The rapid rise in global population and market demands have mandated industries to introduce better and quality products to meet up their rushing needs. However, achiev-ing such goals need optimal production system and robust strategies. Exploring in depth it can be visualized that most of the manufacturing set ups suffers losses or relatively lower benefits due to improper and high wastages. Hence it is very important for man-ufacturing industries to explore the techniques which help them to improve their pro-duction system. The key techniques from Lean Manufacturing (LM) such as Value Stream Mapping (VSM) and Ishikawa diagram were explored in this work for enhanc-ing production capacity, reducing rework, reducing wastages and arriving to a well-defined optimal process flow which in turn help in achieving higher productivity. How-ever, the implementation of Lean and Value stream mapping depends on the production scale and has its own significance to different manufacturing setup. With that motive, in this thesis work the emphasis was made on exploring VSM technique for better pro-duction optimization in manufacturing sector.

Due to the deterministic nature of manufacturing processes, measuring important process parameters and performing timely adjustment is an effective way to improve manufacturing efficiency and quality. In-process measurement is such a method. It is capable of monitoring manufacturing processes in real time. However, the current information flow between different manufacturing processes is segmented due to the lack of a consolidated data model to represent sufficient information of a product. This directly results in segmented process planning for in-process measurement. The establishment of STEP (STandard for Exchange of Product data) offers manufacturers a new method to exchange product data through the entire product lifecycle. As an extension to STEP, STEP-NC provides the potential to finally close the gap between design and manufacturing in the drive for a complete and integrated product development environment. The STEP/STEP-NC data model is a long overdue improvement in the domain of process planning for Computer Numerical Controlled (CNC) machining in the industry where G-codes have been in use for more than half a century. STEP/STEP-NC brings richer information to the CNC machining industry presenting an opportunity for the development of more intelligent, interoperable and informative machining processes. The research work documented in this thesis introduces a consolidated STEP/STEP-NC data model and system for an automatic and integrated process planning system for machining, in-process measurement, and feedback. This research first developed the current STEP/STEP-NC data model with new definitions covering tolerance requirement information, and measurement operation information. A mechanism to link tolerance requirements and machining feature information was also developed to provide the crucial connection between machining and measurement. With sufficient information provided by the proposed STEP data model, the concept of an integrated process planning system was conceived to carry out automated process planning for machining and in-process measurement. The system is able to analyse and select critical tolerance(s) from an input data file, generate measuring operation(s) for each critical tolerance in-between machining operations. Measurement of each critical tolerance is also planned by the developed system including generating, allocating, and sequencing measurement points for each measuring operation. After the measurement results of each measuring operation are collected, the system analyses the results and provides proper adjustments to the immediate subsequent machining operation(s). A software prototype was developed to test the proposed data model and the integrated process planning and feedback concept. The ultimate goal of performing measurement in a manufacturing system is to gain close control of the machining process based on tolerance requirements and to adjust process errors as they occur. The key issue is to connect machining and tolerance requirements. What to measure and when to measure is another critical issue. This research has made an attempt to address these issues in order to realize a long-awaited paradigm of automatic placement of measurement procedures in-between machining operations and provide automated process-intermittent feedback to the machining process.

No description available.

