Proceedings of the 18 th International Conference on
Flexible Automation and Intelligent Manufacturing
FAIM 2008
June 30 th – July 2 nd , 2008 University of Skövde, Sweden
Volume 1(2)
Editor: Leo J. de Vin Co-editors: Amos H.C. Ng
Peter Thorvald
William G. Sullivan
Munir Ahmad
Copyright
The papers published in these proceedings reflect the opinion of their respective authors.
Information contained in papers has been obtained by the editors from sources believed to be reliable. Text, figures, and technical data should have been carefully worked out.
However, neither the publisher nor the editors/authors guaranteed the accuracy or completeness of any information published herein, and neither the publisher nor the editors/authors shall be responsible for any errors, omissions, or damages arising out of this publication. Trademarks are used with no warranty of free usability.
© 2008 FAIM. Personal use of this material is permitted. However, permission to reprint/republish this material for advertising or promotional purposes or for creating new collective works for resale or redistribution to servers or lists, or to reuse any copyrighted component of this work in other works must be obtained from the FAIM 2008 organisation.
Printed in Sweden by Runit AB, Skövde
“June 30
th– July 2
nd2008, University of Skövde, Sweden”.
“FAIM2008”
ISBN: 978-91-633-2757-5
The 18th International Conference on Flexible Automation and Intelligent Manufacturing, FAIM2008, is hosted at First Hotel Billingehus in Skövde, beautifully located on top of table hill Billingen, offering a stunning view over the surrounding countryside (on a clear day as far as Lake Vänern) and with bountiful nature just around the corner. A former Viking refuge can be found at just a short walk from the hotel. The 1st International FAIM conference in 1991 resulted from collaboration between the University in Limerick (UL) and the Virginia Polytechnic Institute. Prof. Munir Ahmad (then UL), and Prof. Bill Sullivan (then Virginia Tech.) have been central to the development of the Conference since its inception. Since 1991 FAIM has been hosted in many prestigious Universities on both sides of the Atlantic:
1991 University of Limerick, Limerick, Ireland 1992 Virginia Tech (in Washington DC), USA 1993 University of Limerick, Limerick, Ireland 1994 Virginia Tech, Blacksburg, Virginia, USA 1995 University of Stuttgart, Germany
1996 Georgia Institute of Technology, Atlanta, USA 1997 University of Teesside, Middlesbrough, UK 1998 Portland State University, Portland, Oregon, USA 1999 Tilburg University, Tilburg, Netherlands
2000 University of Maryland, Maryland, USA 2001 Dublin City University, Dublin, Ireland
2002 Dresden University of Technology, Dresden, Germany 2003 University of South Florida, Tampa, USA
2004 Ryerson University, Toronto, Canada 2005 University of Duesto, Bilbao, Spain 2006 University of Limerick, Limerick, Ireland 2007 Penn State Great Valley, Philadelphia, USA
This year, the FAIM conference is organized by the University of Skövde, Sweden.
Papers were accepted from authors from 33 countries. All accepted 172 papers for this year’s conference proceedings were rigorously peer reviewed and carefully selected from over 200 papers submitted, which resulted from more than 300 abstracts from 35 countries submitted to the Conference. The topics covered in the papers include:
• Bio-Engineering
• Business Process Re-Engineering (BPR)
• CAD/ CAM
• Change Management
• Computer Integrated Manufacturing (CIM)
• Concurrent Engineering
• E-manufacturing
• Engineering for Sustainability
• Environmental Engineering
• Global Manufacturing
• Health and Safety
• Human Factors and Human Resources in Manufacturing
• Industrial Automation and Process Control
• Industrial Engineering and Operations Management
• IT and Internet Applications
• Lean & Agile Manufacturing
• Manufacturing Education and Training
• Manufacturing Processes and Technology
• Manufacturing Systems
• Materials Technology
• Modelling & Simulation
• Product Design/ Design for Manufacture/ Assembly (DFM/DFA)
• Product Development
• Quality Control
• Quality Management and Total Quality Management (TQM)
• Rapid Prototyping
• Service & Maintenance Strategies
• Supply Chain Strategies and Management
The 18th International Conference on Flexible Automation and Intelligent Manufacturing
(FAIM2008) focuses on current research, best practices and future trends within the areas
of global competitiveness, and rapidly advancing technologies in flexible automation,
information management, and intelligent manufacturing. This year’s special theme
focuses on decision making in manufacturing, services and logistics. The conference
provides a forum for both researchers and practitioners in the above fields to share the
latest research, developments and practices in the areas of the conference scope. This
tradition will be continued next year in Middlesbrough, UK where The University of
Teesside will host the next FAIM conference.
