Research and Application of Improving Manufacturability Based on Creating Production Bottlenecks
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The relatively balanced status of production process is a goal which all businesses want to achieve,but the conflicts of business operations will be covered up by the long-term relatively balanced production process and the further expansion of business scale will be restricted too.Based on the Theory of Constraints(TOC),a management mode creating production bottlenecks actively is presented to cope with systems which are relatively balanced in a long period and a fuzzy relation matrix is introduced.By applying this method to powder metallurgy parts manufacturing corporation,it is validated that the production capacity will improve in the reciprocating cycle of making and eliminating the production bottlenecks.And it is also found that the method can be applied to the operation of the whole system.Keywords:
Theory of Constraints
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Summary: This paper presents a novel manufacturing quality-oriented control strategy for a product-driven production. The product-driven production of- fers a high degree of flexibility for production, which is provided by the application of Gentelligent Components, which inherently store their fabrication data and can autonomously initiate and influence their production. Analogously to a cars navigation system, the optimum route through production is validated by the production control system out of a quantity of alternatives, considering traffic jams like bottlenecks or disturbances in order to avoid production interruptions. By considering only the avoidance of interruptions, the manufacturing quality is an often underestimated aspect of production control. Therefore, this paper deals with a novel quality-oriented production control strategy for a product-driven production of Gentelligent Components. In order to ensure manufacturing quality, especially for highly dynamic low batch productions, the existing product-driven production control was advanced by a novel quality-oriented control strategy. This paper presents the product-driven process control and the autonomous selection of alternative routes as well as the novel quality-oriented production control.
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This thesis takes the assembly lines in the electric bicycle manufacturing enterprise as the research object.The data related to the production efficiency of the assembly lines are collected and organized so as to transform it into intuitive production efficiency data which is supervised daily.Then,the primary reason for the production efficiency change is sought and analyzed and guide all staff think and act.Eventually,objective for the fundamental problem is set in order to solve it as planned.The purpose of it is to provide related management idea for enterprise,and to solve the problem of production system which is inefficient and uncontrolled.
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Under the increasingly intensive competition,manufacturing companies often suffer from capacity shortage. In the theory of constraints,for any system,there are bottlenecks restricting the output efficiency of the entire production system. Eliminating the bottleneck constraints is the optimal way to solve the problem of inefficiency in a manufacturing line. Based on the analysis of a packaging workshop production lines of a lithium energy enterprises,using the theory of constraints(TOC)to calculate the bottleneck process,combined with witness simulation software to take simulation study for the plant's production lines,it puts forward the corresponding improvement scheme,improving the production system,achieving the goal of reducing costs and improving production efficiency.
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Ever increasing demand for individualized and customized products induce the need for high variability in production and manufacturing through Mass Customisation. Mass Customisation requires more flexibility and adaptability capabilities in production systems. Matrix Production is a tact free job-shop like production system enabling variable production routing through a matrix shaped layout of partially redundant machines. Hence, it is one way to increase a production system's flexibility and adaptability. A more powerful production control system comes hand in hand with the evolution towards a tact free Matrix Production System. However, the additional degree of freedom due to the flexibility not only touches production control, but also production planning, thus enabling the production of portfolio external products. Implementation of a Product Generation Module optimizes the workload of Matrix Production Systems to increase their efficiency by assessing the suitability of co-production of portfolio external products. Generation of suitable production orders increase machine utilization without impeding the original multi-dimensional production goals. Thus, reaching new production strategies that include the creation of value through effective manipulation of minor products and byproducts. The flexibility of Matrix Production Systems acts as the Product Generation Modules enabler, insofar as flexibility is the ability of a system to perform within an acceptable production corridor without layout and planning adjustments. This can be enhanced by making use of the Matrix Production Systems adaptability to increase the set of portfolio external products through layout and planning adjustments. Hence, this strategy leads to a continuous automated planning phase and additional revenue due to the additional manufacture of minor products within a Matrix Production System. Doing so allows the Matrix Production System to react towards external demand related and internal capacity related events without sacrificing precious value creation opportunities.
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In today's global and volatile market, manufacturing enterprises are subjected to intense global competition, increasingly shortened product lifecycles and increased product customization and tailoring while being pressured to maintain a high degree of cost-efficiency. As a consequence, production organizations are required to introduce more new product models and variants into existing production setups, leading to more frequent ramp-up and ramp-down scenarios when transitioning from an outgoing product to a new one. In order to cope with such as challenge, the setup of the production systems needs to shift towards reconfigurable manufacturing systems (RMS), making production capable of changing its function and capacity according to the product and customer demand. Consequently, this study presents a simulation-based multi-objective optimization approach for system re-configuration of multi-part flow lines subjected to scalable capacities, which addresses the assignment of the tasks to workstations and buffer allocation for simultaneously maximizing throughput and minimizing total buffer capacity to cope with fluctuating production volumes. To this extent, the results from the study demonstrate the benefits that decision-makers could gain, particularly when they face trade-off decisions inherent today's manufacturing industry by adopting an SMO approach.
