Submitted by ROBSON FLÁVIO CASTRO null (robson.afl@gmail.com) on 2016-05-04T14:03:14Z No. of bitstreams: 1 ROBSON_CASTRO_AUTOARQUIVAMENTO.pdf: 19394323 bytes, checksum: 7e472e92d451cc588e98cedecc565eba (MD5) / Approved for entry into archive by Juliano Benedito Ferreira (julianoferreira@reitoria.unesp.br) on 2016-05-06T14:50:11Z (GMT) No. of bitstreams: 1 castro_rf_me_bauru.pdf: 19394323 bytes, checksum: 7e472e92d451cc588e98cedecc565eba (MD5) / Made available in DSpace on 2016-05-06T14:50:11Z (GMT). No. of bitstreams: 1 castro_rf_me_bauru.pdf: 19394323 bytes, checksum: 7e472e92d451cc588e98cedecc565eba (MD5) Previous issue date: 2016-03-29 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Por meio de experimentos baseados em simulação computacional, este trabalho tem como objetivo avaliar o desempenho do Sistema de Coordenação de Ordens (SCO) Simplified Drum-Buffer-Rope (S-DBR) aplicado a ambientes de produção para estoque, denominado Make-to-Availability (MTA). Composto por um conjunto de técnicas, o MTA visa maximizar o nível de serviço a partir da garantia de estoques de produtos acabados para pronta entrega. Nesta pesquisa, são criadas derivações do MTA com as retiradas das técnicas Gerenciamento do Pulmão, Priorização pelo Status do Pulmão e Carga Planejada. O desempenho das derivações é comparado com o MTA em sua forma completa. Para tanto, quatro indicadores de desempenho são utilizados: fill rate, estoque em processo, estoque de produtos acabados e tempo de reposição. Quatro cenários foram simulados, variando as taxas médias de demanda e o coeficiente de variação dos tempos de processamento. O MTA não obteve o melhor desempenho em nenhum dos indicadores, nos quatro cenários, porém a retirada das técnicas não trouxe melhoras significativas na disponibilidade dos produtos, e em alguns casos aumentou extremamente os níveis de estoque e o tempo de reposição. Ao final as técnicas se mostraram importantes para manter a disponibilidade dos produtos com menores níveis de estoque e menor tempo de reposição. / Through experiments with computer simulation, this work aims to evaluate the performance of an Ordering System Coordinator (OSC), Simplified Drum-Buffer-Rope applied to a make to stock environment, called Make-To-Availability (MTA). Composed of a set of techniques, the MTA aims to maximize the level of service from the supply guarantee for immediate delivery. In this research, MTA derivations are created pulling out the techniques Buffer Management, Status of Buffer Prioritization and Planned Load. The performance of derivations was compared with MTA in its complete form. For this purpose, four performance indicators were utilized: fill rate, work in process, finished goods inventory and reposition time. Four scenarios were simulated, with different median demand rates and the coefficient of variation of the process time. The MTA does not obtain the best performance in any indicator, at the four scenarios, however the pulling out of techniques does not bring significant improvement on product availability, and in some cases, stocks and reposition time greatly increased. In the end, the techniques have shown important to keep the availability of products with lower stocks and smaller reposition time.

The aim of this thesis is to design a conceptual self-propelled forestry winch for removing and skidding in thinning steep terrain. The thesis contains patent search of design solutions the machines using in the field, conceptual design of structural layout, assembly drawing overall concept of the equipment and drawing concept chassis design.

This master thesis deals with a concept of two columned shelf stacker’s upper beam. The first part contains a research of storage systems used in logistics and a description of the shelf stack’s basic parts. The second part is dedicated to the draft of the pulley arrangement with a rope calculation, pulleys and shafts, in the same the draft of the pulley attachment to the rope leading to the counterweights. It is followed by the concept of the couple winch drive ensues synchronized with the electronic cardan. The final part depicts the dynamic analysis of the lifting truck’s movement in the dependence on the load size and distribution respecting the dynamic effect of the counterweight act.