Ce travail de recherche traite un problème qui joue un rôle très important pour le succès desprogrammes de fabrication : le tolérancement tridimensionnel, essentiel pour définir la géométried'une pièce mécanique assurant sa meilleure fonctionnalité dans un assemblage avec uneprécision optimale.Une méthode des chaînes de cotes angulaires tridimensionnelles a été développée. Cette méthodepermet d’une part l’optimisation du calcul des dispersions angulaires tridimensionnelles etd’autre part de valider la gamme de fabrication par la vérification du respect des tolérancesimposées par le bureau d’études en tenant compte des précisions des procédés utilisés.Cette étude est basée sur l’analyse de deux fonctions paramétrées qui sont étudiées pourdéterminer le défaut fabriqué : le défaut angulaire et la longueur projetée. Le défaut angulairereprésente le cumul des défauts angulaires générés par le processus de fabrication de la pièce. Lesdéfauts angulaires sont déterminés en fonction de la précision des machines outils. La longueurprojetée de la surface tolérancée est une caractéristique qui dépend uniquement de la forme de lasurface.Ensuite, à partir de ces deux fonctions paramétrées, le défaut fabriqué est déterminé puiscomparé avec la condition fonctionnelle afin de vérifier si la gamme choisie permet en fin duprocessus de fabrication de donner une pièce conforme. / To verify the capacity of a manufacturing process to make the corresponding parts it is necessaryto simulate the defects that it generates and to analyze the correspondence of produced parts withthe functional tolerances. In order to check the capability of a manufacturing process to carry outsuitable parts, it is necessary to analyze each functional tolerance.The main objective of our work is to define a methodology of tolerancing analysis. Thedeveloped method allows to determine the manufacturing tolerances in the case of angular chainsof dimensions and to check its correspondence with the functional tolerances.The objective of this work is to analyze two parameterized functions: the angular defect and theprojected length of the toleranced surface. The angular defect represents the angular defectgenerated by the manufacturing process. It is determined according to the machine toolsprecision. We consider only the geometrical defects, making the assumption that the form defectsare negligible. The projected length of toleranced surface is a characteristic which depends onlyon the form of surface.The manufactured defect is determined from these two parameterized functions. Then it will becompared with the functional condition in order to check if the selected machining range allows,at end of the manufacturing process, to give a suitable part.

Manufatura aditiva é um processo de fabricação de objetos que tem chamado a atenção de acadêmicos, empresas e órgãos de governo. Alguns setores específicos possuem demandas que podem ser mais bem atendidas com a utilização da manufatura aditiva na produção de peças de alto valor agregado. O problema prático que motiva a realização deste trabalho é a dificuldade enfrentada pelas empresas em avaliar as tecnologias de manufatura aditiva existentes para decisão de adoção ou não adoção delas em seus fluxos produtivos. A análise da situação atual na literatura indica que falta um modelo de processo específico de avaliação para adoção da manufatura aditiva na indústria de alto valor agregado. Visando preencher essa lacuna e propor uma solução para o problema identificado, este trabalho tem como objetivo a definição de um modelo de processo específico de avaliação para adoção de manufatura aditiva na indústria de alto valor agregado. Tal modelo é desenvolvido a partir de modelos de processo existentes para avaliar a adoção de outras tecnologias de manufatura avançada (Advanced Manufaturing Technologies - AMTs) e do levantamento das características específicas da manufatura aditiva. O modelo de processo de avaliação para adoção da manufatura aditiva na indústria de alto valor agregado proposto contempla nove passos para decidir sobre a adoção ou a não adoção da manufatura aditiva. A aplicabilidade do modelo proposto foi avaliada por meio de entrevistas com especialistas. A avaliação dos resultados indica que os passos e as atividades propostos no modelo contribuem para auxiliar na avaliação para adoção da manufatura aditiva na indústria de alto valor agregado. / Additive manufacturing is a manufacturing process that has gained attention of scholars, companies and government bodies. Some specific sectors have demands that can be better met with the use of additive manufacturing to produce high added value parts. The practical problem that motivates this work is the difficulty met by companies in assessing additive manufacturing technologies for decision to adopt or not adopt them in their production flows. The analysis of the current situation in the literature indicates a gap of a specific process model to evaluate the adoption of additive manufacturing in the high added value industry. To fill this gap and to propose a solution for the identified problem, this work has the goal to define a specific process model to evaluate the adoption of additive manufacturing in the high added value industry. This model is developed based on existing process models to evaluate the adoption of other Advanced Manufacturing Technologies and the study of specific characteristics of additive manufacturing. The model proposed contemplates nine steps to decide on the adoption or not adoption of additive manufacturing. The applicability of the proposed model was evaluated through interviews with experts. The evaluation of the results indicates that the steps and the activities proposed in the model contribute to assist in the evaluation of the adoption of additive manufacturing in high added value industry.