C
HAIRSGeneral Chair: Leo J. De Vin Co-Chairs: William G. Sullivan
Munir Ahmad
Amos H.C. Ng
I
NTERNATIONALP
ROGRAMMEC
OMMITTEEEsther Alvarez, Spain
Jalal Ashayeri, The Netherlands Felipe Baesler, Chile
Keith Case, UK
George Chryssolouris, Greece Joost Duflou, Belgium Peter Funk, Sweden Bill Gaughran, Ireland Hinnerk Hagenah, Germany Olli-Pekka Hilmola, Finland Fred van Houten, The Netherlands George Q Huang, Hong Kong Björn Johansson, Sweden Christer Johansson, Sweden Anders Kinnander, Sweden
Warse Klingenberg, The Netherlands Huw Lewis, Ireland
Eric Lutters, The Netherlands Philip Moore, UK
Dimitris Mourtzis, Greece Farhad Nabhani, UK Aydin Nassehi, UK Stephen T Newman, UK Chike Oduoza, UK
Patricia Ong Soh-Khim, Singapore Robin Qiu, USA
CSP Rao, India David Russell, USA Con Sheahan, Ireland
Jannes Slomp, The Netherlands Johan Stahre, Sweden
Tamas Szecsi, Ireland Reijo Tuokko, Finland Hendrik Van Brussel, Belgium Lihui Wang, Canada
Gerald Weigert, Germany
S
PECIALS
ESSIONC
OORDINATORSYu-Hung Chien, Taiwan
Per Hilletofth, Sweden
Olli-Pekka Hilmola, Finland
Anna Syberfeldt, Sweden
Magnus Holm Peter Thorvald Erika Vikström-Szulc
L
OCALO
RGANISINGC
OMMITTEEJosef Adolfsson Marcus Andersson Tehseen Aslam Catarina Dudas Gustav Holst Dan Högberg Mats Jägstam Pernilla Klingspor Thomas Lezama Sandor Ujvari Matías Urenda Moris
T
ECHNICALS
UPPORTMartin Andersson Robert Farmer Ingemar Karlsson Jacob Svensson
I
NDUSTRIALL
IAISONSGunnar Bäckstrand, Volvo Powertrain Petter Solding, Swerea Swecast
C
ONFERENCEP
ARTNERSAmerican Express Business Travel, Groups & Events, Gothenburg
Acknowledgements
We, the chairpersons of the 18th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2008), are indebted to many individuals for their contribution, support, and endorsement. We wish to thank all keynote speakers who shared their views and visions towards flexible automation and intelligent manufacturing.
We also wish to acknowledge, with many thanks, the contributions of all authors who presented their work at the conference and submitted quality papers for this proceedings publication. Our special thanks are extended to all FAIM 2008 peer reviewers and session moderators who helped ensure the high quality of the conference.
The continued success of FAIM can be attributed to the guidance of its two founders, Prof. M.M. Ahmad and Prof. W.G. Sullivan, whom we would like to acknowledge and thank. We would also like to thank many former organisers of FAIM for their heart- warming advice and support.
We would further like to acknowledge the contribution of the International Program and Local Organizing Committees, and our conference partners American Express, for their work in paper reviewing, scheduling, the preparation of the papers, session moderation, organization of the social events, and the general operation involved in running this international conference. We would like to thank Volvo Powertrain Skövde for hosting the FAIM industrial study visit.
We would like to acknowledge the role of the University of Skövde, in being able to run such a prestigious conference, and thank all the support staff who often goes unnoticed.
Many thanks to those who took over some of our regular duties whilst we were organising FAIM. Finally, we would like to thank Magnus Holm, Peter Thorvald, and Erika Vikström-Szulc for their work as local Conference Secretariat.
Leo J. De Vin
Amos H.C. Ng
William G. Sullivan
Munir Ahmad
Skövde, Sweden
Table of Contents
K
EYNOTESEconomic and Technical Motivation for Rapid Manufacturing
Richard A. Wysk ... 1 Barriers, Drivers and Challenges for Sustainable Product Recovery and Recycling
S. Rahimifard, G. Coates, T. Staikos, C. Edwards and M. Abu-Bakar ... 2
CIM, R
APIDP
ROTOTYPING ANDCAD/CAM
A Novel Approach for Recognizing the Milling Features using STEP File
D. Sreeramulu, C.S.P.Rao and G. Srihari... 13 Determination of Component Machineability in CNC Manufacture
Aydin Nassehi and Parag Vichare... 23 An Impeller Machining Strategy Support System using Case-Based Reasoning
Min-Ho Cho, Dong-Won Kim, Jong-Yeong Lee, Eun-Young Heo, F.Frank Chen... 31 STEP-NC data model extension for manufacturing traceability and CNC process monitoring
Julio Garrido Campos, Ricardo Marín Martín, Juan Sáez López and José Ignacio Armesto Quiroga... 39 Hybrid Rough-Cut Machining of an Impeller with a 5-axis NC Machine
Eun-Young Heo, Dong-Won Kim, Jong-Yeong Lee, Hyung-Lo Lee, Bo-Hyun Kim... 47 Application of SolidWorks COSMOSMotion module to generation of the spiral bevel gears motion graph Piotr Skawinski, Przemyslaw Sieminski ... 55 A Web Integrated Manufacturing System for Turned Components using Sinutrain and AutoCAD
