International Conference on Manufacturing Research (ICMR 2013)

Permanent URI for this collection

https://dspace.lib.cranfield.ac.uk/handle/1826/9337

11th International Conference on Manufacturing Research (ICMR2013)

19th - 20th September 2013

Editors: Essam Shehab, Peter Ball, Benny Tjahjono

Organised by: Cranfield University

ISBN: 978-1-907413-23-0
ISSN: 2053-3373

Browse

Now showing 1 - 20 of 108

Open Access
An integrative lean assessment model for distribution centres
(Cranfield University Press, 2013-09-19) Mahfouz, Amr; Smith, Laura; Arisha, Amr
It is hard to benefit fully from lean manufacturing without having an efficient distribution centre. Applying lean distribution concept helps to reduce distribution centres waste while maintains customer service level high. The purpose of this study is to develop a lean assessment model that enables distribution managers to measure and improve the leanness levels of their companies. A data driven analytical approach (i.e. factor analysis) is used to assess leanness quantitatively. A lean index score is calculated to benchmark the leanness level of four distribution companies based in Ireland and UK. Results recommend that special attention should be taken on simplifying distribution network structure, establishing long term suppliers’ collaboration, managing customer demand, improving storage space utilisation, and managing distribution operations more efficiently.
Open Access
Towards an ontology-based platform-independent framework for developing KBE systems in the aerospace industry
(Cranfield University Press, 2013-09-19) Sanya, Isaac; Shehab, Essam
Aerospace engineering is considered to be one of the most complex and advanced branches of engineering. The use of knowledge based engineering (KBE) technologies has played a major role in automating routine design activities in view of supporting the cost-effective and timely development of a product. However, technologies employed within KBE systems are usually platform-specific. The nature of these platform-specific models has significantly limited knowledge abstraction and reusability in KBE systems. This research paper presents a novel approach that illustrates the use of platform-independent knowledge models for the development of KBE systems in the aerospace industry. The use of semantic technologies through the definition of generic-purposed ontologies has been employed to support the notion of independent knowledge models that strengthens knowledge reusability in KBE systems. This approach has been validated qualitatively through experts’ opinion and its benefit realised in the abstraction, reusability and maintainability of KBE systems.
Open Access
Risk analysis in manufacturing footprint decisions
(Cranfield University Press, 2013-09-19) Rösiö, Carin; Bruch, Jessica; Wiktorsson, Magnus; Bellgran, Monica
A key aspect in the manufacturing footprint analysis is the risk and sensitivity analysis of critical parameters. In order to contribute to efficient industrial methods and tools for making well-founded strategic decisions regarding manufacturing footprint this paper aims to describe the main risks that need to be considered while locating manufacturing activities, and what risk mitigation techniques and strategies that are proper in order to deal with these risks. It is also proposed how the risk analysis should be included in the manufacturing location decision process.
Open Access
The effect of temperature changes on to quasi-static tensile and flexural performance of glass fibre reinforced PA66 composites
(Cranfield University Press, 2013-09-19) Butterworth, Ian; Abhyankar, Hrushikesh; Westwood, Keith; Njuguna, James; Brighton, James; Mouti, Zakaria
A significant method of reducing CO2 emissions in road vehicles is to reduce the vehicle mass. One means in which this can be achieved is to adopt lightweight materials such as thermoplastic composites. Thermoplastics offer advantages in term of weight when compared to conventional steel and aluminium casting. In this study thermal mechanical testing has been conducted on two types of commercial polyamide 66 (PA66) with 35 wt.% short glass fibre reinforcement. One of the materials was impact modified with an elastomer to increase material toughness. Experimental results showed both the reinforced PA66 materials to be temperature dependent. All test results demonstrated the trade-off in the mechanical properties of the two materials especially the impact modified. PA66 with 35 wt.% short glass fibre exhibits the best tensile strength, flexural strength and modulus for each temperature tested. Whereas the impact modified PA66 with 35 wt.% short glass fibre exhibits the higher strain and toughness for each temperature tested.
Open Access
Multiple-sensor integration for efficient reverse engineering of geometry
(Cranfield University Press, 2013-09-19) Li, Feng; Longstaff, Andrew; Fletcher, Simon; Myers, Alan
This paper describes a multi-sensor measuring system for reverse engineering applications. A sphere-plate artefact is developed for data unification of the hybrid system. With the coordinate data acquired using the optical system, intelligent feature recognition and segmentation algorithms can be applied to extract the global surface information of the object. The coordinate measuring machine (CMM) is used to re-measure the geometric features with a small amount of sampling points and the obtained information can be subsequently used to compensate the point data patches which are measured by optical system. Then the optimized point data can be exploited for accurate reverse engineering of CAD model. The limitations of each measurement system are compensated by the other. Experimental results validate the accuracy and effectiveness of this data optimization approach.
