Made available in DSpace on 2016-06-02T19:50:27Z (GMT). No. of bitstreams: 1 TeseCRNS.pdf: 1772351 bytes, checksum: 17b2dc82dae0e985204bfa2fd68f873b (MD5) Previous issue date: 2005-04-29 / Universidade Federal de Minas Gerais / The management of manufacturing systems have become more complex, once that new products are arising, product demands are uncertain, life cycles get shorter, and a wide variety of products compete for common resources. This thesis deals with the design and planning of discrete manufacturing systems, based on open queueing network models to support the decision making of capacity allocation. As manufacturing systems may be represented by generalized queueing networks, and there are no exact solution methods, here is employed the decomposition approximate method to evaluate the performance of systems under different configurations. It is shown in the thesis how these approximations are suitable and effective to estimate the work-in-process (WIP) and the production leadtime of an actual metallurgical industry queueing network. It is also shown that discrete capacity allocation models, based on the approximations, are effective to evaluate and optimize the performance of the case study under different configurations. Trade-off curves between capacity investment and WIP are generated and are useful not only to support a manager to estimate how much capacity he/she should allocate, but also to decide where it should be allocated in the queueing network. These curves also support the decision making in terms of capacity, if the variability of the external arrivals, the product mix and/or the throughput for the network change. Besides adding capacity, partitioning the facility is another alternative to reduce the system complexity. This thesis also approaches the focused factory design problem, involving the partition of the facility into smaller shops and the capacity allocation in each shop. Again, the decomposition approximations were employed to evaluate the system performance. Despite its importance, this problem has rarely been reported in the literature. In this thesis, the goal is to reduce the system complexity either from the product management point of view or from the workstation management point of view. From the product management point of view, a model whose complexity constraint is na upper limit on the production leadtime variance of the products passing through the network was studied. From the workstation management point of view, the complexity constraint of the model keeps constant the expected waiting time of a product at a workstation, once it waits for being served. It is shown through these models for some instances that the partition of the facility into smaller shops decreases the complexity system without necessary capacity additional investments. Futhermore, sometimes it is possible to keep the network performance (or even to improve it), partitioning the network into smaller shops which need less capacity than the original configuration with a single shop. / A gestão de sistemas de manufatura tem se tornado mais complexa na medida em que novos produtos estão surgindo, a demanda de produtos é incerta, os ciclos de vida são mais curtos e uma grande variedade de produtos competem pelos mesmos recursos. Esta tese trata o projeto e planejamento de sistemas discretos de manufatura, baseados em modelos de redes de filas abertas, para auxiliar no processo de tomada de decisões. Porque sistemas de manufatura podem ser representados por redes de filas genéricas, e não existem métodos exatos de solução, aqui é empregado o método aproximado de decomposição para avaliar o desempenho dos sistemas em diferentes configurações. Mostra-se nesta tese que estas aproximações são adequadas e efetivas para estimar os estoques em processo (WIP) e o leadtime de produção de uma rede de manufatura real de uma indústria metal-mecânica. Mostra-se ainda que os modelos de alocação de capacidade discreta, baseados nestas aproximações, também são efetivos para avaliar e otimizar o desempenho da rede do estudo de caso em diferentes configurações. Curvas de trade-off entre investimento em capacidade e WIP são geradas e são úteis não somente para auxiliar um gerente a estimar quanto alocar de capacidade, mas também para decidir onde alocá-la na rede de filas. As curvas também auxiliam a tomada de decisões em termos de capacidade, se a variabilidade das chegadas externas, o mix de produtos e/ou a taxa de produção da rede mudam. Além de adicionar capacidade, a partição da instalação é outra alternativa para reduzir a complexidade do sistema. Esta tese também aborda o problema de projeto de fábrica focalizada, envolvendo a partição da instalação em subplantas e a alocação de capacidade em cada estação das subplantas. Novamente, as aproximações por decomposição foram utilizadas para avaliar e otimizar o desempenho do sistema. Apesar de sua importância, este problema tem sido muito pouco reportado em literatura. Nesta tese, o objetivo é reduzir a complexidade do sistema do ponto de vista da gestão do produto, ou do ponto de vista da gestão da estação. Do ponto de vista da gestão do produto, é apresentado um modelo cuja restrição de complexidade é um limitante superior para a variância do leadtime dos produtos na rede. Do ponto de vista da gestão da estação, a restrição de complexidade do modelo fixa o tempo médio de espera de um produto na estação, quando há espera. Mostra-se, por meio destes modelos para alguns casos que, a partição da instalação em subplantas reduz a complexidade do sistema, sem necessidade de investimentos adicionais em capacidade. Além disso, algumas vezes, é possível manter (ou até melhorar) o desempenho da rede, particionando-a em subplantas que necessitam de menos capacidade do que a configuração original com uma planta única.