P.Subhash Chandra Bose, C. S. P. Rao, G. Srihari... 61 Automatic manufacturing process planning basis on part-process characteristics
Sina Ghaemi, Mohsen Shakeri ... 71 A Unified Manufacturing Resource Model for Representation of CNC Machining Systems
Parag Vichare, Aydin Nassehi, Sanjeev Kumar and Stephen T. Newman... 79 Failure Modes and Effects Analysis (FMEA) in Maintenance and Diagnostics
Keith Case and Amin Nor ... 87 A Function Block Designer for Generic Process Plan Encapsulation
Lihui Wang, Yijun Song and Qiaoying Gao ... 95 Multidisciplinary Design Optimization of Reconfigurable Parallel Machining Systems
Z. M. Bi and Lihui Wang ... 103 Agent-Based Workflow Management for RFID-Enabled Real-Time Reconfigurable Manufacturing
George Q. Huang, Y.F. Zhang, P.Y. Jiang, Oscar. Ho and Frank Xu... 111 Automation of a Robotised Metal Deposition System using Laser melting of Wire
A.-K. Christiansson, F. Danielsson, A. Heralić, M. Ottosson, K. Hurtig... 122
Development of Industrial SFF system using Digital Mirror System and Optimal Process
Sung Woo Bae, Dong Soo Kim and Kyung Hyun Choi ... 130 Performance Evaluation of FDM Waterworks System on Dimensional Accuracy
Omar Mohd Faizan, Safian Sharif and Saparuddin Arifin ... 139 Rapid Product Development using Virtual Prototyping Technologies
Y. Ravi Kumar, T.A. Janardhan Reddy and C.S.P. Rao ... 145 Two Stage Method of Manufacturing Feature Recognition
Janusz Pobożniak ... 155 Automated Setup Planning using Integration of Geometric and Knowledge-based Algorithms with CAM Software Dusan N. Sormaz, Chintan R. Patel and Narender Neerukonda ... 163
I
NTEGRATEDP
RODUCTD
EVELOPMENTSimulation-based linked design and manufacturing decisions in PLM: a case study
G.-C. Vosniakos, T. Giannakakis, X. Gogouvitis and A. Papantoniou... 171 Ontology-Based Data Integration and Decision Support for Product e-Design
Xiaomeng Chang, Janis Terpenny... 179 Multi-objective Optimisation of Product Modularity
Mike Lee, Prof. Keith Case and Dr. Russell Marshall ... 187 An Experimental Verification of Clinching Stud by Collar Drawing Process Technology
Park, Sang-bong ... 197 Tolerance Analysis of an Aircraft Tail Beam
Massimiliano Marziale, Wilma Polini ... 205 Integration of systems for design and assembly process planning
Jan Duda, Michal Karpiuk... 215 Two Stage Method of Manufacturing Feature Recognition
Janusz Pobożniak ... 222 Limiting Customer Requests with a Functional Description of Resources Based on Features
Jörg Militzer, Tobias Teich, Katja Unger and Matthias Zimmermann... 230 Conception and Manufacturing of Eco-Marathon Vehicle Mechanical Systems
Simões, José, Leite, Afonso and Vieitas, José... 237 Grammatical and Behavior Analysis of Functional Sentences of Geometric Details of Part
Francisco das C. Mendes dos Santos and Altamir Dias ... 245 Market Research for Time Constrained Product Development
Rajanikant Mohan and Ramanan Rajagopalan... 252 Manufacturing Engineering Challenges In Product Development Of Software Based Systems In Automotive Industry: A Case Study
Joakim Pernstål, Ana Magazinovic and Peter Öhman... 260
Q
UALITY, S
ERVICE& M
AINTENANCEA Study for Dispatching with Quality Distribution Index
Kim, Dong-hyun, Ko, Hyo-heon and Kim, Sung-shick ... 268 Robust economic design of a Variable Sampling Interval Shewhart control chart constrained by the labor resources G. Celano, A. Costa and S. Fichera ... 276 Robust and Easy to Use Quality Control of Roughness on Milled Tool Steel Surfaces
J. Berglund, B.-G. Rosén... 284 Performance Excellence in Healthcare Organisations
Sameh M Saad and Fakhureldein A Abdelmotleb ... 290 iTQM Index System: Beyond the SMEs Sustainable Quality Transformation
Xu Wang, Prof. Chris Chatwin, Dr. Rupert Young, Dr. Pouwan Lei ... 298 Implementing and improving Quality Management for SMEs
Paul Eric Dossou, Philip Mitchell ... 307 Using business excellence models for supporting decision making in strategic planning and business improvements Luis Rocha Lona, Steve Eldridge, Kevin D. Barber and José Arturo Garza Reyes ... 315 Optimization of opportunistic maintenance policies in a global service
Toni Lupo and Antonino Passannanti ... 325 Maintenance Strategy – An Enabler for Improved Competitiveness
Antti Salonen... 333 Accessing relevant data within maintenance - problems and possibilities in the realisation of a common database Mirka Kans ... 340 A Method for Implementing Condition Based Maintenance in Industrial Settings
Marcus Bengtsson ... 348 Optimal maintenance for a system with required reliability
A. Certa, G. Galante, T. Lupo and G. Passannanti... 357 eMaintenance - Information Driven Maintenance and Support
