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Manufacturing Systems
Published in Leo Alting, Geoffrey Boothroyd, Manufacturing Engineering Processes, 2020
Leo Alting, Geoffrey Boothroyd
In the product layout (or flow-line production) a dedicated production line is constructed to manufacture a specific product. This is the layout principle developed by Henry Ford in the automotive industry, which revolutionized industrial manufacturing. The basic principle is that production is divided into the smallest possible operations, machines and workers are positioned in lines, and the products move from workplace to workplace where a minor operation is done on the product. The advantage of the product line is the high productivity achieved with a small level of work in progress. The drawbacks of the product line include limited flexibility concerning changing to other types of products and the vulnerability of the production system to breakdowns and other stoppages in the line. Breakdowns will stop the whole production line because only minor buffers are placed between the workplaces.
Bibliographies and Abstracts
Published in Victoria J. Mabin, Steven J. Balderstone, The World of the Theory of Constraints, 2020
Victoria J. Mabin, Steven J. Balderstone
The traditional MRP system for planning and controlling production systems is being replaced more and more by JIT and TOC. Because JIT and TOC share many elements with MRP and because MRP is very flexible, it is not difficult to make MRP behave like JIT or TOC. Consequently manufacturers with MRP systems need not dismantle them to implement JIT or TOC. A five-step technical procedure for embedding TOC into MRP is presented in this paper along with an illustrative example from a microelectronics plant. Next a simple production line is analysed using a Markov chain model to examine the types of improvements each approach makes and the effect of these improvements on the performance of the line. Performance measures are the mean and variance of the output, shortage, inventory level, and cycle time of the production line. Insights and reasons for the superior performance of JIT and TOC are provided.
Production Lines
Published in Abdul Al-Azzawi, Advanced Manufacturing for Optical Fibers and Integrated Photonic Devices, 2017
Assembly or production lines can be defined as “an arrangement of workers, machines, tools, and equipment in which the product being assembled passes consecutively from first operation to next operation until completed.” The production line can be one operation needed to complete a product, or multiple operations could go on, with more than 10 or even 20 operations to complete a product. Mechanical production methods require workers to perform a repetitive task on a product as it moves along on a conveyor belt or track. In photonics production, a product can be moved between stations using one type of tray as a holder and handler, while at the same time moving the product. An assembly line has the advantages of repeating the work and standardizing the product.
Multiple-sensor fault detection and isolation using video processing in production lines
Published in International Journal of Computer Integrated Manufacturing, 2020
Ali Abdo, Jamal Siam, Bashir Salah, Mohammed Krid
To the best of the authors’ knowledge, a similar FTC scheme has not been previously proposed in the literature. The major contributions of this study are as follows: Introduction of a sensor global-redundancy scheme.Development of a simple and efficient technique for multiple-sensor fault detection and isolation based on video and image processing.Improvement of the production line monitoring system and manufacturing process workflow by providing alternative signals to isolate the faulty-sensor measurements.Prevention of any production line and manufacturing process interruptions.Allowance of online and post-process maintenance of the production line sensors.Evaluation of the reliability of the production line sensors.Improvement of the global safety and reliability of the production line (i.e. the avoidance of human injury, machine damage, and production deterioration).
Scenario-based robust dominance criteria for multi-objective automated flexible transfer line balancing problem under uncertainty
Published in International Journal of Production Research, 2020
Cong He, Zailin Guan, Guangyan Xu, Lei Yue, Saif Ullah
Production line is made for mass production of assembling or machining products. Transfer line involves machining operations and was first introduced for mass production (Dolgui, Guschinsky, and Levin 1999). Transfer line balancing problem (TLBP) aims to balance the line in order to optimise the objectives, i.e. minimise line cycle time (Nilakantan, Huang, and Ponnambalam 2015), number of workstations (Borisovsky, Dolgui, and Kovalev 2012; Liu, Li, and Chen 2016), or line cost (Dolgui, Guschinsky, and Levin 1999). TLBP presented in the literature is mostly focused on single or multiple spindle head machines to process parts (Dolgui, Guschinsky, and Levin 1999; Dolgui, Guschinsky, and Levin 2006; Dolgui et al. 2014). (Dolgui, Guschinsky, and Levin 1999), presented a transfer line problem in which operations assigned to each workstation are partitioned into blocks. Later, (Essafi, Delorme, and Dolgui 2010a, 2010b), considered the balancing problem of transfer lines with an aim to assign a given set of operations required for the manufacturing of parts to minimise the total number of machines. (Osman and Baki 2014) considered balancing of transfer lines to minimise the non-productive time and presented ant colony algorithm for its optimisation (Borisovsky, Delorme, and Dolgui 2014), investigated balancing problem of machining line with an aim to determine feasible transfer lines to minimise the total cost.
Designing a resilient production system with reconfigurable machines and movable buffers
Published in International Journal of Production Research, 2022
Tong Qin, Ruxu Du, Andrew Kusiak, Hui Tao, Yong Zhong
With ever increased global competition and manufacturing uncertainty, manufacturing companies need to re-examine their operations from the resilient perspective (Kusiak 2020). Many studies on resilience in different domains have been published, e.g. ecological resilience (Müller et al. 2016), economic resilience (Simmie and Martin 2010), urban resilience (Ouyang, Dueñas-Osorio, and Min 2012), transportation system resilience (Mattsson and Jenelius 2015), distribution network resilience (Gao et al. 2015), food supply resilience (Tendall et al. 2015), psychological resilience (Xi, Zuo, and Wu 2012), and manufacturing resilience (Dinh et al. 2012; Kusiak 2019). Production resilience examines possible breakdowns and recovery in global and local contexts. It has been reported that a seemingly small number of events may result in significant damage to the industry worldwide (Sawik 2018). For example, the 2016 earthquake in Taiwan shut down many semiconductor factories, and directly affected Japan, Korean, China, and the USA (Wan 2016). In 2011, a flood in Thailand caused a sharp drop in global hard disk shipments with soaring prices (Coughlin 2011). Some kinds of breakdowns are uncontrollable and unpredictable, it is generally agreed that breakdowns should be managed rather than simply suppressed (Hollnagel 2012). In other words, resilience should emphasise the system ability to withstand, absorb, and recover from internal breakdowns or external disturbances (Alliance 2021). Typically, the resilience of a production system depends on many factors including product design (Haug 2018), material/component supply (Cavalcante et al. 2019), production system setup (Jin and Xi 2016), production system control (Zou et al. 2019), as well as sales and service network (Kakadia and Ramirez-Marquez 2020). This paper focuses on the design of production systems, particularly, production lines.