O cenário do mercado exige que as empresas desenvolvam produtos inovadores e feitos com processos eficazes. Uma das alternativas que as empresas automotivas tiveram para atingir tais objetivos é o uso de sistemas de produção enxuta (SPE). Neste contexto, este trabalho apresenta diretrizes para reprojeto de células de manufaturas enxutas. A aplicação do método é ilustrada por meio do caso de reprojeto de uma célula em uma fábrica de autopeças. A célula foi reprojetada em função da necessidade de adaptação à entrada de um novo produto demandado por um dos principais clientes. Como ponto de partida para o reprojeto, a célula existente foi analisada segundo o nível de uso da produção enxuta, por meio de uma ferramenta de avaliação das práticas de produção enxuta disponível na literatura. Essa aplicação permitiu aperfeiçoar a ferramenta de avaliação e identificar oportunidades de melhoria nas células. Depois disso, o reprojeto seguiu as seguintes etapas: projeto preliminar, projeto detalhado e planejamento da implementação das novas células de manufatura. Contudo, os resultados satisfatórios de um Processo de Desenvolvimento de Produtos (PDP) dependem da comunicação entre as etapas e atividades relativas ao processo e a necessidade de integração interfuncional. / The scenario of the market requires that companies develop innovative products and with effective processes. One of the alternatives that the automotive companies had to achieve these goals is to use the lean production systems. In this context, this paper presentsguidelines to redesign lean manufacturing cells, an auto parts factory. Cells were redesigned according one need to adapt to the entry of a new product demanded by a major customer. As a starting point for redesign, existing cells were analyzed according to the level of use of lean production, using an assessment tool of lean production practices available literature. This application allowed improving the assessment tool and identifies opportunities for improvement in the cells. After that, redesign involved the following steps: preliminary design, defining the detailed design and planning of the implementation of new manufacturing cells. However, a satisfactory result of a PDP depends on the communication between the steps and activities related to the process and the need cross-functional integration.

The conditions for a highly competitive and global market demand great company flexibility, both in its productive, as in its administrative processes. Many companies have beam consider the adoption of Flexible Manufacturing Systems (FMS). In this study, we pretend analyse the integrated manufacturing team implantation and propose alternatives which incorporate several information technologies in order to minimize its limitations, where the production focalization with manufacturing cells is a Just-in-Time (JIT) tool, based in work group technology and decentralized production structures oriented for a speedy product family production, like demand these markets. Observing the production focalization with manufacturing cells importance, this work presents a methodology, that uses the group technology with integrated manufacturing teams to introduce this tool in companies. Moreover, this work presents a automobile company case study where this methodology was applied. The obtained results demonstrate the benefits proportionated by production focalization with manufacturing cells. / As condições de um mercado altamente competitivo e globalizado exigem das empresas uma grande flexibilidade, tanto nos seus processos produtivos, quanto nos seus processos administrativos. Este fato tem levado as empresas a considerar a adoção de Sistemas Flexíveis de Manufatura (SFM). Neste trabalho, analisam-se as características do sistema de manufatura celular, seus objetivos, vantagens e limitações, com focalização na produção com células de manufatura, uma ferramenta originada da produção Just-in-Time (JIT), baseada na tecnologia de grupo e na utilização de estruturas de produção descentralizadas e orientadas para a fabricação de famílias de produtos de forma ágil, como os mercados hoje exigem. Observando a importância da focalização da produção com células de manufatura, este trabalho apresenta uma metodologia que utiliza a tecnologia de grupo, com times integrados de manufatura, para a introdução e gerenciamento dessa ferramenta nas empresas. Além da apresentação do modelo, foi realizado um estudo de caso de uma empresa do ramo automobilístico, onde ocorreu a sua implementação. A partir da análise dos resultados obtidos foi possível ter-se uma idéia clara a respeito das vantagens proporcionadas pela focalização da produção com células de manufatura.