Olov Candell and Ramin Karim ... 365 Designing Automatic Test Systems: an Adapted Methodology Inspired on Pahl & Beitz’s Systematic Approach Luciano Antonio Mendes, Nelson Back and Gustavo H. C. Oliveira ... 373 Evaluation of the leadership performance in total quality management
Sameh M Saad and Fakhureldein A Abdelmotleb ... 381
S
USTAINABLE ANDE
NVIRONMENTALE
NGINEERINGA Generic Energy Consumption Model for Decision Making and Energy Efficiency Optimisation in Manufacturing Anton Dietmair, Alexander Verl ... 389 A Simulation Based Methodology to Define the Reuse Process of Printed Circuit Board´s Components
Arantxa Renteria, Esther Alvarez, Jesus M. López ... 397
Enhancing decision making in remanufacturing
Winifred L. Ijomah... 404 New Trends in Reducing Environmental Costs in Industrial Engineering in the Czech Republic
Tereza Fidlerová, Lilia Dvořáková and Marcela Srchová... 412 Performance Indictors for Effective Management of Carbon Emissions
Nasreddin Dhaf, Chris Ennis, Garry Evans and Munir Ahmad ... 420
M
ANUFACTURINGS
TRATEGIESA Highly Flexible, Automated, Parts Sorting and Transfer System
Michael A. Saliba, Gracelee Spiteri, Bernard Grech Sollars and Karl Farrugia ... 428 An Introduction to Customer-Led Design For Mechanically Oriented Products
Adeyinka Adeoye, Dr. Tamas Szecsi ... 436 An Intelligent i-CNC Controller For Interoperable Manufacturing Systems
M. Bachlaus, F. F. Chen, W.H.A. Wang and D.W Kim ... 443 A Tabu Search Method for Selecting Alternative Routing in Reconfigurable Manufacturing Approaches
I. Eguia, J. Racero, F. Guerrero, and S. Lozano ... 452 A Real-Time Method for Forward Kinematic Analysis of a Reconfigurable Parallel Robot
Younan Xu, Jingsong Wang, and Jeff Xi... 460 Custom ordered House Manufacturing: The Integration of Design, Lean Production and Flexible Automation Magnus Widfeldt, Per Gullander and Dan Engström ... 468 Lean Production planning as appropriate mechanism in manufacturing company under demand uncertainty Joanna Oleskow-Szlapka, Anna Sobis ... 476 Model Reference Adaptive Order Control in Consideration of Transient Demand and Transient Production Lead Time
Markus Zschintzsch, Bernd Scholz-Reiter ... 484 Lean Supply Chain in the Construction Industry using the SCOR Model
Fredrik Persson and Rajesh Maddineni... 492 Implementation of Value Stream Mapping in a Medium-Sized Manufacturing Company
Joao C.E. Ferreira and Kleber D. Ristof... 500 Introducing lean, not mean, to improve productivity in a cutting tool manufacturing company
Mohammed Sarwar and Julfikar Haider... 508
G
LOBALM
ANUFACTURING ANDS
UPPLYN
ETWORKSAIDC Technologies: Calculating the Return on Investment (ROI) through the elimination of non value adding activities
Farhad Nabhani, Athanasios Klonis and Paul McGrath... 516 A Multi-objective Simulated Annealing Approach to Solving the Supply Chain Design Problem
Uday Venkatadri, Soumen Bose and Amir Azaron... 525 Integration and Formalization of Strategic Product Development and Commercialization in a Manufacturing Company – A Challenge for Supply Chain Management
Per Hilletofth, Dag Ericsson, Olli-Pekka Hilmola and Sandor Ujvari ... 532
Differentiated Supply Chains Strategies Based on Customer Insights
Per Hilletofth, Dag Ericsson, Olli-Pekka Hilmola and Sandor Ujvari ... 540 Procurement risk management using the portfolio strategy: A multistage stochastic programming approach L.K.Chu, Yuan Shi and Ming Chuan Li... 548 Supply Chain Management and Optimisation - the impact of Enterprise Modelling
Paul Eric Dossou, Philip Mitchell ... 558 A new encoding for solving the multi-stage supply chain network problem through genetic algorithms
A. Costa, G. Celano, S. Fichera and E. Trovato... 566 A Multi Objective Particle Swarm Optimization for distribution planning in Supply Chain Network
S.Prasanna Venkatesan, S.Kumanan ... 574 An Evaluation of System Design Decisions for Global Supply Chains
Ronald G. Askin, Shishir Shenoy... 582 Customer Service Process in the Supply Chain Management Dynamics: Telecom Industry Case Study
Fatiha Naoui ... 590 Building a Competitive Supply Chain based on a Collaborative Strategy
Alberto de la Calle, Esther Alvarez ... 600 Improvement of Success of a network-based Cooperation by the Application of the FRIDA-Concept
Hendrik Jähn, Thomas Burghardt, Marco Fischer and Tobias Teich... 608 Assembly layout set-up for an agile market environment
Pekka Syvänen, Esko Niemi... 616
H
UMANF
ACTORS, T
RAINING ANDC
HANGEM
ANAGEMENTERP System implementations: The role of critical success and failure factors in development of a pre- implementation diagnostic.
