Advances in Manufacturing II (eBook)

Preface 6
Organization 8
Steering Committee 8
General Chair 8
Chairs 8
Scientific Committee 8
Program Committee 9
Special Sessions 10
Collaborative Manufacturing and Management in the Context of Industry 4.0 10
Sec8 10
Intelligent Manufacturing Systems 10
Sec10 10
Tooling and Fixtures: Design, Optimization, Verification 10
Sec12 10
Advanced Manufacturing Technologies 10
Sec14 10
The Changing Face of Production Engineering and Management in a Contemporary Business Landscape 11
Sec16 11
Enabling Tools and Education for Industry 4.0 11
Sec18 11
Staff for the Industry of the Future 11
Sec20 11
Advances in Manufacturing, Properties, and Surface Integrity of Construction Materials 11
Sec22 11
Materials Engineering 12
Sec24 12
Advanced Mechanics of Systems, Materials and Structures 12
Sec26 12
Virtual and Augmented Reality in Manufacturing 12
Sec28 12
Contents 13
A Framework for SME Performance Evaluation 16
Abstract 16
1 Introduction 16
2 A Formal Model for SME Performance Evaluation 18
3 Practical Issues for a SME Performance Evaluation Procedure 21
4 Application to Two SMEs Registered in the PMInnova Program 22
4.1 Modular Kitchens’ Enterprise 22
4.2 Cheese Factory 23
5 Conclusion 24
Acknowledgments 24
References 25
Environmental Management and Green Attitudes of the European SME Sector 27
Abstract 27
1 Introduction 27
2 Environment Value Growth Stages in the Aspect of Natural Environment Perception Change Evolution 28
3 Environmental Management of SMEs – Evolutionary Grasp 30
4 Green Activity of the European SME Sector 32
5 Summary 39
References 39
A Comparative Analysis of Various Production Organisation Forms on the Basis of Customised Manufacturing 41
Abstract 41
1 Introduction 41
2 Analysis of the Literature 42
2.1 Types of Production Organisation 42
2.2 Forms of Production Organisation 43
3 Overview of the Company Division Under Analysis 43
4 Analysis of Results 45
5 Summary 48
Acknowledgments 48
References 49
Tooling CAD Models Preparation Process for Automated Technology Design System 51
Abstract 51
1 Introduction 51
2 KBE Systems for Engineering Design 52
3 Case Study - Dies for Assembling Connectors with Corrugated Pipes 53
4 Assumptions of Automated Technology Design System 54
5 Generative CAD Models of Dies 56
6 Conclusions 58
References 59
Selection of Assembly Sequence for Manual Assembly Based on DFA Rating Factors 60
Abstract 60
1 Introduction 60
2 Criteria for the Evaluation of Assembly Sequences 61
3 Comparison of the Validity of Criteria 63
3.1 Multicriteria Decision Making Methods 64
3.2 F-AHP 64
4 Generating All Feasible Assembly Sequences 66
5 Determining the Most Advantageous Sequence of Assembly 66
6 Algorithm of the Method 67
7 Implementation 67
7.1 Determining All Feasible Assembly Sequences 67
7.2 Ordering and Giving Weights to Selected Criteria 69
7.3 Evaluation of Assembly Sequences 70
8 Summary 71
References 71
Technology Management as a Process – A View from In-Depth Studies in Metal Processing Companies 73
Abstract 73
1 Introduction 73
2 Technology Management and Process Management Approach 74
3 Research Method 75
4 Process Activities and Their Duration 76
4.1 Process 1 76
4.2 Process 2 77
4.3 Process 3 78
4.4 Process 4 78
4.5 Process 5 79
4.6 Process 6 80
5 Discussion 81
6 Conclusions 83
Acknowledgments 83
References 83
Formal Recording of Product Manufacturing Structure Oriented on Customer-Based Production 85
Abstract 85
1 Introduction 85
2 Manufacturing Structure of the Product Family 86
3 Design of Technological Process Oriented on Customer Specification 91
4 Computer Characteristics of Representation of Product Family 92
5 Case Study 93
6 Conclusions 95
Acknowledgments 95
References 95
Multi-objective Aggregate Production Planning Model Considering Overtime and Outsourcing Options Under Fuzzy Seasonal Demand 96
Abstract 96
1 Introduction 96
2 Problem Description 99
2.1 Fuzzy Programming 103
3 Weighted Goal Programming (WGP) 104
4 Computational Results 105
4.1 Sensitivity Analysis 107
5 Conclusion and Future Works 109
References 109
Welding Workstation Planning with Use of CAD Software and Simulation 112
Abstract 112
1 Introduction 112
2 Design of a Robotic Welding Workplace 113
2.1 Selection of a Suitable Industrial Robot 114
2.2 Selection of Suitable Welding Gun 115
2.3 Variant A – Manually Operated Workplace 115
2.4 Variant B - Workplace with Industrial Robot with Welding Gun (Type “X”) and Human Service 116
2.5 Variant C - Workroom with Robotic Service and Stationary Point Welding 117
3 Conclusion 118
Acknowledgements 119
References 119
A New Algorithm for Generating the Material Order in ERP Systems 121
Abstract 121
1 Introduction 121
2 Presentation of the Problem 122