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Business goals of manufacturing systems are typically in a state of constant change and greater rates of change are predicted in the future. Whereas contemporary approaches to the design and construction of these systems often results in inflexible enterprises that cannot readily be tuned to changing business goals. This study has specified and prototyped the use of a new model-driven approach to the design and (re)configuration of"change capable" manufacturing cells. Manufacturing cells represent a typical domain of manufacturing systems in which the existence of inflexible links between tasks and resources can result in sub-optimal performance and an inability to cope with change. The approach is based on a) the use of a semi-generic model of manufacturing cells, that structures and targets the use of CIMOSA modelling constructs (as implemented by the SEWOSA tool) towards producing a requirements specification and conceptual design in the form of a graphical and computer executable model of a particular manufacturing cell, and b) the complementary use of new computer executable modelling constructs and tools, that structure and support the detailed design and runtime operation of a particular cell in the form of an explicit, model-based configuration of cell resources and software components that realise the control processes required in a particular cell. Part of the semi-generic model comprises descriptions of common tasks found in a given domain of manufacturing cells. That part of the model has been captured and formalised by using CIMOSA modelling constructs. A new development of this modelling structure allows pre- modelled tasks to be selected, detailed and organised and suitable resources and reusable control system components (or building blocks) assigned to groups of tasks. Thereby this new approached to designing and building manufacturing cells can facilitate rapid and effective design and reconfiguration of manufacturing cell control systems. General information requirements found during the modelling and real world application of target cells, have also been formally defined and are met by using a suitable modelling structure and specially developed tools. Furthermore, the research has shown how modelled sets of software component building blocks can be specified and implemented as modular, reusable elements of manufacturing cell control systems. New modelling structures have been conceived and fonnalised and examples of their use evaluated under laboratory conditions. The research has also deployed and developed pre-existing enterprise modelling concepts and integration tools, including CIMOSA, STEP, EXPRESS, CIMBIOSYS infrastructure services and component-based software design concepts. This has enable the creation of a prototype tool-set that demonstrates how the concepts can be beneficially applied. The main contributions made by this research are that: a) It proposes and develops an approach to the design of manufacturing cell systems that successfully bridges a previous gap between top-down modelling concepts, methods and tools (that typically support formal modelling of system requirements, tasks and resources) and bottom-up detailed design and build techniques that lead to the operation, control and monitoring of real cells, b) It provides a modelling and implementation structure that 'integrates' the use of a classical enterprise modelling approach (namely CIMOSA), design primarily to support the designers of manufacturing systems, to the emerging component-based design and build concepts, that are becoming popular with software and system vendors.

O objetivo deste trabalho é propor um procedimento híbrido para a solução do problema de formação de células de manufatura com réplicas de máquinas. Constrói-se um modelo matemático de otimização multiobjetivo cujos valores das funções-objetivo são obtidos por meio da execução de um modelo de simulação de eventos discretos, o qual representa um sistema de manufatura celular. Em seguida, geram-se soluções eficientes segundo o conceito de otimalidade de Pareto através de um processo de busca por valores ótimos executado por um algoritmo genético. Três funções-objetivo conflitantes são consideradas: inventário em processo, movimentação intercelular e investimento total em máquinas. Um algoritmo de análise de agrupamento é utilizado para a redução do conjunto final de soluções. A eficácia do procedimento é avaliada mediante a aplicação a dois casos da literatura. Os resultados obtidos são analisados e comentados. Conclui-se, por fim, que o procedimento é capaz de gerar um conjunto de configurações sub-ótimas equivalentes para as células de manufatura, representando aproximadamente os trade-offs entre as três funções-objetivo. / The purpose of this work is to propose a hybrid procedure for solving the manufacturing cell formation problem. A multiobjective optimization model is built whose objective function values are realized by running a discrete-event simulation model, which represents a cellular manufacturing system. Thereafter, efficient solutions are generated following the Pareto optimality concept through a search for optimum values carried out by a genetic algorithm. Three conflicting objective functions are considered, namely, work-in-process, intercell moves and total machine investment. A clustering algorithm is applied to the final solution set so as to reduce it. The procedure efficacy is evaluated via its application to two cases from the literature. The obtained results are analyzed and commented. Finally, it is concluded that the procedure is capable of generating a set of equivalent sub-optimal manufacturing cell configurations, representing approximately the trade-offs betvveen the objective functions adopted.