Maeve Fitzpatrick and Con Sheahan ... 624 Demands on Technology from a Human Automatism Perspective in Manual Assembly
Peter Thorvald, Gunnar Bäckstrand, Dan Högberg, Leo de Vin and Keith Case ... 632 Effecting Change and Innovation in a Highly Automated and Lean Organization: The Temporal Think Tank™
(T3™)
Richard R. Lindeke, David A. Wyrick and Hongyi Chen ... 639 Evaluation of flexibility for the effective change management of manufacturing organizations
K. Georgoulias, N. Papakostas, G. Chryssolouris, S. Stanev, H. Krappe and J. Ovtcharova ... 647 Systemic change management: An opportunity for manufacturing organizations
D. Karlsson and G. Linnéusson... 654 Educating Engineers for Environmental Sustainability
William F. Gaughran and Sonya Quinn ... 660
I
NDUSTRIALA
UTOMATION ANDP
ROCESSC
ONTROLA General Virtual Manufacturing Concept for Programming, Verification and Optimisation of Complex Control Functions
Henrik Carlsson, Bo Svensson and Fredrik Danielsson ... 668 The Standardisation of Process Control for CNC Manufacturing
S. Kumar, A. Nassehi, P. Vichare and S.T. Newman... 676 Milling Chatter Detection Based on Probability Distribution of Wavelet Modulus Maxima
Lei Wang and Ming Liang ... 684 Performance of a Vision System Using a Dual Fiber Optics Design
H. Golnabi, A. Asadpour, R. Jafari and M. Kavei... 692 Analysing changeability and time parameters due to levels of Automation in an assembly system
Åsa Fasth, Johan Stahre and Kerstin Dencker... 700 Parts Presentation and Handling for Packaging – Case Study: Conceptualisation and Prototyping of a Flexible Mechanism for the Placing of Plastic Valves into Pouches
Michael A. Saliba, Andrea Amato, Jonathan C. Borg and Kevin Alamango... 708 Adaptive control of novel welding process to seal canisters containing Sweden’s nuclear waste using PID algorithms
Lars Cederqvist, Gunnar Bolmsjö and Carl D. Sorensen ... 716 Automation in Manufacturing Operation of Crankshaft
Nand K. Jha ... 721 Using Weibull Analysis to evaluate different project duration forecasting methods
Chia-Pin Huang, Ching-Chih Tseng... 729
I
NDUSTRIALE
NGINEERING ANDO
PERATIONSM
ANAGEMENTAn immune algorithm and fuzzy logic for multi criteria optimization in the area of scheduling
B. Skolud, I. Wosik ... 738 A Job Assignment Model for Conveyor Aided Picking System
Jiang-Liang Hou, Nathan Wu and Yu-Jen Wu... 746 Tools & Techniques, Technologies and Infrastructures; three important dimensions in Lean Production: A Model for assessing of leanness degree of the Manufacturing firms
A. Safaee ghadikolaee, M. Sajjadi Sini ... 754 The implementation of an almost real-time control system for administrative services
Adrian Murgau and Peter Almström ... 764 Jobs Scheduling in an Assembly Factory with Space Obstacles
Chyuan Perng, Yi-Chiuan Lai, Zih-Ping Ho ... 770 A Clustering and Urgency-Based Method for Dispatching Multiple-Load AGVs
Ying-Chin Ho and Hao-Cheng Liu ... 778 A Concurrent Solution for Intra-Cell Serpentine Flow Path Layouts and I/O Point Locations in a Cellular Manufacturing System with a Straight Line Inter-Cell Flow Path
Ying-Chin Ho and Ta-Wei Liao... 786
Genetic Algorithm for Two-Stage Hybrid Flowshop Blocking Scheduling with Setup Times and Machine Availability Constraints
George Q. Huang, Hao Luo and Y.F. Zhang... 794 Enterprise Continuous Improvement Techniques – A Perceived Gap Between Theory and Practice.