<p>This thesis was done at Siemens Industrial Turbomachinery AB in Finspång.</p><p>Placed in the inlet to a steam turbine is a filter, a steam strainer, which separates particles and larger objects from the steam. These particles and objects will cause solid particle erosion in the actual turbine if they pass by. The strainer is exposed to large pressure drops when clogged, i.e., static loads which require a good creep resistance in the material. The temperature of the steam in the turbines is increased in order to deliver more energy; today’s turbines are dimensioned for almost 600°C. The material in parameters, such as the strainer, should also be adjusted to the higher temperatures. Today’s temperature is suspected to be the cause of damage in the strainer because the present material might get brittle at higher temperatures.</p><p>The purpose of the thesis is to find a new material for the strainers and also to find a new concept for how to manufacture them. There are nine sizes of steam strainers but only five of them are exposed to the highest temperatures and pressure drops, which make only these five interesting to examine in this thesis.</p><p>The concepts were chosen according to the method of Ulf Liedholm (1999), Systematic Concept Development. The thesis did not end up with only one concept because not all possible methods were tested but the suggestions are all based on a strainer built out of membranes as before. The discussed methods to join the membranes are EB-welding, laser welding and brazing.</p><p>An investigation to find if it was possible to improve the strength of the strainer by simple design changes and a calculation of what percentage of clogging the strainer would hold for was also done.</p><p>The chosen material was a creep resistant, alloy special steel. Three suggestions on concepts were presented. The improvements in strength from simple changes in design were too small and too costly but are enclosed as an appendix in this report. Calculations on the strength were done without regard taken to fatigue caused by possible vibrations, so-called high cycle fatigue.</p><p>What would be interesting to do as a future work based on this thesis is, of course, to test the three manufacturing methods and evaluate them thoroughly but also to discuss other ways of improving the strength through design changes. These should be done regarding the flow. Also high cycle fatigue should be considered.</p> / <p>Examensarbetet utfördes i Finspång på Siemens Industrial Turbomachinery AB.</p><p>I inloppet till en ångturbin sitter ett filter, en ångsil, som silar bort partiklar och större föremål från ångan. Dessa partiklar och föremål skadar turbinen genom erosion om de tillåts passera. Ångsilen i sig utsätts för stora tryckfall när den blir igensatt, vilket kräver god krypresistans i materialet. För att kunna leverera allt mer energi utvecklas ångturbiner som kan arbeta vid allt högre ångtemperaturer. De som konstrueras idag dimensioneras för närmare 600 °C. Då måste även materialet i detaljer, som silen, anpassas. De temperaturer som används idag misstänks vara en orsak till skador på silarna eftersom nuvarande material kan bli sprött då temperaturen stiger.</p><p>Syftet med arbetet är att välja ett nytt material till ångsilarna samt att finna nya koncept för hur ångsilen kan tillverkas. Nio storlekar på ångsilar finns men bara fem av dessa används vid högsta temperatur och tryck och därför har enbart dessa fem använts vid beräkningar i detta examensarbete.</p><p>Koncept valdes enligt Liedholms (1999) metod, Systematisk Konceptutveckling. Istället för ett slutligt koncept lämnas istället tre förslag. Detta görs då de olika förslagen inte har testats ordentligt. Samtliga tre förslag är baserade på den typen av sil uppbyggd av membran som används idag men med nya metoder att sammanfoga membranen med. Metoderna är EB-svetsning, lasersvetsning och vakuumlödning.</p><p>En undersökning om det var ekonomiskt rimligt att förbättra hållfastheten genom enkla designändringar samt en beräkning över hur stor igensättning silen klarar gjordes.</p><p>Materialet som valdes var ett krypresistant, legerat specialstål. De tre förslagen på koncept lades fram. Designändringarna gav inte det resultat som det hade hoppats på och var framförallt för dyra att genomföra. Hållfasthetsberäkningar gjordes utan hänsyn till utmattning på grund av eventuella vibrationer, så kallad högcykelutmattning.</p><p>Som framtida arbete med detta examensarbete som språngbräda rekommenderas i första hand att testa de föreslagna metoderna för sammanfogning av membranen men även djupare diskussioner kring hur hållfastheten skulle kunna förbättras genom designförändringar borde tas. Dessa skulle kunna genomföras med avseende på flödet. Även högcykelutmattning, HCF, borde undersökas.</p>

