A necessidade de aumento de produção, da redução de custos e do aumento da qualidade de bens de consumo, tem motivado a constante evolução dos sistemas de produção, migrando os tradicionais sistemas de produção para os modernos e complexos sistemas de manufatura, onde a performance depende da eficiência dos equipamentos e do controle do processo. Por outro lado, a eficiência dos equipamentos depende de sua confiabilidade e manutenabilidade. Neste trabalho a análise de performance é avaliada com o uso de Rede de Petri p-t-Temporizada e através de simulações, incluindo a avaliação da confiabilidade do processo pela análise da otimização da saída do sistema, isto é, quantidade de itens produzidos. Nesta abordagem, uma lógica linear foi desenvolvida e validada utilizando-se uma comparação de resultados das classes de estados do algoritmo proposto com a ferramenta de simulação Tina para um modelo de um esquema produtor consumidor. Apresenta-se um estudo de caso na indústria automotiva, consistindo na análise dos problemas reais enfrentados em uma fábrica de carrocerias, com o uso da Rede de Petri p-t-Temporizada. / The necessity of growing in production, with reduction of costs and improvement in the quality of consumption good, has motivated the constant evolution of production systems, transforming traditional production systems into the modern and complex manufacturing systems, where the performance depends on the efficiency of the equipment and process control. On the other hand, the equipment efficiency depends of their reliability and maintainability. In this work it is proposed a performance evaluation and analysis with the use of p-t- Timed Petri Nets using simulations, including process reliability analysis of the system through the throughput optimization, i.e., produced amount of goods. In this approach, a linear logic statement was developed and validated using a comparison of results of classes of states between the Tina simulation environment and the algorithm considered for a model of a producing consuming system. A case study in the automotive industry is presented, consisting of the analysis of the real problems found in a body shop plant, with the use of Timed Petri Net.

This master’s thesis focusing on design of technological workplaces layout in the workshop of trading and manufacturing company, which offers range of industrial gaskets. The main part of thesis is a detailed analysis, which includes description of the production processes and system in workshop of surface finishes that is scheduled for modernization of spaces. On the basis of this analysis will be using selected methods recommended solutions, which will help decide what types of production equipment purchase and how to deploy technology work in new premises.