The research in this report seeks to develop a highly flexible geometry station for joining futureBody-in-White (BiW) assemblies. The goal is to eliminate the need for a complete reconstructionof a production line during integration of new car bodies in a contemporary production.Today's BiW production is performed in sequential lines, where joining equipment is arranged ina specific order for each model geometry. An increasing model portfolio forces manufacturers todevelop production systems that allow an integration of new models. Electrified alternatives ofexisting models are now developed and put into production. These models have similarappearance as conventional models, but with a completely different principle of driveline due tothe propulsion. This means that new interfaces and platforms have to be developed and mustnow be integrated into a current production. Today's production lines are not prepared forcoming changes, and current stations can only handle a limited number of variants. Integration ofnew geometries into a contemporary production line is not sufficiently efficient from aproduction perspective. The goal of the future is to make such an integration possible.Initially, current and future production scenarios were studied. Based on this, four types ofproduction scenarios, which a highly flexible geometry station can be integrated into, were set up.An integration can take place in different ways depending on how a highly flexible geometrystation is compounded, therefore, different cases were created and compared in a case study.Internal and external benchmarking of production systems were made to compare the availablesolutions for increasing stations flexibility in a BiW production.As reference for the project, a concept for a highly flexible geometry station has been developedand is therefore described initially before an additional depth has been realized. The furtherconceptualization of a highly flexible geometry in this report is presented in the form of amorphological composition of technologies that can increase a station's flexibility, as well asvisualization of a station principles through layouts and cycle time charts. The result of theanalysis generated several concepts that hold different degrees of capacity, footprint andflexibility. The focus was to achieve a high level of flexibility for integration of new models, withnew geometries, in a current production. The conclusion was that the highly flexible geometrystation can, in a contemporary production, produce independently in low volumes. Alternatively,produce higher volumes when it is integrated as a complement in a novel, not yet implemented,production concept. / Forskningen i denna rapport syftar till att utveckla en högflexibel geometristation för fogning avkommande Body-in-White-karosser (BiW). Målet är att eliminera behovet av en fullständigrekonstruktion av en produktionslinje under integrering av nya bilar i en samtida produktion.Dagens BiW-produktion sker i sekventiella liner, där fogningsutrustning är arrangerad i enspecifik ordning för respektive modellgeometri. Ett ökande antal modellalternativ drivertillverkare till att utveckla produktionskoncept som möjliggör integration av nya modeller.Elektrificerande alternativ till befintliga modeller utvecklas kontinuerligt. Dessa modeller ärutseendemässigt lika de konventionella modellerna, men med en helt annan princip för drivlina.Det innebär att nya gränssnitt och plattformar har tagits fram och måste nu integreras i ennuvarande produktion. Dagens produktionslinjer är inte förberedda för kommande förändringaroch nuvarande geometristationer kan endast hantera ett begränsat antal karosstyper. Integrationav nya karosstyper i en befintlig produktionslinje är inte är tillräckligt effektivt ur ettproduktionsperspektiv. Framtidens mål är att göra en sådan integration möjlig.Inledningsvis studerades nuvarande- och kommande produktionsscenarion. Utifrån det beskrevsfyra produktionstyper, vilket en högflexibel geometristation kan komma att integreras i. Enintegration kan ske på olika