Oduoza C.F, Barber K.D and Smith P.G... 807 Identifying the Most Likely Activity Sequence in a Resource Constrained Project with Uncertain Durations Ching Chih Tseng and Po-Wen Ko ... 815 Overall Resource Effectiveness (ORE) – an improved approach for the measure of manufacturing effectiveness and support for decision-making
Jose Arturo Garza Reyes, Steve Eldridge, Kevin D. Barber, Eddie Archer and Tim Peacock ... 823 A candidate list strategy for circuit based problems to be contained within metaheuristics
M. Morady Gohareh, R. Ghasemy Yaghin, S.M.T Fatemi Ghomi... 831 A Decision Support System for Production Planning focused on both Customer Service and Technological aspects Pierpaolo Caricato and Antonio Grieco... 837 Hybrid Genetic Algorithm to Resolve Multi-Objective Problem for Flexible Flow Shop Including Job Splitting Masahiro Arakawa... 845 Applying Biological Control Approaches to Finite Capacity Scheduling
D.J.Stockton, M.Schilstra, R.A.Khalil and M.McAuley ... 853 Performance Measurement Model for a Just-in-Time Manufacturing Plant
Y.G. Sandanayake and C.F. Oduoza ... 860
M
ATERIALS ANDP
ROCESSINGT
ECHNOLOGIESResearch on Effective Real Time Dispatching in a Manufacturing Process
Ji Myoung, Yoon, Hyo-heon, Ko and Sung-Shick, Kim ... 868 Printed and Self-aligned Technology of Organic Thin Film Transistors
Kang Dae Kim, Taik Min Lee, Jeong Dai Jo, Byung Oh Choi, Dong Soo Kim ... 874 A Framework for the Manufacture of Personalised Sport Orthotic Insoles
P. Crabtree, V.G. Dhokia, M.P. Ansell and S.T.Newman... 879 Sintering Effect for Titanium Foam Prepared by Slurry Method
Sufizar Ahmad, Norhamidi Muhamad, Andanastuti Muchtar, Jaafar Sahari, Khairur Rijal Jamaludin and Mohd Halim Irwan Ibrahim ... 887 The Development of Cryogenic Machining Knowledge
V.G.Dhokia, P. Crabtree, S.T.Newman, M.P.Ansell and A.R.Mileham... 894 A Virtual Test Bed for PCB Assembly
J. Cecil, N. Gobinath, Atipol Kanchanapiboon ... 902 A Relational DEA Approach to Measure the Efficiencies of PCB Manufacturing firms
Shiang-Tai Liu... 910 An application prototype for offline continuous tool path planning on rebuilt surfaces
Cristiane P. Tonetto and Altamir Dias... 916
Intelligent irradiation planning for new laser applications
Florian Klämpfl, Michael Schmidt, Hinnerk Hagenah... 924 Optimization of Manufacturing Processes Based on Business Process Management Application
Jiri Tupa... 931 Effect of Lighting on the Performance of a Machine Vision System
B. Miles, B.W. Surgenor and J. Killing... 939 Development of an Intelligent Support System for Determining the Process Parameters of Injection Molding Jae Yong Baek, Il Rang Yie, So Young Chung, Bo Hyun Kim and Byoung Wook Choi ... 947
M
ANUFACTURINGS
YSTEMSVirtual Reality modelling concepts of automated manufacturing systems
X.V. Gogouvitis and G.-C. Vosniakos ... 955 Modeling a Walking Worker Assembly System
A.R. Mileham, Q.Wang, S. Lassalle and G.W. Owen... 963 Prerequisites for real-time control of manufacturing systems
Peter Almström and Adrian Murgau ... 971 Are Small and Medium sized Manufacturing Enterprises a Homogenous Group? – An Empirical Study of Manufacturing Characteristics
Malin Löfving and Mats Winroth... 979 Fractal Manufacturing Partnership - A Revolutionized Manufacturing Approach
Sameh M Saad, Aririguzo C Julian ... 987 Similarities and Differences between Lean Production, Tayloristic and Socio-Technical Systems Revealed in the Methodology Characteristics Map
K. Rask and J. Johansson ... 995 Analysis of Manufacturing System Complexity: Effect of Part Mix Ratios to System Performance
Rami Al-Amoudi, Sohyung Cho and Shihab Asfour ... 1002 The emergence process of an adaptable manufacturing system based on an evolution paradigm
Kai Salminen, Paul Andersson and Hasse Nylund... 1011 Design and Construction of Reconfigurable Screw-Pin Tooling for Vacuum Forming System
Zhijian Wang, Yan Wang and Nabil Gindy ... 1019 SIMTER: A Production Simulation Tool for Joint Assessment of Ergonomics, Level of Automation and
Environmental Impacts
Salla Lind, Boris Krassi, Björn Johansson, Juhani Viitaniemi, Juhani Heilala, Johan Stahre, Saija Vatanen, Åsa Fasth, Cecilia Berlin ... 1025 Software aided data collection methodology
Damir Petku, Nawzad Mardan, Petter Solding... 1032 Changeability Issues in Adaptive Manufacturing Systems
Hasse Nylund ... 1037 Improvement of production flow control in a machines’ assembly plant in conditions of delivery and process lead times uncertainty
Paulina Golinska, Marek Fertsch and Pawel Pawlewski... 1045
Process oriented approach versus description of technological routes - their role in production management Pawel Pawlewski, Jesus A. Trujillo, Paulina Golińska, Zbigniew J. Pasek, Marek Fertsch ... 1053 Application of Ant Colony, Genetic Algorithm and Data Mining based Techniques for Scheduling