I den tillverkande industrin ställer idag kunder krav på korta leveranstider samtidigt som de tillverkande företagen ser tid som en begränsad resurs. Detta innebär att företag tvingas fokusera på att reducera ledtiden och däribland produktionsledtiden. Vid tillverkning av kundanpassade produkter finns inte möjligheten att hålla lager för att snabbt kunna besvara kunders efterfrågan och därför måste dessa företag sträva efter att effektivisera sina processer för att reducera ledtiden. Syftet med detta examensarbete är att undersöka hur ledtiden kan reduceras i ett produktionssystem för kundanpassade produkter. Två frågeställningar har upprättats för att uppfylla syftet: 1. Vilka möjliga orsaker finns till långa ledtider i ett produktionssystem som tillverkar kundanpassade produkter? 2. Hur kan långa ledtider reduceras i ett produktionssystem som tillverkar kundanpassade produkter? För att kunna besvara dessa två frågeställningar har författarna genomfört en fallstudie samt litteraturstudier. I fallstudien har observationer, intervjuer, dokumentstudier samt en följesedel använts för att samla in empiri. Empirin har strukturerats, bl.a. i en värdeflödeskarta, och sedan analyserats mot teori som tagits fram i de litteraturstudier som genomförts. I den analys författarna genomfört har hög nivå av PIA identifierats som huvudorsak till lång ledtid. Vidare har en djupare analys bidragit till att författarna kunnat utröna underliggande orsaker till uppbyggnaden av PIA, fem i fallstudien och fyra i litteraturstudierna. De underliggande orsakerna författarna identifierade både i fallstudien och i litteraturstudierna var varierande materialflöden, pushbaserad materialstyrning, flaskhals och partiformning. Den femte identifierade orsaken i fallstudien var prioriteringsregler. Författarna har sedan tagit fram lösningsalternativ för respektive orsak och därefter diskuterat vilka lösningsalternativ som bäst kunde tillämpas i det studerade produktionssystemet. De lösningsalternativ som valts för att eliminera respektive orsak är omläggning av materialflöden för att minska variationerna, implementering av CONWIP för huvudflödet genom produktionssystemet, eliminering av flaskhals genom att tillämpa ett extra skift för denna maskin, användning av FIFO som prioriteringsregel samt tillämpning av överlappning för batcher av höga kvantiteter. Genom att tillämpa dessa förändringar anser författarna att ledtiden i det studerade produktionssystemet kan reduceras. / In the manufacturing industry today, customers require short lead times at the same time that manufacturing companies consider time as a scarce resource. This means that companies are forced to focus on reducing lead time, including production lead time. When manufacturing customized products there is not possible to keep stock to quickly answer customer demand and therefore, these companies strive to streamline their processes to reduce lead time. The purpose of this study is to examine how the lead time can be reduced in a manufacturing system for customized products. Two issues have been established to answer the purpose of this study: 1. What are the possible reasons for long lead time in a manufacturing system that produces customized products? 2. How can long lead times in a manufacturing system that produces customized products be reduced? In order to answer these two questions, the authors conducted a case study and literature reviews. In the case study observations, interviews, document studies, and a delivery note have been used to collect empirical data. The empirical data have been structured, for example in a value stream map, and then analyzed on theory developed in the conducted literature studies. In the conducted analysis the authors identified a high level of WIP as the main cause of the long lead time. Furthermore, a deeper analysis contributed by the authors have been able to determine the underlying causes for the development of WIP, in the case study five causes were identified and in the literary studies four causes. The underlying causes identified by the authors in the case study as well as in the literature studies were material flow variation, push-based material handling, bottleneck and lot sizing. The fifth identified cause in the case study was priority rules. The authors then developed optional solutions for each cause and then discussed the different solutions that could be applied in the manufacturing system the authors studied. The chosen solution for eliminating each cause is reduce diversion of material flows to reduce variability, implementation of CONWIP for the main flow through the manufacturing system, eliminating the bottleneck by applying an extra shift for this machine, using the FIFO priority rule and the application of overlapping batches of high quantities. By applying these changes, the authors consider that the lead time in the studied manufacturing system can be reduced.

The difficulties in responding to variation in product order mixes and load levels effectively in make to order are known. Most of the existing approaches consider releasing jobs to the shop (input control), changing capacity levels (output control) in a controlled way, order acceptance with different definitions of work load and due date assignment. Controlling the processes, routing options and the order accepting capacity with various tool combinations that will decrease tool loading are not considered properly. However the manufacturing flexibility provided by the computer numerically controlled (CNC) machines, provides both part variety and due date achievement given a reasonable extra capacity. Positive effects of flexibility on the due date achievement of the make to order is shown with a variety of experimental and field studies leaving little doubt. However taking flexibility only as a strategic issue and not considering it as a means of planning and management in either the short term or medium term decisions have been commonplace practice. In this study, benefits of providing three kinds of flexibility, considering order pool and acceptance probability of the new arrivals in a periodic setting, is the focal issue. If the required flexible environment is provided, the necessity to make a detailed job loading, route planning and scheduling will be reduced to a low level and a high shop congestion and due date achievement will be realized simultaneously. A typical realistic shop with a scaled part mix is assumed in the flexibility management modeling and simulation experiments are conducted applying periodical flexibility planning approach. These experiments briefly support the ideas that worth of anticipation is more than plain expectations and flexibility improves robustness.