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As globalisation takes place, the market is getting more and more competitive.Manufacturing enterprises are facing tremendous pressure to succeed in the market with promising market shares.This has led to enterprises seeking for competitive advantage in order to vie with their rivals.In manufacturing context, efforts have been put in, for instance, to reduce production lead times, maximise productivity and optimise resource utilisation.These efforts aim to reduce all types of costs incurred, as a means to achieve cost competitiveness.There is also a challenge for the manufacturers to be competent to efficiently and cost-effectively cope with dynamic changes of customer demands in the market.These demands are related to a wide range of product mixes with short product lifespan and with unpredicted demand pattern (Zhang, 2011).From a manufacturing perspective, the efficiency of manufacturing operations (such as process planning and production scheduling) are the key element for enhancing manufacturing competence.Process planning and production scheduling functions have been traditionally treated as two separate activities, and have resulted in a range of inefficiencies.These include infeasible process plans, non-available/overloaded resources, high production costs, long production lead times, and so on (Saygin & Kilic, 1999;Khoshnevis & Chen, 1993;Zhang, 1993).Above all, it is unlikely that the dynamic changes can be efficiently dealt with.Despite much research has been conducted to integrate process planning and production scheduling to improve manufacturing efficiency, there is still a gap to achieve the competence required for the current global competitive market.In this research, the concept of multi-agent system (MAS) is adopted as a means to address the aforementioned gap.A MAS consists of a collection of intelligent autonomous agents able to solve complex problems.These agents possess their individual objectives and interact with each other to fulfil a global goal.This chapter describes a novel use of an autonomous agent system to facilitate the integration of process planning and production scheduling functions to cope with unpredictable demands.This refers to the uncertainties in product mixes and demand patterns.The novelty lies with the currency-based iterative agent bidding mechanism to allow process planning options and production scheduling www.intechopen.comProduction Scheduling 186 options to be evaluated simultaneously, so as to search for an optimised and cost-effective solution.This agent based system aims to achieve manufacturing competence by means of enhancing the flexibility and agility of manufacturing enterprises.This chapter is organised as follows.Section 2 reviews the literature of the existing approaches to integrated process planning and production scheduling.The limitations of these approaches will also be discussed.Section 3 describes the concept of MAS and Section 4 introduces the currency-based iterative agent bidding mechanism proposed in this study.A Tabu search optimisation technique to facilitate the adjustment of current values for agent bidding is presented in Section 5. Section 6 discusses the findings of the simulation results for the iterative bidding mechanism and further analyses the bidding results with three heuristic integrated process planning and scheduling approaches.Section 7 concludes this chapter. How to referenceIn order to correctly reference this scholarly work, feel free
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An Approach for Optimizing the Preparation and Production Planning Process in Single Item Production
The high variability of customer expectations results in the complexity of product development and manufacturing processes, which exists obviously in all types of production systems. One of these production systems with a high level of complexity, is single-item production, which is addressed in this paper. The preparation process in single-item production is usually wasteful and complicated. The question is: how can a product be produced most efficiently in the single-item production process. Recently, due to the increasing application of variant-oriented product modelling, the efficiency of preparation processes has been increased. But deficiency of harmonisation between design and production structures limits the automation of the preparation and planning process after the design process. In this paper, we introduce an approach to restructure the production processes and also harmonise the design and production structures in single-item production system. Due to this structure, a parts list has been adapted. This adaptation promotes the automation of the preparation and planning process. To achieve this goal, ERP (Enterprise Resource Planning) and PDM (Product Data Management) systems should not only be configured but also interconnected on the base of this introduced method. As a result, we put forward an integrated model to minimize circle times in single-item production.
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The engineering of manufacturing systems encompasses two main areas of development: the manufacturing process (manufacturing technologies, and flow and handling of materials), and the production management (flow of information - signals). These two areas must be designed to perform according to the expressed needs. This paper shows that the Axiomatic Design (AD) theory can be used to analyse a manufacturing system to find the origin of the lack of productivity, and, subsequently, to redesign a solution avoiding the weakness points. A case study of a tree nursery of a large wood production enterprise was used to show the application of the axiomatic design principles, particularly through analysing the design equation and including new design parameters with the independence in mind. The redesign solution based on the independence of functions promoted the simplification of the information (signals) flow, avoiding the identification of each production element, and avoiding errors, which increases the productivity and the production volume, by elimination of waste of time in production operations. The proposed solution brought results that encourage the application of AD to increment the productivity of manufacturing systems, in alternative to expensive investments.
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