A capacidade de reconfiguração de sistemas de manufatura tem sido procurada pelas empresas para assegurar características de agilidade, eficiência e exibilidade para atender as mudanças de tipo/quantidade de produtos, processos, recursos e, além disso, para assegurar a devida reação à ocorrência de falhas. Por outro lado, a Indústria 4.0\" impõe novos desafios para os sistemas de controle, tais como a integração de tecnologias de interação entre homem e máquina em cadeias de valor compondo uma rede de plantas industriais geograficamente dispersas. O controle de sistemas reconfiguráveis de manufatura deve considerar: (i) funcionalidades de sistemas distribuídos e dispersos, tais como agilidade de resposta às mudanças, autonomia e colaboração entre os componentes para alcançar os objetivos do sistema de forma conjunta; (ii) interfaces para sua interoperabilidade e portabilidade; (iii) modularização para facilitar a manutenção, expansão e atualização do sistema, evitando a sobreposição de escopos; e (iv) mecanismos de controle para supervisionar as ações e interações dos componentes, o diagnóstico e a tomada de decisão. O pleno atendimento a estes requisitos não é trivial e formalismos para o desenvolvimento de soluções devem ser adotados. Uma solução é combinar técnicas voltadas para sistema multiagente e holon com arquitetura orientada a serviço através de uma adequada técnica de modelagem usando extensões de rede de Petri: Production Flow Schema e Input Output Place Transition. Portanto, este trabalho prop~oe uma arquitetura de controle e o método de modelagem de seus componentes para sistemas reconfiguráveis de manufatura combinando estas técnicas e considerando os aspectos de personalização, convertibilidade, escalabilidade, modularidade, integrabilidade, diagnosticabilidade, interoperabilidade e colaboração entre os componentes do sistema de controle, inclusive do homem. Um exemplo de aplicação é apresentado para demonstrar a viabilidade da proposta e comprovar os resultados alcançados. / The reconfiguration ability of the manufacturing systems has been approached by companies to ensure agility, efficiency and exibility characteristics to address the changes of type/quantity of products, processes and resources and, furthermore, to ensure proper reaction to the fault occurrence. On the other hand, the\"Industry 4.0\" imposes new challenges for control systems, such as interaction between man and machine into value chains composing a network of geographically dispersed industrial plants. The control of reconfigurable manufacturing systems should consider: (i) functionalities requirements of distributed and disperse systems, such as responsiveness to changes, autonomy and collaboration among components to achieve the global system aim; (ii) interfaces for interoperability and portability; (iii) modularity to facilitate maintenance, expansion and upgrade of the system, avoiding the overlapping of scopes; and (iv) control mechanisms to supervise the actions and interactions among components, diagnosis and decision making. The compliance with these requirements is not trivial and formalisms to develop solutions must be adopted. A solution is combining techniques based on holonic and multi-agent system with service-oriented architecture through appropriate modeling using Petri net extensions: Production Flow Schema and Input Output Place Transition. Therefore, this paper proposes control architecture and a method to model components for reconfigurable manufacturing systems, combining these techniques and considering aspects of customization, convertibility, scalability, modularity, integrability, diagnosability, interoperability and collaboration among control system components, including humans. An application example is presented to demonstrate the feasibility of the proposal and verify the results.