Le contrôle de systèmes industriels à cause de l’automatisation et la réduction de nombre des opérateurs devient un enjeu crucial. Les systèmes de production automatisés (AMS) sont d’autant plus touchés car une défaillance du programme de contrôle peut réduire considérablement la productivité voire entraîner l’arrêt du système de production. Pour certains de ces systèmes où le partage des ressources est pondérant, la notion de blocage partiel ou global est fréquente et la validation avant implantation est préférable pour réduire les risques.En raison de la capacité des réseaux de Petri à décrire aisément l’exécution concurrente des processus et le partage des ressources, de nombreuses méthodes de vérification d’absence de blocage et de synthèse de contrôleurs basées sur la théorie structurelle ou le graphe d’accessibilité des réseaux de Petri ont été proposées au cours des deux dernières décennies.Traditionnellement, une méthode de prévention de blocage est évaluée selon trois critères de performance: la complexité structurelle, la permissivité comportementale, et la complexité de calcul. Les méthodes fondées sur l’espace d’état aboutissent généralement à un contrôle maximal permissif mais souffrent de l'explosion combinatoire de l'espace d'états. En revanche, les méthodes de synthèse de contrôleurs fondées sur l’analyse structurelle évitent le problème de l’explosion de l’espace d’état mais aboutissent à des superviseurs pouvant restreindre considérablement les comportements admissibles du système. De plus si la théorie structurelle de contrôle de siphons pour la synthèse des superviseurs est mature dans le cas des réseaux de Petri ordinaires, elle est en développement pour les réseaux de Petri généralises. Par ailleurs, la plupart des travaux existants partent du principe que les ressources sont constamment disponibles. Or l’indisponibilité de ressources est en réalité un phénomène ordinaire. Il serait donc judicieux de développer une politique de vérification de blocage qui soit efficace tout en considérant des ressources non fiables.Cette thèse vise principalement à faire face aux limitations mentionnées ci-dessus. Nos principales contributions à la fois théoriques et algorithmiques sont les suivantes.Premièrement, après avoir revisité les conditions de contrôlabilité des siphons (cs–propriété) et précisé les limitations de la max cs- propriété et max’ cs- propriété, nous définissons la max’’ cs-propriété et nous démontrons que cette nouvelle propriété est une condition non seulement suffisante mais aussi nécessaire pour la vivacité de la classe des GS3PR (Generalized Systems of SimpleSequential Processes with Resources).Par la suite nous montrons comment le problème de la vérification de cette propriété et donc la vivacité des GS3PR peut se ramener à la résolution d’un programme linéaire en nombre entiers.Dans une seconde partie, nous proposons une classe de réseaux de Petri appelée M-Nets dotée d’une forte capacité de modélisation des systèmes de production automatisés. En combinant la théorie du contrôle siphon avec la théorie des régions, nous développons une méthode de prévention de blocage ayant un bon compromis entre l'optimalité du comportement et la complexité de calcul. De plus, nous proposons une méthode de synthèse d'un contrôleur maximal permissif pour une sous-classe de réseaux notée b-nets.Enfin, nous proposons dans cette thèse une méthode de conception d’un superviseur de systèmes de production automatisés où les ressources ne sont pas toutes fiables et particulièrement efficace pour la classe des S3PR (Systems of Simple Sequential Processes with Resources). / Because of automation and reduction of the number of operators, the control of industrial systems is becoming a critical issue. For automated manufacturing systems (AMS) where resource sharing is preponderant, the notion of partial or total blocking is frequent and validation before implementation is preferable to reduce the risks.Due to the easy and concise description of the concurrent execution of processes and the resource sharing by Petri nets, many methods to verify deadlock-freeness and to synthesize controllers using structural theory or reachability graph have been proposed over the past two decades.Traditionally, a deadlock control policy can be evaluated by three performance criteria : structural complexity, behavioral permissiveness, and computational complexity. Generally, deadlock control policies based on the state space analysis can approach the maximal permissive behavior, but suffer from the state explosionproblem. On the contrary deadlock control policies based on the structural analysis of Petri nets avoid in general the state explosion problem successfully, but cannot lead to the maximally or near maximally permissive controller. Morover, the current Deadlock control theory based on siphons is fairly mature for ordinary Petri nets,while for generalized Petri nets, it is presently at an early stage.On the other hand, most deadlock control policies based on Petri nets for AMS proceed on the premise that the resources in a system under consideration are reliable. Actually, resource failures are inevitable and common in most AMS, which may also cause processes to halt. Therefore, it is judicious to develop an effective and robust deadlock control policy considering unreliable resources.This thesis aims to cope with the limitations mentioned above. Our main theoretical and algorithmic contributions are the following. Firstly, after revisiting the controllability conditions of siphons and limitations of max and max' controlled-siphon properties, we define the max'' cs property and we prove that this new cs-property is not only sufficient but also a necessary liveness condition forgeneralized systems of simple sequential processes with resources (GS3PR). Moreover, we show how the checking of this property and hence liveness of GS3PR nets can be translaled into resolution of an integer programming (IP) model.Secondly, we propose a class of manufacturing-oriented Petri nets, M-nets for short, with strong modeling capability. Combining siphon control and the theory of regions, we develop a deadlock prevention method that makes a good trade-off between behavioral optimality and computational tractability Moreover, this thesis proposes a maximally permissive control policy for a subclass of Petri nets (calledBéta-nets) based on the token distribution pattern of unmarked siphons.Finally, we propose a designs method for robust liveness-enforcingsupervisors for AMS with unreliable resources appropriate in particular for systems of simple sequential processes with resources(S3PR)

