To improve product quality and reduce cost, batch production is often implemented in many exible manufacturing systems. However, the current literature does not provide any method to analyze the quality performance in a flexible manufacturing system with batch production. In this research, we present an analytical method with closed-form formula to evaluate the quality performance in such systems. Based on the model, we discover and investigate monotonic and non-monotonic properties in quality to provide practical guidance for operation management. To improve product quality, we introduce the notions of quality improvability with respect to product sequencing. In addition, we develop the indicators for quality improvability based on the data available on the factory floor rather than complicated calculations. We define the bottleneck sequence and bottleneck transition as the ones that impede quality in the strongest manner, investigate the sensitivity of quality performance with respect to sequences and transitions, and propose quality bottleneck sequence and transition indicators based on the measured data. Finally, we provide a case study at an automotive paint shop to show how this method is applied to improve paint quality. Moreover, we explore a potential application to reduce energy consumption and atmospheric emissions at automotive paint shops. By selecting appropriate batch and sequence policies, the paint quality can be improved and repaints can be reduced so that less material and energy will be consumed, and less atmospheric emissions will be generated. It is shown that such scheduling and control method can lead to significant energy savings and emission reduction with no extra investment nor changes to existing painting processes. The successful development of such method would open up a new area in manufacturing systems research and contribute to establish a solid foundation for an integrated study on productivity, quality and exibility. In addition, it will provide production engineers and operation managers a quantitative tool for continuous improvement on product quality in flexible manufacturing environment

The analysis of 110 automotive paint samples was conducted for the research presented here. Laser-induced breakdown spectroscopy (LIBS) was the central instrument utilized for analysis although scanning electron microscopy / energy dispersive x-ray spectroscopy (SEM/EDS) and Fourier transform infrared spectroscopy - attenuated total reflection (FTIR-ATR) analyses were also performed. Two separate methods of LIBS analysis of samples were used: a cross sectional analysis and a drill down analysis. SEM/EDS analysis focused on the cross section while FTIR-ATR analysis concentrated on the clearcoat layer. Several different data/statistical analyses were evaluated including principal components analysis (PCA), two tailed t-tests based on several different metrics (Hit Quality Index (HQI), Pearson's correlation and Sorenson index), multivariate analysis of variance and receiver operating characteristic (ROC) curves. Full spectrum data analysis from LIBS spectra resulted in 99.7% discrimination between different sample comparisons and 12% between same sample comparisons based on HQI and t-tests. Peak analysis of LIBS spectra resulted in 87.5% discrimination between different sample comparisons and 5% between same sample comparisons based on MANOVA. When combining the results of the FTIR-ATR and SEM/EDS analyses, 88% of the samples could be discriminated.

Automotive industry is facing fundamental challenges due to the rapid depletion of fossil fuels, energy saving and environmental concerns. The need of sustainable energy development has motivated the research of energy reduction and renewable energy sources. Efficient use of energy in vehicle manufacturing is demanded, as well as an alternative energy source to replace gasoline powered engines. In this thesis, we introduce a case study at an automotive paint shop, where the largest amount of energy consumption of an automotive assembly plant takes place. Additionally, we present a summary of recent advances in the area of hybrid and electrical vehicles battery manufacturing, review commonly used battery technologies, their manufacturing processes, and related recycling and environmental issues. Our study shows that energy consumption in paint shops can be reduced substantially by selecting the appropriate repair capacity, reducing the number of repainted jobs and consuming less material and energy. Also, it is seen that considerable effort needs to be devoted to the development of batteries for hybrid and electric vehicles in the near future, which will make this area challenging and research opportunities promising.