Orientador: Antonio Batocchio / Dissertação (mestrado profissional) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-06T08:19:28Z (GMT). No. of bitstreams: 1 Barbeiro_FranciscoMiguel_M.pdf: 3666365 bytes, checksum: 90bcb4b2a8648ea08f9f8360c1b7ed50 (MD5) Previous issue date: 2005 / Resumo: O Planejamento de Vendas e Operações é um processo integrado de gerenciamento do negócio, que pode gerar vantagem competitiva através de uma visão e entendimento do cenário futuro e do envolvimento de um time multifuncional para definir e executar um conjunto de planos operacionais alinhados de modo a maximizar os resultados do negócio e melhor atender os clientes. Este trabalho tem como objetivo apresentar uma metodologia que suporte a implementação de um Processo de Planejamento de Vendas e Operações e testá-la através de sua aplicação prática numa Divisão de Negócios que atende o mercado de consumo a partir de uma manufatura de produção para estoque. Identifica os fatores relevantes para uma implementação de sucesso, abordando os três elementos básicos do S&OP: i) Pessoas - Uma vez que o processo é gerenciado e operacionalizado por pessoas, estas precisam estar conscientes, treinadas, além de entender o que se espera delas. Precisam, também, operar o processo em conformidade com os princípios aprovados, políticas e procedimentos; ii) Processo - Um processo precisa estar formalizado, com etapas, entradas, saídas, definição de responsabilidades e de medidas de desempenho; iii) Ferramentas - Devem estar disponíveis para suportar as pessoas na execução de suas atividades. Podem incluir hardware, software, manuais e sistemas de comunicação. O trabalho aborda, também, os potenciais benefícios de um processo eficaz de S&OP, bem como suas limitações, demonstrando a melhoria do trabalho em equipe, do serviço aos clientes e da gestão de ativos, obtidos pela implementação do processo na Divisão de Negócio analisada / Abstract: Sales and Operations Planning is an integrated business management process to generate competitive advantage by looking forward, understanding future scenarios and involving a multifunctional team to define and execute a set of operational plans, aligned to maximize the business results and best attend the customers. This project aims to present a methodology to support a Sales and Operations Planning Process implementation and test it through a practical application in Business Division that attends consumer market through make to stock manufacturing. Identifies the relevant factors to a well succeeded implementation, covering S&OP basic elements: i) People - Whatever is a process managed and operated by people, they need to be acknowledgeable, trained and understand what is expected of them. They also need to operate the process in accordance with agreed-upon principles, policies and procedures; ii) Process - A process needs to be formalized, defining process steps, inputs, outputs, roles, responsibilities, and measurements; iii) Tools - Need to be available allowing people to fulfill their part in the process. These tools may include hardware, software, manual and communication systems. This project also wants to discuss Sales and Operations Planning potential benefits and limitations, demonstrating the improvements the Business Division achieved related to teamwork, customer service and asset management, due to the S&OP process implementation / Mestrado / Planejamento e Gestão Estrategica da Manufatura / Mestre em Engenharia Mecânica

Este trabalho tem por objetivo atualizar um Sistema Flexível de Manufatura, (SFM) didático, que devido às suas características construtivas apresentava inúmeras dificuldades de operação e manutenção, necessitando sempre de mão de obra altamente especializada. As dificuldades com a manutenção tornavam o SFM totalmente inoperante para a utilização nas aulas de uma das unidades da escola SENAI, o que prejudicava as atividades práticas, em laboratório, das disciplinas do curso técnico da área de produção. O projeto deste trabalho consistiu em uma reengenharia completa da parte elétrica de um Veículo Guiado Automaticamente (AGV) como também no desenvolvimento de um sistema supervisório, que comanda a comunicação entre os CNCs, AGV e computadores. Após as modificações efetuadas, os alunos das disciplinas da área de produção poderão interagir com o sistema, modificando a logística de produção conforme as necessidades didáticas a serem estudadas. Por outro lado os alunos de automação, por meio do acesso à documentação e à estrutura do sistema de manufatura, poderão desenvolver estudos e possíveis modificações, uma vez que o sistema se tornou mais didático e amigável. / This paper aims to update a didactic Flexible Manufacturing System (FMS) that due to their construction had numerous difficulties in operation and maintenance, and so constantly require manpower to operate and maintain highly specialized. The difficulties with maintaining the SFM became totally irrelevant, for use in the classroom of an unit school SENAI, would hinder the practical activities in the disciplines of laboratory technician course from the production area. The design of this work consisted in re-engineering of the complete electrical part of an Automatically Guided Vehicle (AGV) and development of a supervisory system and communication between the CNCs, AGV and computers. After the modifications to the students of the disciplines of production may interact with the system by modifying the production logistics as required didactic to be studied. Furthermore students automation through access to documentation and structure of the manufacturing system can develop studies and possible changes, since the system became more didactic and friendly.