Due to a global increase in competitiveness in manufacturing,companies strive to increase the effectiveness of their manufacturing systems. The new industrial revolution, Industry 4.0, is a consequence inmotion to aid in creating improved manufacturing systems. A common tool within Industry 4.0 is simulation, where one could simulate changes in a virtual representation of a real world system. Discrete Event Simulation (DES) is a tool that has been widely adopted within industries to test manufacturing system changes virtually before implementing them physically. However, there is a need to discover the advantages, disadvantages and barriers to the application of simulation modeling in industry, as well as how to show the value with using the technique. A case study at the global manufacturing company Atlas Copco's plant In Tierp, Sweden has been undertaken with the purpose of using DES to aid a manufacturing plant in improving a manual manufacturing system, and how this could develop the current approach to a more long-term and sustainable one. Process mapping have been used to facilitate better understanding of the system prior to simulation modeling, as a manual system proved to be difficult to map otherwise. The results of this study points to that simulation can provide advantages of that decisions regarding implementation of system improvements could have better basis for being taken, simulation can be used to test system changes virtually to prevent eventual implementation problems, and simulation can be used as a tool to generate long-term solutions. However, disadvantages and barriers were identified as resistance from management in difficulties to convince the value of using simulation, extensive modeling competency required, and lack of the right prerequisites makes simulation modeling implementation more difficult. Further research should focus on uncovering the difficulties and barriers to the implementation of simulation modeling in industry, as this was not widely discussed in existing literature.

A necessidade de aumento de produção, da redução de custos e do aumento da qualidade de bens de consumo, tem motivado a constante evolução dos sistemas de produção, migrando os tradicionais sistemas de produção para os modernos e complexos sistemas de manufatura, onde a performance depende da eficiência dos equipamentos e do controle do processo. Por outro lado, a eficiência dos equipamentos depende de sua confiabilidade e manutenabilidade. Neste trabalho a análise de performance é avaliada com o uso de Rede de Petri p-t-Temporizada e através de simulações, incluindo a avaliação da confiabilidade do processo pela análise da otimização da saída do sistema, isto é, quantidade de itens produzidos. Nesta abordagem, uma lógica linear foi desenvolvida e validada utilizando-se uma comparação de resultados das classes de estados do algoritmo proposto com a ferramenta de simulação Tina para um modelo de um esquema produtor consumidor. Apresenta-se um estudo de caso na indústria automotiva, consistindo na análise dos problemas reais enfrentados em uma fábrica de carrocerias, com o uso da Rede de Petri p-t-Temporizada. / The necessity of growing in production, with reduction of costs and improvement in the quality of consumption good, has motivated the constant evolution of production systems, transforming traditional production systems into the modern and complex manufacturing systems, where the performance depends on the efficiency of the equipment and process control. On the other hand, the equipment efficiency depends of their reliability and maintainability. In this work it is proposed a performance evaluation and analysis with the use of p-t- Timed Petri Nets using simulations, including process reliability analysis of the system through the throughput optimization, i.e., produced amount of goods. In this approach, a linear logic statement was developed and validated using a comparison of results of classes of states between the Tina simulation environment and the algorithm considered for a model of a producing consuming system. A case study in the automotive industry is presented, consisting of the analysis of the real problems found in a body shop plant, with the use of Timed Petri Net.