This thesis discusses and demonstrates the benefits of simulating and optimising a manufacturing control system in order to improve flow of production material through a system with high variety low volume output requirements. The need for and factors affecting synchronous flow are also discussed along with the consequences of poor flow and various solutions for overcoming it. A study into and comparison of various planning and control methodologies designed to promote flow of material through a manufacturing system was carried out to identify a suitable system to model. The research objectives are; • Identify the best system to model that will promote flow, • Identify the potential failure mechanisms within that system that exist and have not been yet resolved, • Produce a model that can fully resolve or reduce the probability of the identified failure mechanisms having an effect. This research led to an investigation into the main elements of a Drum-Buffer-Rope (DBR) environment in order to generate a comprehensive description of the requirements for DBR implementation and operation and attempt to improve the limitations that have been identified via the research literature. These requirements have been grouped into three areas, i.e.: a. plant layout and kanban controls, b. planning and control, and c. DBR infrastructure. A DBR model was developed combined with Genetic Algorithms with the aim of maximising the throughput level for an individual product mix. The results of the experiments have identified new knowledge on how DBR processes facilitate and impede material flow synchronisation within high variety/low volume manufacturing environments. The research results were limited to the assumptions made and constraints of the model, this research has highlighted that as such a model becomes more complex it also becomes more volatile and more difficult to control, leading to the conclusions that more research is required by extending the complexity of the model by adding more product mix and system variability to compare results with the results of this research. After which it will be expected that the model will be useful to enable a quick system response to large variations in product demand within the mixed model manufacturing industry.

High variety and low volume manufacturing environment always been a challenge for organisations to maintain their overall performance especially because of the high level of variability induced by ever changing customer demand, high product variety, cycle times, routings and machine failures. All these factors consequences poor flow and degrade the overall organisational performance. For most of the organisations, therefore, process improvement has evidently become the core component for long term survival. The aim of this research here is to develop a methodology for automating operations in process improvement as a part of lean creative problem solving process. To achieve the stated aim, research here has investigated the job sequence and buffer management problem in high variety/low volume manufacturing environment, where lead time and total inventory holding cost are used as operational performance measures. The research here has introduced a novel approach through integration of genetic algorithms based multi-objective combinatorial optimisation and discrete event simulation modelling tool to investigate the effect of variability in high variety/low volume manufacturing by considering the effect of improvement of selected performance measures on each other. Also, proposed methodology works in an iterative manner and allows incorporating changes in different levels of variability. The proposed framework improves over exiting buffer management methodologies, for instance, overcoming the failure modes of drum-buffer-rope system and bringing in the aspect of automation. Also, integration of multi-objective combinatorial optimisation with discrete event simulation allows problem solvers and decision makers to select the solution according to the trade-off between selected performance measures.

published_or_final_version / Sports Science / Master / Master of Science in Sports Science