L'industrie est aujourd'hui, comme elle a toujours été, une pierre angulaire de l'économie pour chaque pays développé. Avoir une base solide en entreprises industrielles est très important parce qu’elles poussent et stimulent tous les autres secteurs de l'économie, et offrent également une grande variété d'emplois qui apporte des bonnes conditions de vie dans de nombreux secteurs de la société. L’augmentation de la concurrence mondiale, l’évolution rapide du marché, la nécessité de créer des entreprises stables avec des usines rentables obligent la mise en oeuvre d’une démarche globale prenant en compte à la fois les aspects techniques, économiques, logistiques et sociétaux lors de la conception d’un système de production innovant. L’objectif de cette thèse est de contribuer au développement d’un concept innovant de Systèmes de Production Reconfigurables et Agiles (SPRA) permettant de s'adapter rapidement et efficacement aux exigences imposées du marché, des clients, de la technologie des procédés, de l’environnement et de la société afin que l’entreprise soit dynamique, compétitive et rentable. Dans ces travaux de thèse, la proposition d'un modèle générique et la caractérisation de ce nouveau type de système de production ont été décrits en utilisant le langage de modélisation des systèmes complexes (SysML : Systems Modeling Language). Ensuite, nous avons développé un processus de reconfiguration qui représente une démarche à suivre pour concevoir et implanter une nouvelle configuration. De plus, un pilotage opérationnel adapté au SPRA a été introduit. Enfin, quelques travaux développés au cours de cette thèse ont été partiellement déployés sur un démonstrateur industriel au sein de la plate-forme AIP-PRIMECA Auvergne. / Industry is, today as it has always been, a cornerstone of the economy for any developed country. Having a strong manufacturing base is very important because it impels and stimulates all the other sectors of the economy. It provides a wide variety of job, which bring higher standards of living to many sectors of society, and builds a strong middle class. Increasing global competition, rapid changes in the marketplace and the need to create stable companies with profitable plants require the implementation of a global approach, taking into account technical, economic, logistic and societal aspects in the design of an innovative manufacturing system. The aim of this dissertation is to contribute to the development of an innovative concept of Reconfigurable and Agile Manufacturing Systems (RAMS) to adapt quickly and effectively to the requirements imposed by markets, customers, technology processes, the environment and society, to ensure that the enterprise is dynamic, competitive and profitable. In this thesis work, the characterization and proposal of a generic model for this new type of manufacturing system have been described using the language of complex systems modeling (SysML: Systems Modeling Language). We have developed a reconfiguration process that represents the approach to follow in the design and implementation of a new configuration. In addition, the operational control of a RAMS has been introduced. Finally, some works developed in this thesis have been partially deployed on an industrial demonstrator within the AIP-PRIMECA Auvergne organisation.

This Master’s thesis is focused on the production system design, analysis material flow of the production system in the company ABC Ltd. Part of it is detection of critical places and proposal for their elimination. The theoretical part contains the basic concepts of production. In the analytical part, there is described a current situation in selected manufacturing segment of company. In the final part, the solutions are designed to help improve the business.

Today's society is characterized by a high degree of change where the manufacturing systems are affected by both internal and external factors. To adapt to current manufacturing requirements in the form of short lead-time, more variants, low and fluctuating volumes, in a cost-efficient manner, new approaches are needed. As the global market and its uncertainties for products and its lifecycles change, a concept called 'reconfigurable manufacturing system' has been developed. The idea is to design a manufacturing system for rapid structural change in both hardware and software to be responsive to capacity and functionality. A company's development towards the concept is often based on a strategy of incremental investments. In this situation, the challenges are to prioritize the right project and maximize the performance as well as the financial efficiency of a multi-approach problem. The report is based on three different issues. Partly how to standardize relevant performance-based metrics to measure current conditions, how new performance-based metrics can be developed in collaboration with reconfigurability characteristics, and set a direction for how decision models can be used to optimize step-based investments. The study is structured as an explorative study with qualitative methods such as semi-structured interviews and document study to get in-depth knowledge. Related literature addresses concepts in search areas such as reconfigurable manufacturing system, key performance indicators, investment decisions, and manufacturing readiness levels. The findings are extracted from interviews and document studies that generate a focal company setting within the automotive industry, which acts as the foundation for further analysis and decisions throughout the thesis. The analysis results in sixteen performance measurements where new measures been created for product flexibility, productionvolume flexibility, material handling flexibility, reconfiguration quality and diagnosability using reconfigurability characteristics. A conceptual decision support model is introduced with an underlying seven-step investment process, analyzing lifecycle cost, risk triggered events in relation to cost, and performance measurements. The discussion chapter describes how different approaches are used during the project that has been revised by internal and external factors. Improvement possibilities regarding method choice and the aspects of credibility, transferability, dependability, and conformability are discussed. Furthermore, the authors argue about the analysis process and how the result has been affected by circumstances and choices. The study concludes that a three-pronged approach is needed to validate the investment decision in terms of system performance changes, cost, and uncertainty. The report also helps to understand which performance-based metrics are relevant for evaluating manufacturing systems based on operational goals and manufacturing requirements.

Due to the changes and improvements that have occurred over the years, the manufacturing sector has evolved. Companies in the 21st-century face changes in the marketplace that are difficult to predict due to international competition and the rapid emergence of new products. To cope, companies must reinvent themselves and design manufacturing systems that seek to produce quality and low-cost products, and respond to the changes that must be faced. These capabilities are encompassed in reconfigurable manufacturing systems (RMS), capable of dealing with uncertainties quickly and economically. On the other hand, production planning with this type of system presents a significant challenge. Although simulation-based optimization techniques have been applied to address certain RMS challenges, only a few studies have applied simulation-based multi-objective optimization to simultaneously address several conflicting design objectives, as is the case in this project. This project aims to investigate some aspects using SBMO that directly affect the performance of a plant and demonstrate the usefulness of the method. / <p>Det finns övrigt digitalt material (t.ex. film-, bild- eller ljudfiler) eller modeller/artefakter tillhörande examensarbetet som ska skickas till arkivet.</p>