vis beroende på hur en högflexibel geometristation tillämpas, därförjämfördes olika fall av det i en Case-studie. En intern och extern benchmarking avproduktionssystem gjordes för att jämföra de lösningar som finns för att öka flexibiliteten i enBiW-produktion.Som referensunderlag till projektet har ett koncept för en högflexibel geometristation tagits framoch är beskrivet inledningsvis innan en ytterligare fördjupning har realiserats.Konceptualiseringen av en högflexibel geometristation i denna rapport är presenterad i form aven morfologisk sammansättning av teknologier som kan öka en stations flexibilitet, samtvisualisering av en principiell station genom layouter och cykeltidsdiagram. Resultatet av analysengenererade flera koncept som innehar olika grad av kapacitet, fabriksyta och flexibilitet. Fokus varatt uppnå en hög flexibilitetsnivå för integration av nya modeller, med nya geometrier, i ennuvarande produktion. Slutsatsen var att den högflexibla geometristationen kan, i en nutidaproduktion, producera självständigt i låga volymer. Alternativt producera högre volymer då denintegreras som ett komplement till ett ännu inte implementerat nytt produktionskoncept. / Die Forschung in diesem Bericht zielt darauf ab, eine hochflexible Geometrie-Station für das Fügen zukünftiger Rohbau-Baugruppen zu entwickeln. Das Ziel ist es, die Notwendigkeit einer vollständigen Rekonstruktion einer Produktionslinie während der Integration neuer Karosserien in einer modernen Produktion zu beseitigen. Die heutige Rohbau Produktion wird in sequenziellen Linien durchgeführt, wobei die einzelnen Fügeverfahren in einer bestimmten Reihenfolge, angepasst an die jeweilige Modellgeometrie, angeordnet sind. Ein zunehmendes Modellportfolio zwingt die Automobilhersteller zur Entwicklung von Produktionssystemen, die eine Integration neuer Modelle ermöglichen. Elektrifizierte Varianten bestehender Fahrzeugmodelle werden nun entwickelt und in Produktion gebracht. Diese Modelle haben ein ähnliches Erscheinungsbild wie herkömmliche Modelle, jedoch mit einem stark veränderten Antriebskonzept. Dies bedeutet, dass neue Schnittstellen und Plattformen entwickelt wurden und nun in eine aktuelle Produktion integriert werden müssen. Heutige Produktionslinien sind nicht auf kommende Änderungen vorbereitet und können nur eine begrenzte Anzahl von Varianten handhaben. Die Integration neuer Geometrien in eine moderne Produktionslinie ist aus Produktionssicht nicht effizient, aber soll in Zukunft das Ziel sein. Zunächst wurden aktuelle und zukünftige Produktionsszenarien untersucht. Darauf aufbauend wurden vier Arten von Produktionsszenarien erarbeitet, in die eine hochflexible Geometriestation integriert werden kann. Je nach Aufbau der Geostation kann eine Integration auf unterschiedliche Art und Weise erfolgen. Daher wurden in einer Fallstudie unterschiedliche Fälle erstellt und verglichen. Ein Benchmarking mit internen und externen Produktionssystemen wurde durchgeführt, um eine größtmöglichste Flexibilität der Stationen in einer Rohbau Produktion zu erzielen. Als Referenz für das Projekt wurde ein Konzept für eine hochflexible Geometriestation entwickelt und im Rahmen der Thesis dokumentiert, bevor eine zusätzliche Tiefe realisiert wurde. Die weitere Konzeptionierung einer hochflexiblen Geometrie-Station wird in Form einer morphologischen Zusammensetzung von Technologien präsentiert. Dieser kann die Flexibilität einer Station erhöhen und zudem die Visualisierung von Stationsprinzipien, beispielsweise durch Layouts oder Zykluszeitdiagramme, fördern. Das Ergebnis der Analyse erzeugte mehrere vi Konzepte, die unterschiedliche Grade an Kapazität, Grundfläche und Flexibilität beinhalteten. Der Fokus lag auf einer hohen Flexibilität bei der Integration neuer Modelle mit neuen Geometrien in einer aktuellen Produktion. Die Schlussfolgerung war, dass die hochflexible Geometriestation in einer zeitgemäßen Produktion in kleinen Stückzahlen produzieren kann. Alternativ ist die Geo-Station auch als Bestandteil eines noch umzusetzenden Produktionskonzepts integrierbar.