The usage of statistical methods in the production industry has resulted in quality improvements for several organisations during the last decade. However, advanced statistical methods are still underutilised and underappreciated in quality improvement programs and projects in many companies. Therefore it is of interest to investigate how these methods can be used for quality improvements in the production industry. A case study was conducted at Teufelberger’s wire rope production plant in Wels, Austria. Wire rope type BS 909 was studied by utilising the arsenal of tools and methods that Six Sigma provides, with an emphasis on statistical methods -- especially Design of Experiments. Teufelberger is currently (2016) experiencing diameter issues along the rope and it has been found through customer reclamations and quality controls in the production that the variation in a production lot can be substantial. Furthermore, there is no master setting of process parameters and each operator has their own way of setting and adjusting them, as there are different ways to achieve a product which is within given tolerances. The purpose of this study is to investigate how statistical tools can be applied to minimise variance in a Teufelberger rope manufacturing process, by conducting a case study utilising the quality improvement methodology DMAIC. Experiments were conducted in the following four sub processes which produce input components used during the manufacturing of BS909: KL-A, KL-B, IL and Al. In KL-A the following main effects were identified as significant: Postformers Spin and Postformers Diameter. In KL-B the main effect Postformers Spin was significant. In IL the following main effects were identified as significant: Compacting device, Postformers Spin and Postformers Diameter. In AL the main effect Compacting device was significant. Based on the conclusion derived from analysing these experiments theoretical master setups were created in order to address the variance issue and standardise process parameters. Further verification testing must be conducted in order to verify and tune the proposed master setups before they can be utilised. / Det senaste årtiondet har användningen av statistiska metoder inom tillverkningsindustrin resulterat i kvalitetsförbättringar för flera organisationer men dessa metoder är fortfarande undervärderade och utnyttjas ej till fullo inom program och projekt för kvalitetsförbättringar. Därför är det av intresse att undersöka hur dessa metoder kan användas för kvalitetsförbättringar inom tillverkningsindustrin. Vid en av Teufelbergers produktionsanläggningar av stålvajrar i Wels, Österrike, har en fallstudie med kvalitetsförbättringsmetodiken DMAIC genomförts. Stålvajer typ BS 909 har studerats genom att använda den arsenal av verktyg och metoder som Six Sigma innefattar, med betoning på statistiska metoder och särskilt försöksplanering. Teufelberger hade för tillfället problem med främst diametern av stålvajern. Det har visat sig genom kundreklamationer och kvalitetskontroller i produktionen att variationen i en produktionsserie kan vara betydande. Dessutom finns det ej några dokumenterade optimala inställningar av processparametrar så varje maskinoperatör har sitt eget sätt att ställa in och justera processparametrarna. Detta är möjligt då det finns olika kombinationer av  parameterinställningar som kan ge en produkt som är inom givna toleranser. Syftet med denna studie är att undersöka hur statistikverktyg kan användas för att minimera variansen i en tillverkningsprocess av stålvajer hos företaget Teufelberger, detta genom att utföra en fallstudie med kvalitetsförbättringsmetodiken DMAIC Experiment utfördes i följande fyra processer som producerar ingående komponenter som används vid tillverkningen av BS909: KL-A, KL-B, IL och Al. I processen för KL-A identifierades följande huvudeffekter som aktiva;  Postformers-Spin och Postformers-Diameter. Den enda huvudeffekt som identifierades vara aktiv för KL-B var Postformers-Spin. För IL var följande huvudeffekter aktiva: Compacting device, Postformers-Spin och Postformers-Diameter. I processen AL var endast huvudeffekten Compacting device aktiv. Baserat på det resultat som framkom vid analysen av dessa experiment har nya teoretiskt optimala inställningar beräknats, som förväntas minska variationen i responsvariabeln diameter. De nya rekommenderade inställningarna bör tills vidare kunna fungera som ny standard för produktionen, men verifieringsförsök bör ändå utföras för att bekräfta och finjustera  inställningarna.

Os modelos de programação e controle Constant Work-In-Process (CONWIP) e Drum-Buffer-Rope (DBR) são mecanismos bastante conhecidos na literatura de Planejamento e Controle da Produção, especialmente, pela robustez e bom desempenho. Esses modelos já foram comparados, sobretudo, em ambientes do tipo flow shop. Há muitos trabalhos que apontam o DBR como superior, outros que sugerem equivalência entre ambos e, em menor proporção, casos onde o CONWIP foi melhor. Contudo, estudos comparativos em ambientes mais complexos, como sistemas com montagem, ainda são escassos na literatura. Diante do exposto, a presente tese visa comparar o CONWIP e o DBR em um ambiente de montagem (assembly flow shop) contra pedido. Para tanto, foram desenvolvidos dois modelos de simulação por eventos discretos e um experimento hierárquico-cruzado, com os seguintes fatores: modelo de programação e controle, posição do gargalo, severidade do gargalo e limite de buffer. Os mecanismos foram avaliados quanto aos indicadores tempo médio de fluxo, lead time médio, utilização do gargalo, percentual de ordens atrasadas e atraso médio. Os resultados demonstraram que, para o ambiente em análise, os modelos se mostraram estatisticamente semelhantes, havendo diferenças significativas apenas para a variável tempo médio de fluxo, o que ratifica e estende conclusões de estudos anteriores. Há evidências de que o CONWIP realiza um controle mais efetivo do estoque em processo e não é significativamente afetado pelas diferentes posições do gargalo. Para o CONWIP, os melhores resultados foram identificados quando a restrição estava no início do sistema, enquanto que para o DBR os melhores resultados foram quando o gargalo estava na última estação da linha de fabricação (operação anterior a montagem). / The Constant Work-In-Process (CONWIP) and Drum-Buffer-Rope (DBR) scheduling and control models are well known mechanisms in the Production Planning and Control literature, especially for robustness and good performance. These models have already been compared, especially, to flow shop environments. There are many papers that point to DBR as superior, others that suggest equivalence between both and, less often, cases were CONWIP was better. However, comparative studies in more complex environments, such as assembly systems, are still rare in the literature. Therefore, this thesis aims to compare CONWIP and DBR in a make-to-order assembly flow shop environment. For that, two models of discrete event simulation and a crossed and nested experiment were developed, with the following factors: scheduling and control model, bottleneck position, bottleneck severity and buffer limit. The mechanisms were evaluated with respect to the indicators mean flow time, mean lead time, bottleneck utilization, percentage tardy and mean tardiness. The results showed that, for the environment under analysis, the models were statistically similar, with significant differences only for the variable mean flow time, which ratifies and extends the conclusions from previous studies. There is evidence that CONWIP performs more effective control of order release and is not significantly affected by the different bottleneck positions. For the CONWIP, the best results were identified when the constraint was at the beginning of the system, while for the DBR the best results were when the bottleneck was at the last station of the manufacturing line (before assembly operation).

