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This book is dedicated to the latest findings on the design and optimization of production lines. The “Fourth Industrial Revolution” (alternatively known as “Industry 4.0”) supports innovative models for energy consumption and fault tolerance in automated lines, and this drives changes in the design and optimization models of production lines. The goal is to collect a series of works that can summarize the latest trends in the field of production line optimization models in order to improve the responsiveness of automated lines to failures, reduce energy consumption and peak electricity demand, and develop other methods to support robust and sustainable production lines.
This book provides a complete overview of production systems and describes the best approaches to analyze their performance. Written by experts in the field, this work also presents numerous techniques that can be used to describe, model, and optimize the performance of various types of production lines. The book is intended for researchers, production managers, and graduate students in industrial, mechanical, and systems engineering.
Efficient assembly line design is a problem of considerable industrial importance. Assembly Line Design will be bought by technical personnel working in design, planning and production departments in industry as well as managers in industry who want to learn more about concurrent engineering. This book will also be purchased by researchers and postgraduate students in mechanical, manufacturing or micro-engineering.
This work presents the concepts of process design, problem identification, problem-solving and process optimization. It provides the basic tools needed to increase the consistency and profitability of manufacturing options, stressing the paradigms of improvement and emphasizing the hands-on use of tools furnished. The book introduces basic experimental design principles and avoids complicated statistical formulae.
In modern manufacturing, it is not simply the equipment that is increasingly complex but rather the entire business system in which a company operates. Convoluted supply chains, complicated resource flows, advanced information systems: all must be taken into account when designing or reengineering a manufacturing system. Introducing a powerful yet
This thesis investigates .Manufacturing design for productivity. surveying a case study of an assembly line for air conditioning control panels. The main aim is to investigate the possibilities of operational improvement on the production time in a cost-effective manner. The specific objective of this study is to investigate the relationship between manufacturing design and productivity issues. In order to achieve the objective of this study, a methodology has been developed. First a thorough literature survey is conducted. The use of methods engineering in the factory system is explained, then the relationships between analytical techniques of methods engineering are discussed. Then examples related to subject are investigated. Later on, an assembly line is selected as the case study. An ex-assembly is redesigned by using the concepts of methods engineering. Then both cases are analyzed and discussed in terms of their output capacity and manufacturing time. After the analysis of MTM for redesigned assembly line it is observed that we can reduce production cycle time 20 % at the end of this study. And this development project has been chosen for investment. At the end of this project, we increased the production quantity from 600 pcs. to 800 pcs. Because efficiency of workers have increased with the redesigned assembly line, production of the goods of quantity increased 13 % more than originally calculated. The new assembly line is reduce the operators waiting time and increases their efficiency. The ex-assembly line was covering 13,5mø square it reduce to 3,6 mø. Finally, because of efficiency and productivity increase of this study, totally we observed 33 % production increase for the same period of time. By the standardization and the elimination of the operations, and reducing the labor cost the factory could increase its competitive strength.
Readers of System Design Optimization for Product Manufacturing will learn about detailed concepts and practical technologies that enable successful product design and manufacture. These concepts and technologies are based on system optimization methodologies that consider a broad range of mechanical, as well as human, factors. System Design Optimization for Product Manufacturing explains the methodologies behind current and future product manufacture. Its detailed explanations of key concepts are relevant not only for product design and manufacture, but also for other business fields. These core concepts and methodologies can be applied to practically any field where informed decision-making is important, and where a range of often conflicting factors must be carefully weighed and considered. System Design Optimization for Product Manufacturing can be used as a fundamental reference book by both engineers and students in the fields of manufacturing, design engineering, and product development.
This book attempts to treat line design and its related subjects in a cohesive manner, with an emphasis on design applications. It discusses general guidelines for setting up assumptions and determining line performance parameters, based on empirical data from literature reports.
A production line is a manufacturing system where machines are connected in series and separated by buffers. The inclusion of buffers increases the average production rate of the line by limiting the propagation of disruptions, but at the cost of additional capital investment, floor space of the line, and inventory. Production lines are also a special case of assembly/disassembly systems as well as closed-loop systems. This thesis makes contributions to production system profit maximization. The profit of a production line is the revenue associated with the production rate minus the buffer space cost and average inventory holding cost. We assume that machines have already been chosen and therefore our only decision variables are the buffer sizes and the loop population. The difficulties of the research come from evaluation and optimization. We improve evaluation of loop systems. The optimization problem is hard since both the objective function and the constraints are nonlinear. Our optimization problem, where we consider the nonlinear production rate constraint and average inventory cost, is new. We present an accurate, fast, and reliable algorithm for maximizing profits through buffer space optimization for production lines, and extend the algorithm to closed-loop systems and production lines with an additional maximum part waiting time constraint. A nonlinear programming approach is adopted to solve the optimization problem. Two necessary modifications are proposed to improve the accuracy of the existing loop evaluation method before optimization of loops is studied. An analytical formulation of the part waiting time distribution is developed for two-machine one-buffer lines. It is used in the profit maximization for production lines with both the production rate constraint and the maximum part waiting time constraint. Numerical experiments are provided to show the accuracy and efficiency of the proposed algorithms. Finally, a segmentation method and an additive property of production line optimization are studied. They enable us to optimize very long lines rapidly and accurately.
Much academic energy has been invested in the study of optimizing assembly or production lines. The Assembly Line Balancing Problem design problem is an artifact of that work. Theory of Constraints purports that an assembly line that is purposely and strategically unbalanced provides superior performance in terms of predictability and throughput over the traditional balanced line. This study articulates a custom production line model based on Theory of Constraints and compares its performance to the traditional operations management paradigm, a balanced line. Results show that a purposely unbalanced line provides superior flow of material and greater throughput than the traditional balanced line configuration. Additionally the simplified model and approach may be more appealing with respect to the design, development, and computational costs than those required of the conventional line balancing methodologies.