A CONWIP (Constant Work-In-Progress) system is basically a hybrid system with a PUSH-PULL interface at the first machine in the line. This research addresses the most general case of a cyclic CONWIP system by incorporating two additional constraints over earlier studies namely; stochastic processing times and limited intermediate storage. One of the main issues in the design of a CONWIP system is the WIP level 'M', to be maintained. This research proposes an iterative procedure to determine this optimal level. The second main issue is the optimization of the line by determining an appropriate job sequence. This research assumes a 'permutational' scheduling policy and proposes an iterative approach to find the best sequence. The approach utilizes a controlled enumerative approach called the Fast Insertion Heuristic (FIH) coupled with a method to appraise the quality of every enumeration at each iteration. This is done by using a modified version of the Floyd's algorithm, to determine the cycle time (or Flow time) of a partial/full solution. The performance measures considered are the Flow time and the Interdeparture time (inverse of throughput). Finally, both the methods suggested for the two subproblems, are tested through computer implementations to reveal their proficiency. / Master of Science

<p dir="ltr">We present a systematic approach for integrating reduced-order models of tableting with upstream pharmaceutical unit operations. This method identifies critical material attributes (CMAs) and process parameters (CPPs) from upstream operations, describing their coupling to both first and second orders, while selecting the appropriate mathematical forms and estimating parameters. The coupling is modeled using normalized bivariate rational functions.</p><p dir="ltr">The approach is demonstrated for dry granulation, a process that enhances powder flowability but compromises tabletability by reducing particle porosity and increasing plastic work. Using a formulation of 10\% w/w acetaminophen and 90\% w/w microcrystalline cellulose, granules with varying densities and size distributions are produced, and tablets of different relative densities are fabricated. This work provides essential insights for end-to-end process integration, control, and optimization of dry granulation and tableting. It also identifies granule properties that predominantly influence the four stages of powder compaction: die filling, compaction, unloading, and ejection.</p><p dir="ltr">Furthermore, we examine the effects of excipients such as lubricants (magnesium stearate) and glidants (silica) on tablet critical quality attributes (CQAs) in continuous manufacturing. Lubricants were found to affect all compaction stages, with sensitivity to mixing time, while glidants influenced bulk density and tensile strength without significantly impacting tablet density or compaction force. Reduced-order models are developed to predict tablet weight, density, and tensile strength based on excipient concentration and mixing time. These models are integral to implementing real-time control under the quality-by-control paradigm.</p>

The forming of an assembly system is a complex task, which should be considered as never ending. In order to successfully plan and implement an assembly system it is of vital importance that the obstacles and preconditions that have an impact on the system are identified and evaluated. This together with the necessary support activities and the attributes of the product to be assembled constitutes the starting point for the forming of the assembly system. The aim of this thesis is to link the theoretical findings with the issues stated above, and through this explain a best practice approach when forming the assembly system. The theoretical work aims at describing the nature and activities within assembly and manufacturing systems and explains these in three different levels of strategies divided into Manufacturing strategies, Layout, material flow and design strategies and finally Logistic, material handling and quality strategies. Then the obstacles and preconditions found are discussed and evaluated which set the basis for the forming of the assembly system and by linking these with the relevant theory, conceptual design proposals for the assembly system and the Logistic support system are formed. These are then evaluated and finally a proposal for the detailed layout of the assembly system is given. This proposal is then to be used as a guideline for the company Aercrete when forming their assembly system.

