A new algorithm is developed for setting WIP level in production lines. It is a pull policy that determines when to authorize a job to be processed. Dynamic information in the system such as machine failures and repairs, and demand variations are taken into consideration to provide an efficient method to dynamically determine the WIP level. Two types of production lines are examined in this paper. The first is production lines which have few random interruptions and the second production line is exposed to frequent interruptions. Experiment results from these two types of production lines illustrate that the new algorithm generates higher service level with lower WIP compared to the CONWIP policy. In addition, the superiority of the new algorithm is more significant when the production line is exposed to frequent random interruptions. / Singapore-MIT Alliance (SMA)

Published Article / This paper presents the work on the development of a digital simulation model for the transportation line in a local automotive manufacturing plant. It describes a structured procedure of data collection, digital design, model building, activity creation, and process simulation using simulation tool Delmia. Based on the digital simulation model, new alternative concepts of production line planning strategy can be easily integrated into the model to evaluate the cycle time/cost and to optimise the production line. The demonstration result indicates that digital simulation can be used as a powerful tool to reduce planning risk, identify material flow bottlenecks, and to improve throughput and knowledge share within the company.

In any developing country an increasingly higher demand for electricity supply exists. South Africa experienced load shedding during late 2007 and early 2008 and again in 2014 due to a supply shortfall. New power stations are being built to increase the capacity of the national power grid. However this is a lengthy process. Demand Side Management (DSM) was adopted by Eskom’s Integrated Demand Management (IDM) division. DSM is a short-term solution to stabilise the national grid in South Africa by managing the electricity demand on the consumer’s or client’s side. DSM aims to reduce the electricity consumption with immediate results in the short-term. DSM projects were successfully implemented at nine South African cement factories since 2012. Cement factories are ideal for the implementation of DSM projects for the following reasons: cement factories are energy intensive; have adequate reserve production capacity; sufficient storage capacity and interruptible production schedules. The aim of this study is to analyse the effect of DSM projects at South African cement factories. A detailed understanding of the cement production process is a prerequisite. Therefore a critical review of energy utilisation in the cement industry was conducted. Previous work done in the cement production field is evaluated to identify the possible literature shortfall on DSM projects. A set of five distinctive parameters was derived from the literature survey to quantify the possible effects of DSM projects at cement factories. The parameters are demand reduction and electricity cost; production targets; infrastructure; product quality and sustainability. One cement factory, Factory #1, was selected as a primary case study for the analysis model. Factory #1 was used to determine and quantify the effects of DSM projects at cement factories. A simulation was developed to verify the analysis model outcome. DSM projects were implemented at various factories in South Africa and the results from nine sites were used to validate the aim of this study. The study concluded that most DSM projects at South African cement factories were sustainable. Both the electricity supplier and the factories benefitted from the projects. The funding received from Eskom to implement DSM projects is a short-term initiative. However, sustainability of DSM projects is made possible in the long-term by the substantial electricity cost savings on the client’s or factory’s side. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

In any developing country an increasingly higher demand for electricity supply exists. South Africa experienced load shedding during late 2007 and early 2008 and again in 2014 due to a supply shortfall. New power stations are being built to increase the capacity of the national power grid. However this is a lengthy process. Demand Side Management (DSM) was adopted by Eskom’s Integrated Demand Management (IDM) division. DSM is a short-term solution to stabilise the national grid in South Africa by managing the electricity demand on the consumer’s or client’s side. DSM aims to reduce the electricity consumption with immediate results in the short-term. DSM projects were successfully implemented at nine South African cement factories since 2012. Cement factories are ideal for the implementation of DSM projects for the following reasons: cement factories are energy intensive; have adequate reserve production capacity; sufficient storage capacity and interruptible production schedules. The aim of this study is to analyse the effect of DSM projects at South African cement factories. A detailed understanding of the cement production process is a prerequisite. Therefore a critical review of energy utilisation in the cement industry was conducted. Previous work done in the cement production field is evaluated to identify the possible literature shortfall on DSM projects. A set of five distinctive parameters was derived from the literature survey to quantify the possible effects of DSM projects at cement factories. The parameters are demand reduction and electricity cost; production targets; infrastructure; product quality and sustainability. One cement factory, Factory #1, was selected as a primary case study for the analysis model. Factory #1 was used to determine and quantify the effects of DSM projects at cement factories. A simulation was developed to verify the analysis model outcome. DSM projects were implemented at various factories in South Africa and the results from nine sites were used to validate the aim of this study. The study concluded that most DSM projects at South African cement factories were sustainable. Both the electricity supplier and the factories benefitted from the projects. The funding received from Eskom to implement DSM projects is a short-term initiative. However, sustainability of DSM projects is made possible in the long-term by the substantial electricity cost savings on the client’s or factory’s side. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

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Simulation is often used to model production processes with the aim of understanding and improving them. In many cases, however, information produced by simulation is not detailed enough and can be misinterpreted. The use of visualization in combination with simulation can provide project participants with a detailed-level model to prevent misinterpretation of information and to understand the production process. The purpose of this research is to automate the visualization process as a post-simulation tool through sharing interactive information between simulation and visualization. The proposed methodology has been applied to the production line of modular buildings with the output of lean, simulation, and visualization in the form of animation. Based on the new scheduling developed by applying lean principles, a simulation model was built and its output was extracted to an ASCII file used to build 3D visualization developed using Maxscript in 3D Studio Max for automation of visualization process. / Construction Engineering and Management

Diploma thesis is focused on implementation of logistics system Milk Run for automotive lines in selected manufacturing company, which allows to deliver raw material for production effectively and on time. The theoretical part deals with the logistics principles, which are supporting lean manufacturing. The practical part is focused mainly on description of new supplying process and steps needed for implementation of Milk Run system in the company. The thesis is concluded with evaluation of project’s expected benefits.

The aim of this thesis is to design a production line for manufacturing of light transmitting bricks LiCrete. This brick is a special interior design component which is made of concrete and light transmitting parts. It’s manufactured by casting into the dismountable molds. The research part explains manufacturing technology and possibilities to build production line. The concept solution part is about two concepts of production line and about a few ways how to integrate vibration machine into the line. Main part of the thesis describes mechanical design solution with focus on manipulators and vibration part. Last part of the thesis is about design of automation integration into the production line.

This diploma thesis is engaged with innovation technology of production machine parts from current production line Debako to the new machining centre Makino A71, which includes the change of technologic process, the tool equipment, creation of CNC program, economical analysis and so on.

The topic of this diploma thesis was chosen by Valeo Compressor Europe Company. The aim is to propose an automation of the production line for grinding of a compressor part. The part is internally termed “Cylinder,” and it is an integral part of a new type of a rotational compressor for air-conditioning units of automobiles. The diploma thesis includes a complete proposal for the automation of workplace. The current state, the proposal of the concept, technical specification of the project, and the choice of a suitable supplier and economical assessment are included. The data were provided by Valeo Compressor Europe Company.