Open Access
Optimization of roughing operations in cnc machining for rapid manufacturing processes
(Cranfield University Press, 2013-09-19) Osman, Muhammed; Case, Keith; Watts, Darren
This paper presents a method for optimizing roughing operations in CNC machining particularly for parts production through a subtractive rapid manufacturing process. The roughing operation in machining is primarily used to remove the bulk of the material and to approximately shape the workpiece towards the finish form. The manufacturing process described utilizes a 3-axis CNC machine with an indexable 4th axis device that is used to hold and rotate the workpiece. The method used is derived from the multiple approaches in roughing operations that differ in the number and the angle of the orientations. Most of the machining parameters are generalized throughout the process to allow some automation in generating the machining program. Overall, the performance of each of the approaches is evaluated based on the lowest machining time to produce the part.
Open Access
Effect of fibre treatments on mechanical properties of flax/tannin composites
(Cranfield University Press, 2013-09-19) Zhu, Jinchun; Zhu, Huijun; Abhyankar, Hrushikesh; Njuguna, James
Due to the inherent environmental benefits of using natural resin (tannin) and natural fibre (flax), flax/tannin composites could be potentially used for vehicle applications. One of the main limitations is the hydrophilic property of flax, resulting in the poor fibre/hydrophobic matrix interface quality. Alkali, acetylation, silane treatment and enzymatic treatment were selected to modify non-woven flax mats to prepare the composites. The fibre morphology was studied through scanning electronic microscopes (SEM). The effects of fibre pre-treatments on dynamic and static mechanical properties of composites were investigated through adequate experiments, such as dynamic mechanical analysis (DMA) and static tensile testing. The modified rougher fibre surface broadened the glass transition peaks of composites due to the improved surface adhesion. However, there is no big improvement of tensile strength after modifications. The pure NaOH (sodium hydroxide) treated composites remain the tensile properties and offer good flax/tannin wettability.
Open Access
Design and development of an emulated human cognition using novel 3D neural networks
(Cranfield University Press, 2013-09-19) Ziarati, Martin; Ziarati, Reza; Akdemir, Başak; Bilgili, Erdem
This paper describes the development of an Emulated Human Cognition (EHC) which is designed and based on a replicated human brain with a right- and a left- hand lobe, one a deductive side and the other a generic one. Right-hand lobe consists of a newly designed Artificial Neural Network (ANN) with a multi-hidden layer topology. Left-hand lobe is a newly designed 3-dimensional cellular neural network. The input variables presented to the EHC are immediately analysed for it to decide which lobe should be activated. The EHC, when fully developed, has almost an unlimited memory capacity and is capable of immediate recall of any data in its almost unlimited memory locations. EHC has been used in several applications where neural networks have been used to establish relationship between two or more sets of variables. In this paper the EHC has been used to forecast demand for a given product.
Open Access
Enabling initiation of a lean management system in SMEs: a case study of a high performance plastics manufacturer
(Cranfield University Press, 2013-09-19) Jalali-Roudsari, Mehdi; Murray, Susan
This paper investigates the challenges in developing a Lean Management System in a typical Small to Medium Size Enterprise (SME’s) in the UK. Through a series of pilot projects measured and implemented by action research this case study reflects on the changes in mind-set and behaviours that are required on the part of the researcher in order to implement a Lean Manufacturing System. The implementation and suggestions by the researcher to adopt the observational methods such as visual data management and Hoshin Kanri were part of the action research. The data gathered influenced management strategy and planning to incorporate lean practices in the organisation. The actions and results were achieved by the workforce commitment to ensure embedding and sustainability for the future. Benefits realised included a 21% increase in on time delivery performance and cross functional problem solving actions resulted in a lead time reduction of 8 to 4 weeks.
Open Access
A collaboration framework to support decision making in new product development with the supply chain
(Cranfield University Press, 2013-09-19) Hasan, Syed; Shah, Satya; Gao, James X.