O objetivo deste trabalho é propor um procedimento híbrido para a solução do problema de formação de células de manufatura com réplicas de máquinas. Constrói-se um modelo matemático de otimização multiobjetivo cujos valores das funções-objetivo são obtidos por meio da execução de um modelo de simulação de eventos discretos, o qual representa um sistema de manufatura celular. Em seguida, geram-se soluções eficientes segundo o conceito de otimalidade de Pareto através de um processo de busca por valores ótimos executado por um algoritmo genético. Três funções-objetivo conflitantes são consideradas: inventário em processo, movimentação intercelular e investimento total em máquinas. Um algoritmo de análise de agrupamento é utilizado para a redução do conjunto final de soluções. A eficácia do procedimento é avaliada mediante a aplicação a dois casos da literatura. Os resultados obtidos são analisados e comentados. Conclui-se, por fim, que o procedimento é capaz de gerar um conjunto de configurações sub-ótimas equivalentes para as células de manufatura, representando aproximadamente os trade-offs entre as três funções-objetivo. / The purpose of this work is to propose a hybrid procedure for solving the manufacturing cell formation problem. A multiobjective optimization model is built whose objective function values are realized by running a discrete-event simulation model, which represents a cellular manufacturing system. Thereafter, efficient solutions are generated following the Pareto optimality concept through a search for optimum values carried out by a genetic algorithm. Three conflicting objective functions are considered, namely, work-in-process, intercell moves and total machine investment. A clustering algorithm is applied to the final solution set so as to reduce it. The procedure efficacy is evaluated via its application to two cases from the literature. The obtained results are analyzed and commented. Finally, it is concluded that the procedure is capable of generating a set of equivalent sub-optimal manufacturing cell configurations, representing approximately the trade-offs betvveen the objective functions adopted.

Orientadores: Helder Anibal Hermini, João Mauricio Rosario / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-14T02:05:53Z (GMT). No. of bitstreams: 1 Paracencio_LuisGustavodeMello_D.pdf: 6716809 bytes, checksum: 4cd9dbc748f0f532de18ea5573d7c2fb (MD5) Previous issue date: 2009 / Resumo: Com o avanço tecnológico na área de engenharia mecatrônica, cada vez mais é necessário acompanhar e aperfeiçoar os estudos. Este trabalho pretende apresentar metodologias para integração de células de manufatura robotizadas com ênfase na modelagem e controle de um dispositivo robótico. O modelo do dispositivo em estudo é composto de três graus de liberdade acionados hidraulicamente, o que permite o posicionamento de uma mesa, onde uma peça possa ser trabalhada por dois robôs industriais, constituindo assim um sistema colaborativo de manufatura. São apresentados estudos referentes à modelagem cinemática e dinâmica, e ao cálculo dos parâmetros do sistema de controle utilizando MatLab-SimulinkTM. Foi desenvolvida uma interface em linguagem LabVIEWTM para aquisição e tratamento de informações provenientes dos sensores das juntas e da implementação do sistema de supervisão e controle. A partir da publicação de uma página de aplicação HTML, a célula colaborativa poderá ser disponibilizada na WEB, permitindo a criação de um laboratório virtual, direcionado à pesquisa científica e tecnológica e com possibilidade de se interligar com outros laboratórios de ensino e pesquisa. Isso permitirá, por exemplo, a realização de experiências e ensino à distância, executando tarefas complexas em tempo real / Abstract: In recent years, with technological advances in mechatronics engineering it is necessary to monitor and improve the studies of these new trends. This research aims to present a methodology to integrate robotic manufacturing cells with emphasis on modeling and controlling of a robotic device. The model of the device of this study consists of three degrees of freedom, driven hydraulically allowing the placement of a table where a piece can be worked by two industrial robots constituting a system of collaborative manufacturing. Studies are presented concerning kinematic and dynamic models and the calculation of parameters of the control system using MatLab-SimulinkTM. An interface was developed in LabVIEWTM language for acquisition and processing of the information from the sensors of the joints and the implementation of the system of supervision and control. Since the publication of an HTML page, a cell collaborative application may be available on the collaborative WEB allowing the creation of a virtual laboratory directed to scientific and technological research and the possibility to connect with other laboratories for teaching and research. For instance, this will allow carrying out the implementation of distance learning experience and performing complex tasks in real time / Doutorado / Mecanica dos Sólidos e Projeto Mecanico / Doutor em Engenharia Mecânica