Ce travail de thèse a contribué au développement d'un outil numérique multi-échelle capable de restituer l'aspect visuel de revêtements de peinture de carrosserie automobile à partir des caractéristiques physico-chimiques et des propriétés diélectriques des différents constituants de base ; l'objectif est la prédiction et la complète maîtrise de l'aspect visuel des matériaux. Dans cette étude, des nanoparticules d'hématite (variété α-Fe2O3), d'oxyde et d'hydroxyde de nickel de différentes formes et tailles ont été synthétisées par un procédé hydrothermal. Les particularités de ces particules en termes de morphologie, de taille et de structure ont été soulignées car elles sont susceptibles d'affecter ses propriétés diélectriques, et donc la couleur obtenue. La réponse diélectrique des particules a été mesurée par spectroscopie de pertes d'énergie des électrons (EELS). Dans un revêtement de peinture, les pigments, qui interagissent les uns avec les autres pour former des floculats, modifient la diffusion de la lumière et donc la couleur perçue. Au cours d'une deuxième phase, des revêtements de peinture « modèles », constitués de particules d'hématite dispersées dans une résine polymère, ont été élaborés. L'auto-organisation spatiale de ces nanoparticules au sein du revêtement a été décrite à partir d'images 2D enregistrées à différentes échelles d'observation. Sur la base des mesures diélectriques locales réalisées sur les nanoparticules et peintures « modèles » synthétisées dans le présent travail, des modèles aléatoires de matériaux hétérogènes ont alors été établis par le Centre de Morphologie Mathématique, pour générer une « microstructure diélectrique» 3D de ces revêtements. Sur la base de ces modèles morphologiques, les propriétés diélectriques effectives des revêtements ont été prédites; les fonctions diélectriques alors obtenues sont en bon accord avec les mesures macroscopiques réalisées par ellipsométrie. / This work contributed to the development of a multi-scale numerical tool able to reproduce the visual appearance of coatings for motor vehicle bodywork from the physico-chemical characteristics and dielectric properties of various base constituents; the goal is the prediction and complete control of the visual appearance of materials. In this study, hematite nanoparticles (the α-Fe2O3 variety), nickel oxides and hydroxides of different shapes and sizes were synthesised using a hydrothermal process. The characteristics of these particles in terms of morphology, size and structure have been particularly emphasised since they are likely to affect the overall dielectric properties of the coating, and therefore the color obtained. The dielectric response of the particles was measured by electron energy loss spectroscopy (EELS). In a coating of automobile paint, pigments which interact with each other to form flocs alter the light scattering and therefore the perceived color. During a second phase, model paint coatings consisting of hematite particles dispersed in a polymer resin were developed. The volume self-organisation of nanoparticles in the coating has been described from 2D images recorded at different scales of observation. Based on our local measurements of the dielectric function at different scales of the nanoparticules and model paint that were synthetized in the present work, random models of heterogeneous materials were then established by a partner within the consortium to generate a "dielectric 3D microstructure" of these coatings. Based on these morphological models, effective dielectric properties of the coatings were predicted, and then satisfactorily compared with macroscopic measurements from ellipsometry.

I pull from what I see in my urban surroundings. There is always a sense of dread fused with optimism that prevails. Is it beautiful? Fragments of low-riders and tricked-out cars become symbols of desire and the glowing red lens of a stop light becomes a Cyclops poised to defend his garden. Candy-coated, blooming, dripping and seductively slick confronts you with the obvious warning: STOP! You could be next… …The grass really is greener on The Other Side of the Fence. At least until winter comes.