Significant research has been initiated recently to devise control strategies that could predict and compensate manufacturing errors using so called explicit Stream-of-Variation(SoV) models that relate process parameters in a Multistage Manufacturing Process (MMP) with product quality. This doctoral dissertation addresses several important scientific and engineering problems that will significantly advance the model-based, active control of quality in MMPs. First, we will formally introduce and study the new concept of compensability in MMPs, analogous to the concept of controllability in the traditional control theory. The compensability in an MMP is introduced as the property denoting one’s ability to compensate the errors in quality characteristics of the workpiece, given the allocation and character of measurements and controllable tooling. The notions of “within-station” and “between-station” compensability are also introduced to describe the ability to compensate upstream product errors within a given operation or between arbitrarily selected operations, respectively. The previous research also failed to concurrently utilize the historical and on-line measurements of product key characteristics for active model-based quality control. This dissertation will explore the possibilities of merging the well-known Run-to-Run (RtR) quality control methods with the model-based feed-forward process control methods. The novel method is applied to the problem of control of multi-layer overlay errors in lithography processes in semiconductor manufacturing. In this work, we first devised a multi-layer overlay model to describe the introduction and flow of overlay errors from one layer to the next, which was then used to pursue a unified approach to RtR and feedforward compensation of overlay errors in the wafer. At last, we extended the existing methodologies by considering inaccurately indentified noise characteristics in the underlying error flow model. This is also a very common situation, since noise characteristics are rarely known with absolute accuracy. We formulated the uncertainty in process noise characteristics using Linear Fractional Transformation (LFT) representation and solved the problem by deriving a robust control law that guaranties the product quality even under the worst case scenario of parametric uncertainties. Theoretical results have been evaluated and demonstrated using a linear state-space model of an actual industrial process for automotive cylinder head machining. / text

This thesis was done at Siemens Industrial Turbomachinery AB in Finspång. Placed in the inlet to a steam turbine is a filter, a steam strainer, which separates particles and larger objects from the steam. These particles and objects will cause solid particle erosion in the actual turbine if they pass by. The strainer is exposed to large pressure drops when clogged, i.e., static loads which require a good creep resistance in the material. The temperature of the steam in the turbines is increased in order to deliver more energy; today’s turbines are dimensioned for almost 600°C. The material in parameters, such as the strainer, should also be adjusted to the higher temperatures. Today’s temperature is suspected to be the cause of damage in the strainer because the present material might get brittle at higher temperatures. The purpose of the thesis is to find a new material for the strainers and also to find a new concept for how to manufacture them. There are nine sizes of steam strainers but only five of them are exposed to the highest temperatures and pressure drops, which make only these five interesting to examine in this thesis. The concepts were chosen according to the method of Ulf Liedholm (1999), Systematic Concept Development. The thesis did not end up with only one concept because not all possible methods were tested but the suggestions are all based on a strainer built out of membranes as before. The discussed methods to join the membranes are EB-welding, laser welding and brazing. An investigation to find if it was possible to improve the strength of the strainer by simple design changes and a calculation of what percentage of clogging the strainer would hold for was also done. The chosen material was a creep resistant, alloy special steel. Three suggestions on concepts were presented. The improvements in strength from simple changes in design were too small and too costly but are enclosed as an appendix in this report. Calculations on the strength were done without regard taken to fatigue caused by possible vibrations, so-called high cycle fatigue. What would be interesting to do as a future work based on this thesis is, of course, to test the three manufacturing methods and evaluate them thoroughly but also to discuss other ways of improving the strength through design changes. These should be done regarding the flow. Also high cycle fatigue should be considered. / Examensarbetet utfördes i Finspång på Siemens Industrial Turbomachinery AB. I inloppet till en ångturbin sitter ett filter, en ångsil, som silar bort partiklar och större föremål från ångan. Dessa partiklar och föremål skadar turbinen genom