<p>The forming of an assembly system is a complex task, which should be considered as never ending. In order to successfully plan and implement an assembly system it is of vital importance that the obstacles and preconditions that have an impact on the system are identified and evaluated. This together with the necessary support activities and the attributes of the product to be assembled constitutes the starting point for the forming of the assembly system.</p><p>The aim of this thesis is to link the theoretical findings with the issues stated above, and through this explain a best practice approach when forming the assembly system. The theoretical work aims at describing the nature and activities within assembly and manufacturing systems and explains these in three different levels of strategies divided into Manufacturing strategies, Layout, material flow and design strategies and finally Logistic, material handling and quality strategies. Then the obstacles and preconditions found are discussed and evaluated which set the basis for the forming of the assembly system and by linking these with the relevant theory, conceptual design proposals for the assembly system and the Logistic support system are formed.</p><p>These are then evaluated and finally a proposal for the detailed layout of the assembly system is given. This proposal is then to be used as a guideline for the company Aercrete when forming their assembly system.</p>

Les travaux proposés dans cette thèse s’intéressent à la commande et la surveillance d’une classe particulière de systèmes de production : les systèmes manufacturiers à contraintes de temps de séjour. Nous supposons dans l'étude que les ressources ont déjà été affectées et que l'ordre des opérations est déjà fixé par le module de planification/ordonnancement. Les hypothèses de fonctionnement répétitif avec et sans postes d'assemblage sont adoptées. De manière assez classique pour ce type de problématique, le formalisme utilisé est celui des Réseaux de Petri P-temporels pour l'étude des instants de débuts et de fins des opérations.Une étude de la robustesse des ateliers manufacturiers à contraintes de temps a été développée. La robustesse est abordée avec et sans modification de la commande relative à la robustesse active et à la robustesse passive respectivement, face aux perturbations temporelles. Un algorithme de calcul d'une borne supérieure de la robustesse passive est présenté. De plus, trois stratégies de commande robuste face aux perturbations temporelles ont été développées.Par ailleurs, l’incertitude dans les systèmes de production manufacturière à été étudié. Notre contribution dans ce cadre porte sur l’intégration des résultats concernant la robustesse dans la génération de symptômes et la classification des comptes rendus associés aux différentes opérations en utilisant la logique floue.Partant d’un système commandé, nous avons présenté en détail une démarche à suivre pour la mise en œuvre d’un modèle de surveillance en se basant sur les chroniques et les arbres de défaillance flous. Cette démarche est appliquée à un atelier de production laitière / The works proposed in this thesis are interested in controlling and monitoring of a particular class of production system : manufacturing job-shops with time constraints. We suppose in the study that the resources are allocated and the operations order is fixed by the module of planning/scheduling. The assumptions of repetitive functioning mode with and without assembling tasks are adopted. For this type of problems, the formalism of P-time Petri nets is used in order to study the operations time constraints.A study of the robustness of the manufacturing workshop to time constraints, has been developed. The robustness is approached with and without control reaction qualified as active robustness and passive robustness respectively, towards time disturbances. A computing algorithm of the upper bound of the passive robustness is presented. In addition, three robust control strategies facing time disturbances were developed.Furthermore, uncertainty in manufacturing systems has been studied. Our contribution in this context is by integration of the analytical knowledge of the robustness in the filtering mechanism of sensors signals that are associated to operations, by using fuzzy logic.Starting from a controlled system, we have presented in detail, a method to be followed for the implementation of a monitoring model based on the chronicles and fuzzy fault tree analysis. This approach is applied to a milk production unit

This master's thesis focuses on the manufacturing system of the company ADOZ, ltd. It describes some systems of production management that leaders of the company want to implement, the company itself, the condition of the default manufacturing system, its deficiencies and motives of the company that led leaders to decide to move to a new space. One section of the thesis describes the space of the new building into which the company wants to move its manufacturing system. The thesis also deals with the calculation of capacity, the quantity of staff, and the size of the areas of the new manufacturing system that should be placed into the new building. The workplaces of the manufacturing system have been divided into various type groups. The relationships between these groups have been analysed, whereupon accurate plans of the placement of workplaces of the new manufacturing system in the manufacturing space of the new building have been created. On the basis of two different attitudes towards calculation of capacity, two different proposals have been created, and a plan of workplace placement has been made individually for each proposal. Both proposals have been compared from a financial viewpoint.

The aim of this work was to design the construction of transport equipment under industrial robot, pallet holder or other equipment. This manipulation device can be moved in one axis on a rigid guide. The device is designed for use in a linear manufacturing system for handling workpieces and tools. It is capable of operating two rows of machines when it is placed in the middle. The main function of this device is to extend the workspace to the carried devices. This type of construction can be used in combination with an industrial robot for other technological tasks such as welding or light machining. The main parts of this device include statically mounted beds that can be stacked behind each other to form optionally long conveyor paths and a positioning plate that moves along the path formed by these beds. An industrial robot, pallet holder or other device is attached to this positioning plate. In addition to the design itself, the thesis also includes a thorough research of the issue, further possibilities of solution in the form of concepts, verification of the structure by means of calculations and simulations and implementation of the solution into a specific production cell.