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

Orientador: Oswaldo Luiz Agostinho / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-18T20:24:28Z (GMT). No. of bitstreams: 1 Perroni_IsaMariadaPenhaMadeira_M.pdf: 6601142 bytes, checksum: 9f1164593c8b5ceacb9522a30fb09f68 (MD5) Previous issue date: 2011 / Resumo: As organizações reconhecem que a integração intra e inter sistemas de manufatura é fundamental para manter-se não apenas competitivo, mas à frente da concorrência. O Sistema de manufatura pode ser visto como o conjunto de relações entre as atividades de Engenharia, Chão de Fábrica, Negócios e Suporte e suas sub atividades e, a sua Integração, entendida como o fluxo sinérgico de informação, pode ser alcançada ao se aplicar recursos de automação. Uma forma de analisar esta integração é através de Índices de Automação. O presente trabalho propõe o desenvolvimento de um modelo para análise de integração da cadeia de suprimentos baseado em índices de automação e para isto, considera a relação entre os sistemas de manufatura da empresa foco e seus primeiro nível de fornecedores. São apresentadas nove arquiteturas, divididas entre arquiteturas com capacidade de integração e arquiteturas sem capacidade de integração entre fornecedor e empresa. A aplicação do modelo de integração da cadeia de suprimento foi em uma Empresa foco do ramo de máquinas e implementos agrícolas e em três fornecedores primários, utilizando um questionário estruturado em 12 questões de múltipla escolha, referentes ao grau de automação das sub atividades de cada sistema de manufatura. A relação de integração da cadeia de suprimentos estudada se enquadra na arquitetura na qual a empresa foco não apresenta integração estrutural no sistema de manufatura e o primeiro nível de fornecedores apresenta integração estrutural das atividades no sistema de manufatura. Na conclusão, são propostas alternativas de integração para a cadeia de suprimentos e sugeridos trabalhos futuros / Abstract: The organizations recognize that integration within and between manufacturing systems is critical to maintain itself not only competitive, but ahead of the competition. The manufacturing system can be viewed as the set of relations between the activities of Engineering, Floor Factory, Business and Support and its sub-activities and their Integration, understood as the flow of synergistic information can be achieved by applying resources automation. A qualitative way to analyze this integration is through indices Automation. This paper proposes the development of a model for analysis of supply chain integration based on levels of automation and for this, consider the relationship between the manufacturing systems of the main company and its suppliers. Nine architectures are presented, divided in architectures with capability of integration between supplier and company and architectures without capability of integration between supplier and company. The application of the model of the supply chain integration will be in a main company of the field of agricultural machinery and implements and in three primary suppliers, using a questionnaire structured in 12 multiple choice questions, regarding to automation degree of the sub-activities of each manufacturing system. The relationship of integration of the studied supply chain fits in the architecture in which the main company has no structural integration in the manufacturing system and the supplier presents the structural integration of activities in the manufacturing system. In the conclusion, integration alternative for the supply chain are proposed and it is suggested future works / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

This diploma thesis describes optimization of assembly working place of cylinder locks brand FAB company ASSA ABLOY Rychnov, s.r.o. Theoretical part deals with universal process for designing manufacturing systems and for description of selected analytical and engineered methods and ergonomics .The practical part shows evaluation of current situation and create new time standards. in accordance with are designed 3 variants of the solution for lay out working place. For each variant is created simulation model, which is explore especially working load and automatic filling machine. The various options are compared by weight valuation and the most optimal is determined by maximal work in process and optimal warehouse supply of input components.