3 Checking the Correctness of the Material Order Generated by ERP Software 123
4 An Algorithm for Generating the Material Order in ERP Systems 126
5 Conclusions 131
References 131
A Comparison of Production Time Calculation Methods for Customized Products Manufacturing 132
Abstract 132
1 Introduction 132
2 Research Methodology 135
3 Case Study Presentation and Results Discussion 137
4 Summary 141
Acknowledgments 141
References 142
Systematic Literature Review of Theory of Constraints 144
Abstract 144
1 Introduction 144
2 Methodology of Systematic Literature Review 145
3 Research Steps 146
4 Main Areas of Research 150
5 Conclusions 151
Acknowledgments 151
References 151
The Role of the Recycling Cooperatives in Reverse Logistics 154
Abstract 154
1 Introduction 154
2 Theoretical Reference 155
2.1 Recycling Cooperatives 155
2.2 Reverse Logistics 156
2.3 Social Business Model Canvas 158
2.4 Social Business 159
3 Methodology 159
4 Results and Analysis 160
5 Conclusion 163
References 164
Reference Model of a Milk-Run Delivery Problem 165
Abstract 165
1 Introduction 165
2 Distribution System Modeling Paradigms 166
3 Declarative Model of a Milk-Run Delivery Problem 167
4 Supply Cycle Prototyping 169
5 Case Study 170
6 Concluding Remarks 174
References 175
Comparing Two Methodologies for Modeling and Simulation of Discrete-Event Based Automated Warehouses Systems 176
Abstract 176
1 Introduction 176
2 Modeling an Elevator as a Part of Shuttle-Based Storage and Retrieval System in a Modern Manufacturing Facility 177
2.1 Factors that Determine the Performance of an Elevator 179
2.2 An Elevator in an Automated Warehouses Systems 179
3 FlexSim and GPenSIM 180
3.1 Flexsim 180
3.2 GPenSIM 180
4 FlexSim Model 181
5 GPenSIM Model 184
5.1 The Petri Net Model 184
5.2 GPenSIM Implementation 185
6 Simulation 185
6.1 Simulation Experiments in the FlexSim System 186
6.2 Simulation Experiments in the GPenSim System 187
7 Conclusion 189
References 189
The Impact of Manufacturing Accuracy of Selected Components on Contact Stress in the Eccentric Rolling Transmission 191
Abstract 191
1 Introduction 191
2 Idea of the Eccentric Rolling Transmission 192
3 Impact of the Actual Value of an Eccentric on Contact Stress in the Eccentric Rolling Transmission 193
3.1 Simulation Study of Contact Stresses 194
4 Examination of Manufacturing Accuracy of Eccentric Bushes Made According to Different Technologies 196
4.1 Applied Manufacturing Technologies 196
4.2 Measuring Stand 197
4.3 Measurement Results and Their Analysis 198
4.4 FEM Simulation 200
5 Summary 201
Acknowledgments 201
References 202
Performance Measurement of SMED Improved Plastic Injection Molding Production by Using Process Capability Analysis for Attribute Data 203
Abstract 203
1 Introduction 203
2 The Process of Plastic Injection 204
2.1 Plastic Injection Failures Rates 205
3 Using SMED Approach for the Plastic Injection Molding Manufacturing 206
4 Performance Measuring of SMED Using Process Capability Analysis 208
4.1 The Process Capability Analysis 208
4.2 Process Stability for Attribute Data 208
4.3 Process Stability Testing Using U-Control Charts 209
4.4 The Capability Index for Attribute Data 210
5 An Application 211
5.1 Problem Definition 212
5.2 Analysis of Results 213
6 Conclusion 218
References 219
Micro-machining and Process Optimization of Electrochemical Discharge Machining (ECDM) Process by TOPSIS Method 221
Abstract 221
1 Introduction 221
2 Experimentation and Methodology 223
3 Results and Discussion 224
3.1 Effect of Process Parameters on MRR 224
3.2 Effect of Process Parameters on Overcut 225
4 Multi-response Optimization of ECDM Process by TOPSIS Method 226
5 Conclusions 228
Acknowledgments 228
Appendix 229
References 229
Designing an Experimental Research Using the Finite Element Analysis Method 231
Abstract 231
1 Introduction 231
2 Research Design Using the Finite Element Analysis 232
3 The Finite Element Simulation of the Cutting Process 236
4 Results and Conclusions 237
References 242
Simulation of Air Flow on the Bodywork Automobile with Direct and Side Load 243
Abstract 243
1 Introduction 243
2 Materials and Methods 244
3 Realisation of Experiment 246
4 Results and Discussion 255
5 Conclusion 256
Acknowledgments 257
References 257
Assessment of Machining Accuracy of a WaterJet Cutter by Test Workpiece Machining 258
Abstract 258
1 Introduction 258
2 Methodology 261
3 Results 263
4 Conclusions 265
References 266
Analysis and Control of High-Pressure Die-Casting Process Parameters with Use of Data Mining Tools 268
Abstract 268
1 Introduction 268
2 Characteristics of the High-Pressure Die-Casting Process 270
3 Problem Definition. Data Acquisition and Characteristics 272
4 Methodology and Analysis of Study Results 273
4.1 Correlation Analysis 273