Tinta pode ser conceituada como uma película ou camada de polímero utilizada para proteger, sinalizar e iluminar ou mesmo para embelezar o substrato sobre o qual ela é aplicada. Basicamente, esta mistura polimérica é formada por elementos, tais como: resinas, pigmentos, cargas, solventes e aditivos. Os resíduos e o efluente líquido gerados na produção de tintas devem ser tratados de modo que não causem contaminação de rios e das nascentes de água. A reutilização do efluente tratado é uma das possibilidades que deve ser considerada a fim de minimizar os impactos ambientais e reduzir o uso de recursos naturais. Processos de oxidação química são promissores para a degradação de compostos orgânicos tóxicos. O caminho mais eficiente para a oxidação é o ataque pelo radical hidroxila (OH), por meio do processo de oxidação avançada, POA. Um dos exemplos de POA é o que faz uso de aceleradores de feixe de elétrons, adotado por vários países para a remoção de compostos orgânicos. O objetivo deste estudo é aplicar o POA por radiação ionizante para o tratamento do efluente da fabricação de tintas para repintura automotiva, industrial e automotivo. A metodologia utilizada foi um estudo de caso, desenvolvido por meio do processamento com feixe de elétrons aplicados a esses efluentes de indústria de tintas. O estudo foi realizado em três fases. Na primeira, aplicou-se 10 kGy, 30 kGy e 50 kGy de dose absorvida; na segunda, 50 kGy, 80 kGy e 100 kGy, e, na última fase, foi aplicada nas amostras uma dose de 50 kGy e dopadas com 0,005%, 0,05% e 0,5% de peróxido de hidrogénio em volume. Os principais resultados demonstraram uma redução média de cerca de 10% da Demanda Química de Oxigênio, DQO e cerca de 25% da Demanda Bioquímica de Oxigênio, DBO. Os padrões de efluentes finais definidos pelos requisitos legais, em especial pelo Decreto Estadual 8468/1976. para o descarte do corpo no rio ou reutilização em aplicações industriais, foram atendidos. / Paint can be conceptualized as a film or a layer of polymer, to protect, to signal and to illuminate or even to embellish the substrate on which it is applied. Basically, this polymeric compound is formed by elements such as: resin, pigments, fillers, solvents, and additives. Waste and wastewater generated in the production of paint, have to be treated so they do not cause the contamination of rivers and springs water. The reuse of the treated effluent is one of the possibilities that should be considered in order to minimize the environmental impacts and to reduce the use of natural resources. Chemical oxidation processes are promising for degradation of toxic organic compounds. The most efficient path for the oxidation is the attack by hydroxyl radical (OH), and the Advanced Oxidation Process, AOP, using electron beam accelerators have been adopted by several countries for the removal of organic compounds. The aim of this study is to apply the AOP by ionizing radiation to treat the effluent from the manufacture of automotive, automotive refinish and industrial paints. The methodology used was a case study, developed through the electron beam processing of these effluents. The study was developed in three phases: in the first one it was applied 10 kGy, 30 kGy and 50 kGy of absorbed dose, in the second one, 50 kGy, 80 kGy and 100 kGy, and in the last one it was applied 50 kGy in samples and doped with 0.005%, 0.05% and 0.5% of hydrogen peroxide. The main results have shown an average reduction of about 10% of Chemical Oxygen Demand, COD and about 25% of Biochemical Oxygen Demand, BOD. The final effluent standards set by legal requirements for disposal of the body in the river or reuse in industrial application.