Thesis (MScEng)-- Stellenbosch University, 2013. / ENGLISH ABSTRACT: This work entails a study of the control software of transportation systems for use in recon gurable manufacturing systems (RMSs). Various control approaches are considered, with the focus on enhancing recon gurability. The work is unique in the sense that the RMS is designed to manufacture small parts/products and is meant to be used in developing countries. Manufacturing systems that can ensure product quality and delivery, are a critical need in countries where the bulk of manufacturing systems function with manual labour. RMSs and holonic manufacturing systems (HMSs) are identi ed as concepts that can potentially compete with manual manufacturing systems. The competing system must thus have a low initial adoption risk, be able to adapt to changing product functionality and demands, and have a comparable throughput rate. IEC61311-3, IEC64199 function block and agent-based control architectures are evaluated. The control software is tested on an experimental conveyor system. The thesis shows that IEC61131-3 and IEC64199 architectures are advantageous in lower levels of control. IEC64199 function blocks provide human interface and development tools and simpli es the distribution of control. The human interface and development tools of IEC64199 function blocks may prove bene cial in providing system monitoring and rapid low skilled adaptation of the control system, increasing recon gurability of systems in under-developed countries. Unfortunately, the low maturity of the development environments for IEC64199 function blocks is a limitation. It is shown that an IEC64199 function block controller becomes complex as the actuator/sensor count exceed 10. Agent-based systems o er reliable control and powerful communication tools but requires a higher level of expertise than IEC64199 function blocks. Agent-based systems are proposed for the core high level control. Complex systems can be controlled with agents and intelligence can be added to control systems in a recon gurable way. For the recon gurable control of large manufacturing systems, agent-based control was found to be superior to IEC64199 function blocks. / AFRIKAANSE OPSOMMING: Hierdie werk behels 'n studie in die beheersagteware van vervoerstelsels vir die gebruik in herkon gureerbare vervaardigingstelsels. Verskeie benaderings word oorweeg, met die fokus op die verbetering van herkon gureerbaarheid. Die werk is uniek in die sin dat die herkon gureerbare vervaardigingstelsel ontwerp is vir die vervaardiging van klein onderdele/produkte en is bedoel vir die gebruik in die ontwikkelende lande. Vervaardigingstelsels wat die kwaliteit van die produk en a ewering kan verseker, is 'n kritieke behoefte in die lande waar die grootste deel van die vervaardiging met handearbeid gedoen word. Herkon gureerbare vervaardigingstelsels en holoniese vervaardigingstelsels is geïdenti seer as konsepte wat moontlik kan meeding met die handmatige produksie-stelsels. Die mededingende stelsel moet dus 'n lae aanvanklike aannemingsrisiko hê, in staat wees om te kan aanpas by die veranderende produk funksionaliteit en aanvraag, en 'n vergelykbare deurvloeikoers kan lewer. IEC61311-3, IEC61499 funksie-blok en agent-gebaseerde beheer argitekture word geëvalueer. Die beheer sagteware is getoets op 'n eksperimentele vervoerband stelsel. Die tesis toon dat IEC61131-3 en IEC61499 argitekture voordelig is in die laër vlakke van beheer. IEC61499 funksie-blokke voorsien menslike koppelvlak en ontwikkelings-gereedskap, en vereenvoudig die verspreiding van beheer. Die menslike koppelvlak en ontwikkelings-gereedskap van die IEC61499 funksieblokke is moontlik voordelig in die voorsiening van stelselmonitering en vinnige laag-geskoolde aanpassing van die beheer stelsel. Dit mag dus moontlik die herkon gureerbaarheid van stelsels, in onder-ontwikkelde lande, verhoog. Die lae vlak van volwassenheid van die ontwikkelingsomgewings vir IEC61499 funksie-blokke verlaag hul bruikbaarheid. Daar word aangetoon dat IEC61499 funksie-blok beheerders baie kompleks raak as die hoeveelheid van aktueerders en sensors meer as 10 raak. Agent-gebaseerde stelsels bied betroubare beheer, en kragtige kommunikasie-gereedskap, maar vereis 'n hoër vlak van kundigheid as IEC61499 funksie-blokke. Agent-gebaseerde stelsels word voorgestel vir die hoëvlak beheer. Komplekse stelsels kan beheer word met agente en intelligensie kan bygevoeg word om stelsels te beheer in 'n herkon gureerbare manier. Dit was gevind dat agent-gebaseerde beheer beter is as IEC61499 funksie-blok beheer vir die herkon gureerbare beheer van groot vervaardigings stelsels.