Le travail présenté dans ce mémoire s'intéresse à la simulation du comportement mécanique de câbles d'ascenseurs. Le but de ce travail est d'élaborer une méthode permettant de simuler le comportement mécanique de tels câbles à moindre coût, et avec une précision suffisante.Dans un premier temps, différentes méthodes permettant de modéliser ou de simuler le comportement de ces câbles ont été comparées, et leurs avantages et inconvénients ont été analysés. Les résultats de modèles analytiques et de simulations éléments finis ont été comparés avec des données expérimentales. Les modèles analytiques considérés dans ce travail présentent un coût de calcul bien moins élevé que les modèles éléments finis, mais n'offrent pas une précision suffisante dans leurs résultats pour simuler le comportement de câbles d'ascenseurs. L'approche éléments finis a été retenue pour cette raison comme la plus adaptée pour simuler ce genre de câbles. Les coûts de calcul liés à cette approche sont cependant très élevés, et demandent la mise en oeuvre de méthodes particulières en vue de les réduire.Afin de réduire les temps de calculs, trois types de méthodes ont été considérées : les méthodes d'homogénéisation, les méta-modèles, et les techniques de réduction de modèle. L'approche de réduction de modèle a été retenue comme la plus appropriée et a été implémentée dans le code de simulation par éléments finis Multifil. Des résultats avec une bonne précision ont été obtenus en utilisant cette méthode, mais les coûts des simulations initiales sur le modèle complet afin d'obtenir un ensemble de solutions permettant de construire une base réduite apparaissent trop élevés dès qu'il s'agit de traiter des câbles de longueurs importantes. Pour remédier à ce problème, une méthode de réduction par tronçon a été formulée et implémentée. Cette méthode tire parti de la structure périodique du câble et permet d'identifier a base de réduction seulement sur un motif périodique élémentaire. Cette base est ensuite utilisée pour représenter la solution sur l'ensemble d'un câble composé de plusieurs tronçons.Le coût des multiplications matricielles nécessaires pour transformer le système linéaire du problème initial, en système linéaire réduit reste cependant trop important pour obtenir un gain significatif, en particulier dans le contexte de la résolution d'un problème non-linéaire. Pour pallier cette difficulté, une technique supplémentaire, appelée ``Discrete Empirical Interpolation Method'' (DEIM), a été mise en oeuvre avec succès, et a permis d'obtenir au final une réduction du coût de calcul d'un facteur 4. / The work presented in this dissertation is focused on the simulation of the mechanical behaviour of lift's wire ropes. The aim of the work is to elaborate a method to simulate the mechanical behaviour of such wire ropes with low computational cost and sufficient accuracy.First of all, several methods to model or simulate wire ropes have been compared and their weak and strong points have been highlighted. Analytical and finite element methods have been compared with experimental tests. It was concluded that analytical methods considered in this work have a lower computational cost than finite element methods, but the results obtained using them are not accurate enough to simulate lift wire ropes. Therefore, finite element methods have been considered as the most appropriate to simulate these wire ropes. However, their computational cost is high so some methods to reduce it must be applied.In order to reduce the computational time, three type of methods have been considered: homogenization, metamodeling and model order reduction. Model order reduction technique was chosen as the most adequate method and it was implemented in the wire rope finite element simulation program Multifil. Accurate results have been obtained, however the computational cost needed by initial simulations to get the snapshots used to define a reduce basis was too high for long wire ropes. To solve this problem, a sectionwise reduction method was proposed and implemented. This formulation takes advantage of the periodic structure of wire ropes: the reduced basis is identified only on a reference elementary section and used for all repetitive sections of a multi-section wire rope. The computational cost induced by the multiplication of matrices in order to transform the linear system of the initial problem into the linear system of the reduced problem was shown to remain too high, particularly in the context of the solving of a non-linear problem, to allow the global computational time to be significantly decreased using the proposed techniques. To overcome this difficulty, an additional technique, namely the so-called Discrete Empirical Interpolation Method (DEIM) was successfully implemented and tested, allowing a time reduction factor of 4 to be obtained.