erosion om de tillåts passera. Ångsilen i sig utsätts för stora tryckfall när den blir igensatt, vilket kräver god krypresistans i materialet. För att kunna leverera allt mer energi utvecklas ångturbiner som kan arbeta vid allt högre ångtemperaturer. De som konstrueras idag dimensioneras för närmare 600 °C. Då måste även materialet i detaljer, som silen, anpassas. De temperaturer som används idag misstänks vara en orsak till skador på silarna eftersom nuvarande material kan bli sprött då temperaturen stiger. Syftet med arbetet är att välja ett nytt material till ångsilarna samt att finna nya koncept för hur ångsilen kan tillverkas. Nio storlekar på ångsilar finns men bara fem av dessa används vid högsta temperatur och tryck och därför har enbart dessa fem använts vid beräkningar i detta examensarbete. Koncept valdes enligt Liedholms (1999) metod, Systematisk Konceptutveckling. Istället för ett slutligt koncept lämnas istället tre förslag. Detta görs då de olika förslagen inte har testats ordentligt. Samtliga tre förslag är baserade på den typen av sil uppbyggd av membran som används idag men med nya metoder att sammanfoga membranen med. Metoderna är EB-svetsning, lasersvetsning och vakuumlödning. En undersökning om det var ekonomiskt rimligt att förbättra hållfastheten genom enkla designändringar samt en beräkning över hur stor igensättning silen klarar gjordes. Materialet som valdes var ett krypresistant, legerat specialstål. De tre förslagen på koncept lades fram. Designändringarna gav inte det resultat som det hade hoppats på och var framförallt för dyra att genomföra. Hållfasthetsberäkningar gjordes utan hänsyn till utmattning på grund av eventuella vibrationer, så kallad högcykelutmattning. Som framtida arbete med detta examensarbete som språngbräda rekommenderas i första hand att testa de föreslagna metoderna för sammanfogning av membranen men även djupare diskussioner kring hur hållfastheten skulle kunna förbättras genom designförändringar borde tas. Dessa skulle kunna genomföras med avseende på flödet. Även högcykelutmattning, HCF, borde undersökas.

Bordetella pertussis is one of two Gram-negative bacteria responsible for causing whooping cough in humans, a highly contagious disease that infects the human upper respiratory tract. Whole-cell and acellular vaccines have been developed but due to side-effects resulting from whole-cell vaccines, acellular vaccines are currently preferred to prevent this disease. A second bacterium known to cause whooping cough is Bordetella parapertussis, but since it causes less aggressive symptoms, only B. pertussis is utilized in the manufacture of the vaccine. One acellular vaccine is based on four virulence factors: pertussis toxin (PT), filamentous hemagglutinin (FHA), pertactin (PRN), and fimbriae (FIM). The focus of this thesis was to explore the use of spectrofluorometry for monitoring and forecasting the performance of the upstream and downstream operations in the PRN purification process at Sanofi Pasteur. The upstream fermentation process includes a series of reactors of increasing volume where the microorganism is grown under controlled conditions. The PRN purification process involves a series of sequential steps for separating this protein from other proteins for later use in the vaccine. The PRN is precipitated in three steps with ammonium sulphate at three different concentrations. The pellet is collected by centrifugation and dissolved in a buffer solution followed by chromatographic separation. The run-through is then ultra-filtered and diafiltered in two separate steps. The resulting concentrate is dissolved in water and subjected to another chromatographic step and diafiltration. The final filtration of PRN involves a pre-filtration and sterile filtration. Finally, the samples are collected for quality control. The objective of this work was to monitor the process at different steps of the upstream and downstream purification process by multi-wavelength fluorescence spectroscopy in combination with multi-variate statistical methods. From the spectra, it was possible to identify fluorescent compounds, such as amino acids and enzyme cofactors, without performing an additional pre-treatment or purification step. Also, the identification of conformational changes in proteins and formation of complexes, such as NAD(P)-enzyme complex, was possible based on the shift in the emission peaks of the compounds identified. These results demonstrated the feasibility of using this tool for qualitative evaluation of the process. Multivariate methods, such as PCA and PLS, were used to extract relevant information and compress the fluorescence data acquired. PCA was effective for correlating variability in the yield of pertactin to a particular fluorescence fingerprint. As a result of the study, it was concluded that a possible source of variability in the productivity that is observed might be a metabolic shift during the fermentation steps that leads to the accumulation of NAD(P)H (or