Presented PhD thesis aims at development of new methodologies and approaches to reduce lead times in production systems. Therefore the thesis examines in detail the design of new, more comprehensive approaches to shortening lead times. The dissertation describes the methodology of using these approaches in production systems, it is suggested their inclusion in the control structure of production and adequate managerial support for the successful application of these new approaches in the industry is developed. The first part summarizes current knowledge in the field of reducing lead times. The various methods that can be used for reducing lead times are defined and described, from which is selected discrete simulation of manufacturing systems as a suitable method for the purposes of issue development. The next part of this work is therefore devoted to simulation approach to reducing lead times and the factors that affect them, such as processing time, size of the batch, queue lengths, etc. In this part is also discussed the use of information technologies (programming languages, libraries, and software tools) that enable efficient creation of simulation models. The second part is focused on industrial applications implemented to reduce production lead times. Specific simulation analysis deal with, for example, reduction of the lead time for manufacture of surgical instruments, screws, slats, but also transport systems, optimization of production orders input to the production system, the issue of supply, etc. The second part also describes a practical approach to data transfer to / from the simulation model, simulation software connection to the ERP database of enterprise and energy intensity of production. The conclusion summarizes the findings that were detected on the issue of reducing lead times, and within the chosen methodology, simulation of manufacturing processes indicates possible further progress in the research and practical applications.

Industry 4.0 has caused exceptional changes in the industrial world. A relevant breakthrough is the concept of Cyber-Physical Production System (CPPS) which involves a system of interconnected entities with the main objective of achieving flexibility, which is essential for the manufacturing industries to remain competitive due to the actual demand for customization. The project suggests the use of a robot cell distribution called robot island as a solution to address this problem. In the implementation, a virtual model and program will be presented with flexible mobile robots, AGVs and a PLC. All are designed following the three principles of the CPS using RobotStudio and CODESYS to simulate and evaluate the results. The research demonstrates how autonomous, modular, flexible and adaptable to changes in product or production process system is, for example with the integration of the concept of the resource pool and variations in the product characteristics. The resulting executable is made with standardised modules so it can be extrapolated to other manufacturing processes, opening a wide range of possibilities for this island of robots. / <p>Utbytesstudenter</p>

Актуальность темы исследования. Эффективная организация производственной системы является инструментом повышения конкурентоспособности предприятия на рынке. В период активного роста конкуренции и снижения спроса на продукцию наиболее успешными становятся компании способные проявлять гибкость в управлении и нацеленные на снижение себестоимости и оптимизации цикла производства. Для поддержания производственной системы на конкурентоспособном уровне необходимо не только соблюдать качество исполнения производственных регламентов и процессов, но и следовать новым трендам в области организации. Актуальность проблемы повышения эффективности функционирования производственной системы методами бережливого производства подтверждается недостаточной конкурентоспособностью российских предприятий на внешних рынках. В ходе работы рассмотрена эксплуатационная, техническая и экономическая документация. В результате проанализирован процесс производства медных катодов, произведены сметные расчеты расходов на внедрение инструментов бережливого производства, произведена оценка экономической эффективности внедряемых инструментов бережливого производства, рассмотрена текущая производственная ситуация при производстве медных катодов АО «Уралэлектромедь» в ключе применения алгоритма развития производственной системы, основанного на анализе результатов деятельности предприятия с применением «колеса бережливого производства» и позволяющий принимать оперативные управленческое решения и управлять развитием производственной системы. / Relevance of the research topic. Efficient organization of the production system is a tool to improve the competitiveness of enterprises in the market. In the period of active growth of competition and reduction in demand for products, companies that are most capable of flexibility in management and aimed at cost reduction and optimization of the production cycle become the most successful. To maintain the production system at a competitive level, it is necessary not only to comply with the quality of performance of production regulations and processes, but also to follow new trends in the organization. The urgency of the problem of increasing the efficiency of the production system functioning by methods of lean production is confirmed by the lack of competitiveness of Russian enterprises in foreign markets. During the work considered operational, technical and economic documentation. As a result, the copper cathode production process was analyzed, cost estimates for the introduction of lean manufacturing tools were estimated, the economic efficiency of the lean manufacturing tools introduced was evaluated, the current production situation in the production of copper cathodes by Uralelectromed JSC was considered in the key to the application of the development system algorithm based on the analysis results of the enterprise with the use of "lean wheel" and poses olyayuschy take operational decisions and manage the development of the production system.