ABSTRACT Self-supply is widely reported across various contexts, filling gaps left by other forms of water supply provision. This research assesses low-cost household groundwater supply technologies in markets in developing country contexts of sub-Saharan Africa and Latin America, with a focus on the potential for improving Self-supply technology implementation and markets in sub-Saharan Africa. Specifically, a mature and unsubsidized Self-supply market for Pitcher Pump systems (suction pumps fitted onto hand-driven boreholes) is studied in an urban context in Madagascar, EMAS low-cost water supply technologies are assessed in Bolivia, and a technical comparison is completed with manual EMAS Pumps and family versions of the Rope Pump in Uganda. In Madagascar, locally manufactured Pitcher Pump systems are widely provided by the local private sector, enabling households to access shallow groundwater. This market has developed over several decades, reaching a level of maturity and scale, with 9000 of these systems estimated to be in use in the eastern port city of Tamatave. The market is supplied by more than 50 small businesses that manufacture and install the systems at lower cost (US$35-100) than a connection to the piped water supply system. Mixed methods are used to assess the performance of the Pitcher Pump systems and characteristics of the market. Discussion includes a description of the manufacturing process and sales network that supply Pitcher Pump systems, environmental health concerns related to water quality, pump performance and system management. The research additionally considers the potential of EMAS low-cost household water supply technologies in accelerating Self-supply in sub-Saharan Africa, and consists of a field assessment of EMAS groundwater supply systems (handpumps on manually-driven boreholes) and rainwater harvesting systems as used at the household level in Bolivia, focusing on user experiences and the medium/long-term sustainability of the pump (cost, functionality, etc.). The EMAS Pump is a low-cost manual water-lifting device appropriate for use at the household level. Developed in the 1980s, the EMAS Pump has been marketed extensively for local manufacture and use at the household level in Bolivia, and marketed to a lesser extent in other developing countries (mainly in South and Central America). The simple design of the EMAS Pump, using materials commonly found locally in developing countries, allows for it to be fabricated in many rural developing community contexts. Its capability for pumping from significant depths to heights above the pump head makes it quite versatile (e.g. for pumping to household tanks, reservoirs at higher elevations, or for installing multiple pumps on wells). A survey/inspection of 79 EMAS Pumps on household water supply systems in areas of three regions of Bolivia (La Paz, Santa Cruz and Beni regions) showed nearly all EMAS Pumps (78 out of 79) to be operational. 85% of these operational pumps were found to be functioning normally, including 72% that were reported to have been installed eleven or more years earlier. It is shown that rural households in Bolivia are able to maintain EMAS Pumps. The EMAS Pump can be installed and repaired by local technicians, and numerous examples were seen of small groups of local technicians that operate small businesses installing and repairing such systems. The cost of a new EMAS Pump was reported by users to be US$ 30-45. Maintenance and repair costs of the EMAS Pump were found to be reasonable, with pump valve replacement (the repair most commonly reported by users) costing an average of US$9 (materials and labor). The Rope Pump has some similar attributes to the EMAS Pump, in that it is can be made locally from materials commonly available in developing communities, it has a relatively low cost, and is simple to understand. The Rope Pump is well-known among international rural water supply professionals, and thus serves as a good baseline to compare the lesser-known EMAS Pump. A technical comparison completed in Uganda of the EMAS Pump and the Rope Pump considered performance (flow rates and energy expended, pumping from various depths), material costs, and requirements for local manufacture. The study concluded that, based on its relative low-cost (material costs ranging from 21-60% that of the family Rope Pump, dependent on depth and pumping pipe size), similar technical performance to the Rope Pump when pumping from a range of depths, and the minimal resources needed to construct it, the EMAS Pump has potential for success in household water supply systems in sub-Saharan Africa. Combined with the conclusion from the research in Bolivia, it is believed that there is considerable potential for the EMAS Pump as a low-cost option for Self-supply systems in sub-Saharan Africa. Recommendations for further research focus on: (1) improvements to the Pitcher Pump system (focusing on reducing risk of water contamination); (2) formative research to identify factors that have led to the sustainability of the Pitcher Pump market in eastern Madagascar, and (3) development of the Self-Supply Market in Madagascar beyond Pitcher Pump systems.