NAD(P)H-enzyme complex) probably due to oxygen transfer limitations. This conclusion was reached after investigating changes in the dissolved oxygen, aeration, agitation, supplementation time and key metabolites (lactate, glucose, glutamine) profiles. The correlation of these parameters with low productivity it was not straightforward; however, some consistencies were observed, for example, high levels of glutamine in batches with low productivity. This fact might be related to the start of the supplementation time, which may be related to the dissolved oxygen, since the addition of the supplement is done manually when an increase of the dissolved oxygen is detected. It is believed that this factor is related to the low production of protein product, such as pertactin. By means of PLS, it was possible to build regression models that allow for predicting the final concentration of pertactin from the fluorescence measurements. The models were built using the new variables obtained from data compression performed with PCA, and the final pertactin concentration measured by a Kjeldahl test. With this method, two regressions were constructed: (i) between NAD(P)H-enzyme complex spectra from the fermenters and pertactin concentration and (ii) between the pertactin fluorescence spectra from the last step of purification and pertactin concentration. A third model was built using the protein content, the NAD(P)H-enzyme complex content in the fermenters and pertactin concentration. Attempts were made to identify the possible enzyme that may bind to NAD(P)H, assumed to be a dehydrogenase. Substrates for different enzymes were employed with the objective of measuring changes in the fluorescence of the characteristic peak for this binding (Ex/Em=280/460 nm). Major changes were detected after addition of the substrates oxaloacetate, ubiquinone and succinate dehydrogenase. Since changes were detected with more than one substrate, it was not possible to unequivocally identify the enzyme; however, the results provide some insight into what may be happening at the metabolic level. The work carried out in this thesis involved both analysis of samples provided or collected by the industrial sponsor as well as analysis of samples prepared at the University of Waterloo for measurement, interpretation and calibration. The proposed fluorescence-based method was found suitable for assessing protein quantity as well as for providing an indication of possible protein aggregation and conformational changes. Future work will be required to identify the exact source of variability in the production of pertactin, by means of monitoring the evolution of fermentation, NAD(P)H and ATP measurements, and oxidation redox potential assays.

Submitted by Eduardo Murbach Junior null (emurbach@yahoo.com.br) on 2016-04-26T01:22:34Z No. of bitstreams: 1 Avaliação de Ciclo de Vida em Processo de Fabricação de Rolamento.pdf: 4713134 bytes, checksum: a227fc8fe662842ed31c722e2242c43e (MD5) / Approved for entry into archive by Felipe Augusto Arakaki (arakaki@reitoria.unesp.br) on 2016-04-28T12:20:12Z (GMT) No. of bitstreams: 1 murbachjunior_e_me_bauru.pdf: 4713134 bytes, checksum: a227fc8fe662842ed31c722e2242c43e (MD5) / Made available in DSpace on 2016-04-28T12:20:12Z (GMT). No. of bitstreams: 1 murbachjunior_e_me_bauru.pdf: 4713134 bytes, checksum: a227fc8fe662842ed31c722e2242c43e (MD5) Previous issue date: 2016-02-23 / Este trabalho se propôs a realizar Avaliação de Ciclo de Vida em Processo de Fabricação de Rolamento de Agulhas, com intuito de identificar impacto ambiental nas etapas do processo de fabricação para eventual direcionamento de ações de melhorias em ternos ambientais, produtivos, e a título informativo. Foram mapeados processos de fabricação dos componentes do rolamento: anel interno, gaiola plástica de agulhas, agulhas e montagem. Os processos de fabricação apresentaram impactos ambientais nas categorias de combustíveis fósseis, respiráveis inorgânicos, alterações no clima, uso da terra, carcinogênicos, acidificação, ecotoxicidade e minerais, utilizando-se software SimaPro® e o método Eco-Indicator 99. Houve a identificação dos impactos ambientais provenientes de cada etapa do processo de fabricação de forma individual e global. / This scientific research offered to perform Life Cycle Assessment in Needles Bearing Process Manufacturing, with focus to identify environmental impacts in process manufacturing steps to eventual guidance of environmentally improvements actions, productivity, and informative notice as well. Manufacturing process components’ were identified inner ring, plastic cage, needles. The manufacture process presents environmental impacts in categories of fossil fuels, inorganic respirable, climate change, land use, carcinogens, acidification, ecotoxicity, minerals, according to software SimaPro® and method Eco-Indicator 99. The environmental impacts were identified concern to each manufacture process steps as individual and global conception.