Surendra Kumar, C.S.P.Rao ... 1060 Guidelines for increasing skills in Kaizen shown by a Japanese TPS Expert at 6 Swedish Manufacturing Companies Yuji Yamamoto and Monica Bellgran... 1070 Better results of interviews with stakeholders for more customeroriented intralogistic plants
H.-A. Crostack, J. Mathis, R. Refflinghaus... 1077 Cutting Tool Management: A Dynamic Assessment of Opportunities for Improvement
G. Linnéusson, M. Jägstam and C. Näsström... 1084 Feature-based functional description of resources
Thomas Gäse, Sebastian Winkler, Tobias Teich, Jörg Militzer and Katja Unger ... 1092
M
ODELLING ANDS
IMULATIONSimulation Modeling and Scenario Planning for Managing Strategy Dynamics
Jalal Ashayeri, Renske Munsters and Loek Lemmens ... 1097 Solving a Task Scheduling Problem Using Genetic Algorithms
Nader Aziz and Ming Liang, Saeed Zolfaghari... 1106 Design of Experiments for training metamodels in simulation-based optimisation of manufacturing systems Anna Syberfeldt, Henrik Grimm, Amos Ng... 1114 Process Modelling in competence cell-based Production Networks by the Help of Coloured Petri Nets
Thomas Burghardt, Hendrik Jähn, Christian Elliger ... 1122 A new tool development to improve enterprise model building and utilisation
B.M. Wahid, C. Ding and R.H.Weston ... 1130 Using Process Knowledge for Simulations of Material Flow in a Continuous Process
Björn Kvarnström and Bjarne Bergquist ... 1138 Analysis and Coupling of Simulation-based Optimization and MIP Solver Methods for Scheduling of
Manufacturing Processes
Andreas Klemmt, Sven Horn and Gerald Weigert ... 1146 Concurrent Consideration of Evacuation Safety and Productivity in Manufacturing Facility Planning using Multi- Paradigm Simulations
Karthik Vasudevan and Young-Jun Son ... 1154 Web Interface for the Conceptualization of AVS/RS and AS/RS
Sunderesh S. Heragu, Xiao Cai, Ananth Krishnamurthy and Charles J. Malmborg ... 1162 Worker allocation in make-to-order assembly cells
Esko Niemi ... 1169 Design and Analysis of a Landfill Compactor Tooth
Farhad Nabhani, Martin G. McKie, Paul McGrath, Oscar E. Rojas ... 1177 Multi-Objective Evolutionary Simulation-Optimisation of a Real-World Manufacturing Problem
Anna Syberfeldt, Henrik Grimm, Amos Ng and Philip Moore ... 1186
Design and manufacture of mechanical test rig to simulate the movements of forces within the shoulder
Farhad Nabhani, Paul McGrath, Martin. G. McKie, Shahrzad Connolly... 1194 A Mathematical Programming Model for a Production Scheduling Problem in the Furniture Industry
A. Toncovich, M. J. Oliveros Colay and J. M. Moreno-Jiménez ... 1202 Multi-Objective Simulation Optimization and Significant Dominance for Comparing Production Control Mechanisms
Amos H.C. Ng, Anna Syberfeldt, Henrik Grimm and Jacob Svensson ... 1210 Mapping process networks within the context of a manufacturing cell: A static and discrete event modelling case study
Alejandro Guerrero, Richard Weston... 1220 Using Petri Nets for DES modeling and optimization of assembly processes
Gerald Weigert, Thomas Henlich... 1228
A
PPLIEDP
ROBABILITY ANDS
TATISTICS INM
ANUFACTURING, S
ERVICES ANDL
OGISTICSThe Effects of a Pro Rata Rebate Warranty on the Age-Replacement Policy with Salvage Value Consideration Mingchin Chen and Yu-Hung Chien... 1236 Comparing of availability between three systems with reboot delay, standby switching failures, and general repair times
Kuo-Hsiung Wang, Yu-Ju Chen and Jyh-Bin Ke ... 1242 Availability analysis of systems with detection delay, switching failure and reboot delay
Jyh-Bin Ke, Bo-Rong Lu, Kuo-Hsiung Wang ... 1249 Ordering Policy For Spare Preventive Replacement
Jih-An Chen... 1257 The discrete-time Geo/Geo/1 system with additional optional service
Jau-Chuan Ke, Chuen-Horng Lin and Hsin-I Huang ... 1262 Controlling arrivals for a queueing system with second optional service
Fu-Min Chang, Chia-Jung Chang and Jau-Chuan Ke ... 1270 A Modified Imperfect Preventive Maintenance Policy under Reliability Limit
Mingchih Chen and Yu-Hung Chien... 1276 Modeling the P2P File Sharing Strategy in the Future Intranet Service
Chih-Chin Liabg, Chia-Hung Wang, Hsing Luh and Ping-Yu Hsu... 1281 Maintenance Strategies for File Delivery on Intranet
Chih-Chin Liang, Chia-Hung Wang, Hsing Luh and Ping-Yu Hsu... 1286 Evaluating the Effectiveness of FDM in Identifying Important Factors in a Dynamic Flowshop
Horng-Chyi Horng, Chi-Chang Hu and Tao-Ming Cheng... 1292 Testing Policies for Parallel-Series Standby Systems
Min Wang and Chun-Hao Chen ... 1298
A
RTIFICIALI
NTELLIGENCE INM
ANUFACTURINGJob Shop Scheduling using Derivational Case-based Reasoning by Priority Assignment
Chandrasekhar Ganduri, Dusan Sormaz and Cynthia Marling... 1305
Manufacturing Analysis via Inductive Classification
Farnaz Ganjeizadeh, Helen Zong and Saeid Motavalli ... 1313 The scope of Artificial Neural Network metamodels for precision casting process planning
G.-C. Vosniakos, V. Galiotou, D. Pantelis P. Benardos and P. Pavlou... 1321
O
UTSOURCEDS
UPPLYC
HAINSLogistics actors – Key Issues for a Service Developer
