch-to-batch uncertainty, making it challenging to evaluate the quality performance of MMS. Previous research considered the incoming part quality and system conditions separately in systematic level. This paper aims to fill the gap by considering the joint effects of these two aspects to evaluate quality performance of a MMS from historical production data driven work. A system quality model was derived to predict the probability of producing good parts at each stage and entire MMS when the incoming good part quality rate and station conditions were given. To overcome the inconvenience of the quality model for its nonlinear transfer function, the concept of quality efficiency was developed to depict the joint effectiveness of incoming part quality and system conditions mathematically at each stage. Based on the quality model, on the paper also discusses how to maintain high good product quality rate. The results of this study suggested a possible approach of evaluating the impacts of system conditions on product quality. The results of the model will lead to guidelines of quality management in multistage manufacturing systems.

Analysis of Sound Signal Generation Due to Flank Wear in Turning

2000 ◽  
Author(s):  
Ming-Chyuan Lu ◽  
Elijah Kannatey-Asibu
Keyword(s):  
Tool Wear ◽  
Manufacturing Systems ◽  
Cutting Process ◽  
Reconfigurable Manufacturing ◽  
Monitoring Tool ◽  
Major Step ◽  
Part Quality ◽  
Audible Sound ◽  
The Individual ◽  
Flank Surface

Abstract Ramp-up is a major step in the implementation of manufacturing systems, and is even more critical in reconfigurable manufacturing systems. For a successful reduction in ramp-up time, it is essential to analyze and monitor both the overall manufacturing system and the individual machine tools/processes that comprise the system. Towards this end, we have addressed the issue of monitoring tool wear using audible sound to enable faulty conditions associated with wear to be identified during the process before the part quality gets out of specification. Audible sound generated from the cutting process is analyzed as a source for monitoring tool wear during turning, assuming adhesive wear as the predominant wear mechanism. The analysis incorporates the dynamics of the cutting process. In modeling the interaction on the flank surface, the asperities on the surfaces are represented as a trapezoidal series function with normal distribution. The effect of changing asperity height, size, spacing, and the stiffness of the asperity interaction is investigated and compared with experimental data.

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.

Modeling and Analysis of Multi-Product Manufacturing Systems With Two Machines and One Buffer

2019 ◽  
Author(s):  
Jing Huang ◽  
Qing Chang ◽  
Jorge Arinez
Keyword(s):  
System Performance ◽  
Manufacturing Systems ◽  
Performance Measure ◽  
Buffer System ◽  
Product System ◽  
Modeling And Analysis ◽  
Product Manufacturing ◽  
Production Orders ◽  
System Performance Measure ◽  
Flow Conservation

Abstract The ability to process multiple product types is an important criterion for evaluating the flexibility of a manufacturing system. The system dynamics of a multi-product system is quite distinct from that of a single-product system. A modeling method for the multi-product system is proposed based on dynamic systems and flow conservation. Based on the model, this paper places its emphasis on the analysis of a two-machine-one-buffer system with two product variants. The system performance measure of a multi-product system is proposed based on production orders. The system performance of two-machine-one-buffer systems is discussed in full details. The conditions for the system achieving the best performance are derived. Finally, several numerical experiments are conducted to validate the propositions on two-machine-one-buffer system.

scholarly journals Modeling Product Manufacturing Reliability with Quality Variations Centered on the Multilayered Coupling Operational Characteristics of Intelligent Manufacturing Systems

Sensors ◽  
2020 ◽  
Vol 20 (19) ◽  
pp. 5677
Author(s):  
Anqi Zhang ◽  
Yihai He ◽  
Xiao Han ◽  
Yao Li ◽  
Xiuzhen Yang ◽  
...  
Keyword(s):  
Product Quality ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Coupling Effect ◽  
Intelligent Manufacturing ◽  
Intelligent Manufacturing Systems ◽  
Operational Characteristics ◽  
Product Manufacturing ◽  
Quality Variation ◽  
Variation Model

For intelligent manufacturing systems, there are many deviations in operational characteristics, and the coupling effect of harmful operational characteristics leads to the variations in quality of the work-in-process (WIP) and the degradation of the reliability of the finished product, which is reflected as a loss of product manufacturing reliability. However, few studies on the modeling of product manufacturing reliability and mechanism analysis consider the operating mechanism and the coupling of characteristics. Thus, a novel modeling approach based on quality variations centered on the coupling of operational characteristics is proposed to analyze the formation mechanism of product manufacturing reliability. First, the PQR chain containing the co-effects among the manufacturing system performance (P), the manufacturing process quality (Q), and the product manufacturing reliability (R) is elaborated. The connotation of product manufacturing reliability is defined, multilayered operational characteristics are determined, and operational data are collected by smart sensors. Second, on the basis of the coupling effect in the PQR chain, a multilayered product quality variation model is proposed by mining operational characteristic data obtained from sensors. Third, an integrated product manufacturing reliability model is presented on the basis of the variation propagation mechanism of the multilayered product quality variation model. Finally, a camshaft manufacturing reliability analysis is conducted to verify the validity of the proposed method. The method proposed in this paper proved to be effective for evaluating and predicting the product reliability in the smart manufacturing process.

scholarly journals Multidomain Simulation Model for Analysis of Geometric Variation and Productivity in Multi-Stage Assembly Systems

2020 ◽  
Vol 10 (18) ◽  
pp. 6606
Author(s):  
Sergio Benavent Nácher ◽  
Pedro Rosado Castellano ◽  
Fernando Romero Subirón ◽  
José V. Abellán-Nebot
Keyword(s):  
Manufacturing Systems ◽  
Production Quality ◽  
Assembly Systems ◽  
New Era ◽  
Multistage Manufacturing ◽  
Multi Stage ◽  
Potential Applicability ◽  
Stream Of Variation ◽  
Manufacturing Environments ◽  
Geometric Variation

Nowadays, the new era of industry 4.0 is forcing manufacturers to develop models and methods for managing the geometric variation of a final product in complex manufacturing environments, such as multistage manufacturing systems. The stream of variation model has been successfully applied to manage product geometric variation in these systems, but there is a lack of research studying its application together with the material and order flow in the system. In this work, which is focused on the production quality paradigm in a model-based system engineering context, a digital prototype is proposed to integrate productivity and part quality based on the stream of variation analysis in multistage assembly systems. The prototype was modelled and simulated with OpenModelica tool exploiting the Modelica language capabilities for multidomain simulations and its synergy with SysML. A case study is presented to validate the potential applicability of the approach. The proposed model and the results show a promising potential for future developments aligned with the production quality paradigm.

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