4.2 Analysis of Variance and Normality Tests 273
4.3 Methodology of Modeling with Use of SPC Results as a Data Source for Data Mining Models 276
4.4 Building a Database of Occurrences of WE Rules Breaches 277
4.4.1 Types of Input Variables 277
4.4.2 Types of Output Data 277
5 Modeling of the Process 278
5.1 Analysis of Results of Input-Type2/Output-Type1 Modeling 278
5.2 Analysis of Results of Input-Type2/Output-Type3 Modeling 279
6 Summary 280
Acknowledgments 281
References 281
Comparison Study of Different Production Control Policies in Condition of Various Demand for Final Products 283
Abstract 283
1 Introduction 283
2 Literature Analysis 284
3 Description of the Current State 285
4 Description of the Future State - Variants of the Method of Production Planning and Control 287
5 Research Methodology 289
6 Aim of Study, Simulation Model, Its Verification and Validation 289
7 Simulation Experiments 291
8 Conclusions 293
Acknowledgments 293
References 294
Methodology of Manufacturing Process Analysis 296
Abstract 296
1 Introduction 296
2 Analysis of the Literature 297
3 Process Mapping Methodology 299
4 Application of the Methodology – Results 304
5 Summary 307
Acknowledgments 308
References 308
Production Scheduling and Capacity Utilization in Terms of Mass Customized Manufacturing 310
Abstract 310
1 Introduction 310
2 Related Work 311
3 Problem Description and Methodology Framework 312
3.1 Description of Proprietary Software 313
4 Theoretical Example 314
4.1 Description of the Example 314
4.2 Production Scheduling and Capacity Utilization 314
4.3 Enumeration of Production Indicators and Its Analysis 317
5 Discussion and Conclusions 319
Acknowledgments 320
References 320
Experimental Examination of Surface Roughness in Low-Environmental-Load Machining of External Cylindrical Workpieces 322
Abstract 322
1 Introduction 322
2 Features of Environmentally Friendly Machining 323
3 Experimental Conditions 324
4 Measurement Results 326
5 Discussion 333
6 Summary 335
Acknowledgments 335
References 335
Application of Strategy Manager Tools for Optimized NC Programming 337
Abstract 337
1 Introduction 337
2 Optimization of Machining Processes 338
3 The Possibilities of Automation of NC Program Creation in CAD/CAM Systems 339
4 Feature Analysis and NC Strategies 340
5 Experiments 344
6 Conclusion 348
Acknowledgments 348
References 348
Parametric Optimization of Fixtures for Multiaxis Machining of Parts 350
Abstract 350
1 Introduction 350
2 Literature Review 351
3 Research Methodology 352
4 Results 356
5 Conclusions 360
References 361
Tools Implementation in Management of Continuous Improvement Processes 363
Abstract 363
1 Introduction 363
2 Problem Description and Proposed System Architecture 365
2.1 Problem Description 365
2.2 Proposed System Architecture 365
3 Systems Functionalities 367
4 Systems Illustrations 368
5 Conclusion 369
Acknowledgments 370
References 370
The Use of Simulation Games in Teaching Lean Manufacturing 373
Abstract 373
1 Introduction 373
2 Simulation Game “Assembly of the Toy House” 374
2.1 The Goal of the Simulation Game 375
2.2 Theoretical Basics of the Game “Assembly of the Toy House” 375
2.3 Game Characteristics 377
3 Observations from the Implementation of the Game 382
4 Conclusions 383
References 383
Improvement of the Educational Process by the Creation of Centers for Intellectual Development and Scientific and Technical Creativity 385
Abstract 385
1 Introduction 385
2 Formation on the Basis of Secondary Educational Institutions of the Computer-Based Learning Environment and Technological Competence Development 387
3 Organization on the Basis of General Educational Institutions, Organizations of General and Additional Education of Innovative Centers of Scientific and Technical Creativity of Youth 391
4 Conclusion 395
References 397
Challenges of Calculations for the Contract Individual Production of Welded Structures 398
Abstract 398
1 Introduction 398
2 Methodology 399
3 Research Problem 401
3.1 The Influence of the Structural Design of a Product on the Calculation 401
3.2 The Role of Customer and Supplier Inclusion in the Calculation of Contract Production 402
3.3 The Influence of Information Accuracy on Calculations 403
3.4 The Influence of Changes in the Project on the Calculation 404
3.5 The Influence of Existing Resources on the Calculation 404
3.6 The Influence of Quality Requirements on the Calculation 405
3.7 Various Methodological Approaches to Calculations 405
4 Results 406
4.1 Product Feature Description for the Case Study 407
4.2 Description of the Technological Process for the Production of a Product in the Case Study 407
4.3 Case Study Execution 407
5 Discussion 409
6 Conclusions 410
Acknowledgements 410
References 410
Author Index 413