Kerstin Jäger, Sandor Ujvari, Anna Hermansson and Per Hilletofth ... 1329 External Economies and Strategic Cooperation
Jouni Juntunen... 1337 Outsourcing of Logistics Functions in Finland and Sweden
Olli-Pekka Hilmola, Ville-Veikko Savolainen and Daiyin Xu... 1345 Risk Management Models for Supply Chain Outsourcing
David L. Olson ... 1351
Papers
Economic and Technical Motivation for Rapid Manufacturing
Richard A. Wysk
Leonhard Chair in Engineering The Pennsylvania State University
ABSTRACT
The presentation looks at the uses and motivation for rapid prototying (RP) of physical parts. The presentation
begins with a brief introduction to RP and then begins to examine both the technologic constraints and then the
economic motivation for RP. An economic model driving the uses of RP is developed. Using this economic
model, the attraction of disposition techniques is first presented. The use and limits of traditional layered
deposition techniques is then discussed followed by RP developments using CNC techniques. Two new CNC
rapid manufacturing techniques will be presented noting their use and limitations.
Barriers, Drivers and Challenges for Sustainable Product Recovery and Recycling
S. Rahimifard, G. Coates, T. Staikos, C. Edwards and M. Abu-Bakar
Centre for ‘Sustainable Manufacturing And Reuse/Recycling Technologies (SMART)’
Wolfson School of Mechanical and Manufacturing Engineering Loughborough University
Loughborough, Leicestershire, LE11 3TU, UK
ABSTRACT
There has been a significant growth in research and applications of product recovery and recycling over the last two decades, in particular with the view of recent product take-back legislation which has extended the responsibility of manufacturers to include the recovery and safe disposal of their products. However, at present the global scale of product recovery applications is significantly disproportional to the total manufacturing output. Hence, to achieve the idealistic goal of “zero landfill”, there is a need to significantly improve and extend both the scale of product recovery activities and the range of manufacturing applications in which such activities have yet to be implemented. This paper examines a range of barriers, drivers and challenges in research and development of the next generation of product recovery initiatives. A range of existing applications and cases studies have been used to analyse issues related; to the need for improvement and expansion of current legislation on Producer Responsibility, product take-back and reverse logistic models for collection of used products, knowledge-based approaches for end-of-life considerations during the design phase, improved technologies and increased automation in pre and post fragmentation recycling processes, and most importantly the requirement for sustainable business models for establishing value recovery chains which can be based on the provision of services rather than products. The paper concludes by summarising the results of this analysis to bridge the gap between existing and future sustainable solutions for product recovery.
1. I
NTRODUCTIONSustainability will be one of the cores themes of the 21st century and presents a truly global challenge for product developers to make additional considerations within their designs regarding material consumption and resource utilisation. Increasing world population, depleting natural resources and the emerges of newly industrialised nations, all highlight the necessity to develop new and innovative products to bridge the gap between current consumer trends and the goal of long-term sustainability. It is often argued that a paradox exists between the ideals of sustainability and those associated with the growth of free-markets and global consumerism. To do more with less, increase a product’s durability or even taking it back for recycling or refurbishment at the end of its useful life, traditionally goes against the grain of a producer’s business model which typically aim to encourage increased consumption. However, with the advert of prescriptive take-back legislation, combined with increasing consumer pressure and ‘greener’ corporate responsibility, the consideration for end-of-life product recovery and recycling is increasingly being included within the scope of a company’s product development process. With this inclusion comes an increased need to improve the interaction between upstream manufacturing and downstream recovery activities, and has generated a number of competing market drivers and convoluted stakeholder relationships.
Product recovery and recycling has historically been undeveloped within the UK, with typical resource
consumption far out stripping that of material recycling, see Figure 1 [1].
0 2,000 4,000 6,000 8,000 10,000 12,000 14,000
Year
(kg/ capit a )
UK DMC/capita [1] 11,851 11,801 11,739 11,714 11,593 11,798 11,353 11,317 11,695 11,297
UK Recycling/capita [2] 27 32 36 40 48 52 60 71 87 113
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005