Tinta pode ser conceituada como uma película ou camada de polímero utilizada para proteger, sinalizar e iluminar ou mesmo para embelezar o substrato sobre o qual ela é aplicada. Basicamente, esta mistura polimérica é formada por elementos, tais como: resinas, pigmentos, cargas, solventes e aditivos. Os resíduos e o efluente líquido gerados na produção de tintas devem ser tratados de modo que não causem contaminação de rios e das nascentes de água. A reutilização do efluente tratado é uma das possibilidades que deve ser considerada a fim de minimizar os impactos ambientais e reduzir o uso de recursos naturais. Processos de oxidação química são promissores para a degradação de compostos orgânicos tóxicos. O caminho mais eficiente para a oxidação é o ataque pelo radical hidroxila (OH), por meio do processo de oxidação avançada, POA. Um dos exemplos de POA é o que faz uso de aceleradores de feixe de elétrons, adotado por vários países para a remoção de compostos orgânicos. O objetivo deste estudo é aplicar o POA por radiação ionizante para o tratamento do efluente da fabricação de tintas para repintura automotiva, industrial e automotivo. A metodologia utilizada foi um estudo de caso, desenvolvido por meio do processamento com feixe de elétrons aplicados a esses efluentes de indústria de tintas. O estudo foi realizado em três fases. Na primeira, aplicou-se 10 kGy, 30 kGy e 50 kGy de dose absorvida; na segunda, 50 kGy, 80 kGy e 100 kGy, e, na última fase, foi aplicada nas amostras uma dose de 50 kGy e dopadas com 0,005%, 0,05% e 0,5% de peróxido de hidrogénio em volume. Os principais resultados demonstraram uma redução média de cerca de 10% da Demanda Química de Oxigênio, DQO e cerca de 25% da Demanda Bioquímica de Oxigênio, DBO. Os padrões de efluentes finais definidos pelos requisitos legais, em especial pelo Decreto Estadual 8468/1976. para o descarte do corpo no rio ou reutilização em aplicações industriais, foram atendidos. / Paint can be conceptualized as a film or a layer of polymer, to protect, to signal and to illuminate or even to embellish the substrate on which it is applied. Basically, this polymeric compound is formed by elements such as: resin, pigments, fillers, solvents, and additives. Waste and wastewater generated in the production of paint, have to be treated so they do not cause the contamination of rivers and springs water. The reuse of the treated effluent is one of the possibilities that should be considered in order to minimize the environmental impacts and to reduce the use of natural resources. Chemical oxidation processes are promising for degradation of toxic organic compounds. The most efficient path for the oxidation is the attack by hydroxyl radical (OH), and the Advanced Oxidation Process, AOP, using electron beam accelerators have been adopted by several countries for the removal of organic compounds. The aim of this study is to apply the AOP by ionizing radiation to treat the effluent from the manufacture of automotive, automotive refinish and industrial paints. The methodology used was a case study, developed through the electron beam processing of these effluents. The study was developed in three phases: in the first one it was applied 10 kGy, 30 kGy and 50 kGy of absorbed dose, in the second one, 50 kGy, 80 kGy and 100 kGy, and in the last one it was applied 50 kGy in samples and doped with 0.005%, 0.05% and 0.5% of hydrogen peroxide. The main results have shown an average reduction of about 10% of Chemical Oxygen Demand, COD and about 25% of Biochemical Oxygen Demand, BOD. The final effluent standards set by legal requirements for disposal of the body in the river or reuse in industrial application.

Indiana University-Purdue University Indianapolis (IUPUI) / Automotive paints have used an ultraviolet (UV) absorbing clear coat system for nearly thirty years. These clear coats have become of forensic interest when comparing paint transfers and paint samples from suspect vehicles. Clear coat samples and their ultraviolet absorbers are not typically examined or characterized using Raman spectroscopy or microspectrophotometry (MSP), however some past research has been done using MSP. Chemometric methods are also not typically used for this characterization. In this study, Raman and MSP spectra were collected from the clear coats of 245 American and Australian automobiles. Chemometric analysis was subsequently performed on the measurements. Sample preparation was simple and involved peeling the clear coat layer and placing the peel on a foil-covered microscope slide for Raman or a quartz slide with no cover slip for MSP. Agglomerative hierarchical clustering suggested three classes of spectra, and principal component analysis confirmed this. Factor loadings for the Raman data illustrated that much of the variance between spectra came from specific regions (400 – 465 cm-1, 600 – 660 cm-1, 820 – 885 cm-1, 950 – 1050 cm-1, 1740 – 1780 cm-1, and 1865 – 1900 cm-1). For MSP, the regions of highest variance were between 230 – 270 nm and 290 – 370 nm. Discriminant analysis showed that the three classes were well-differentiated with a cross-validation accuracy of 92.92% for Raman and 91.98% for MSP. Analysis of variance attributed differentiability of the classes to the regions between 400 – 430 cm-1, 615 – 640 cm-1, 825 – 880 cm-1, 1760 – 1780 cm-1, and 1860 – 1900 cm-1 for Raman spectroscopy. For MSP, these regions were between 240 – 285 nm and 300 – 370 nm. External validation results were poor due to excessively noisy spectra, with a prediction accuracy of 51.72% for Raman and 50.00% for MSP. No correlation was found between the make, model, and year of the vehicles using either method of analysis.