Management use the supply chain features more frequently, as the increasing rate of product introduc-tions demands more efforts from a business to deliver new products effectively and efficiently. To produce products at the targeted cost, time, and quality, the supply chain must be aligned with product development processes. This will allow manufacturing firms to overcome problems such as (partially) failed product launches due to the lack of timely provision of parts and systems caused by insufficient capacities in the supply chain. With integrated New Product Development (NPD) and Supply Chain Management (SCM), enterprises have the benefit of increased supply chain capability, thus increasing the effectiveness of new product introduction and improving their overall performance. In this re-search, the authors have tried to link NPD of an automotive manufacturer to its global network of suppliers. The integration points in the integrated NPD and SCM framework will provide guidelines to identifying where critical decision are made in collaboration with the supply chain.
Open Access
A novel approach to collaborative product development in the medical-equipment industry
(Cranfield University Press, 2013-09-19) Tseng, Kevin C; Chien-Lung, Hsu
In this study, we summarise the requirements for collaborative product development based on our investigation of the differences in the resources and tools that are needed for the various stages of collaborative product development and the needs of system users during these various stages. We proposed a user-oriented approach of collaborative product development for medical equipment and designed a collaborative product development system with the required functionalities to satisfy different areas according to their roles and workflow. The system we developed can drastically simplify the original complex and dispersed process of product development for intelligent medical equipment, thereby allowing the project team to develop new medical-equipment products and promote interactions among the research and development staff, clinical specialists, and the test participants successfully, thereby resulting in a user-oriented collaborative product development process.
Open Access
Optimization and analysis of cutting parameters using cryogenic media in machining of high strength alloy steel
(Cranfield University Press, 2013-09-19) Tahir, Waseem; Jaffery, Husain; Ali, Liaqat; Khan, Mushtaq; Butt, Shahid; Jaffery, Mehdi
In this research, liquid Argon is used as a cryogenic media to optimize the cutting parameters for evaluation of tool flank wear width of Tungsten Carbide Insert (CNMG 120404-WF 4215) while turning high strength alloy steel. Robust design concept of Taguchi L9 (34) method is applied to determine the optimum conditions. This analysis revealed is revealed that cryogenic impact is more significant in reduction of the tool flank wear.
Open Access
Challenges of cloud technology in manufacturing environment
(Cranfield University Press, 2013-09-19) Yadekar, Yaser; Shehab, Essam; Mehnen, Jorn
The rapid growth Information systems and advanced network technologies have significant impact on enterprises around the world. Enterprises are trying to gain competitive advantage in open global markets by using the latest technologies, along with advanced networks, to create collaboration, reduce costs, and maximize productivity. The combination of latest technologies and advanced manufacturing networks technologies lead to growth of new manufacturing model named Cloud Manufacturing which can shift the manufacturing industry from product-oriented manufacturing to services-oriented manufacturing. This paper explores the literature about the current Manufacturing problems, understands the concept of Cloud Computing Technology, introduces Cloud Manufacturing and its role in the enterprise, and investigates the obstacles and challenges of adopting Cloud Manufacturing in enterprises.
Open Access
Research on forming quality of poly-wedge pulley spinning
(Cranfield University Press, 2013-09-19) Xiu-quan, Cheng; Qin-xiang, Xia; Jia-zi, Wang; Dong-he, Li
As an important power transmission part, pulleys are widely used in automobile industry, agricultural machinery, pumps and machines. A near-net forming process for six-wedge belt pulleys manufacturing was put forward. For this purpose, the required tooth shape and size can be formed directly by spinning without machining. The whole manufacturing procedures include blanking, drawing and spinning. The spinning procedure includes five processes, performing, drumming, thickening, toothing and finishing. The forming defects occurred during each forming processes of poly-wedge pulley spinning, such as the drumming failure, flanged opening-end, folded side-wall, insufficient bottom size, flashed opening-end, cutting-off bottom, are introduced, and the factors influencing the defects are analyzed. The corresponding preventive measures are put forward.
Open Access
A vibration measurement system for deaf people’s emergency apparatus
(Cranfield University Press, 2013-09-19) Abulifa, A; Shafik, M; Wilmshurst, T; Lawday, M
A vibration measurement system for deaf people’s emergency warning equipment is presented in this paper. Deaf alarm devices are among the most supportive products that help to alert deaf people in various emergency circumstances. Applicable British standards recommend that acceptable working parameters for such products are frequency: 25 to 150 Hz, enough vibration strength, intensity and stable performance against lifetime. This paper presents research that has been conducted to test and validate the performance of a variety of alerting devices using the proposed vibration measurement system. It introduces the laboratory arrangements, practical measurements carried out and its compliance with the British standards. The products investigated were the Mk I, Mk II Deaf Alerters, the Deafgard alerting device and the C-TEC 24V Pillow Pad. Measurements were taken using an ADXL335 accelerometer, to determine the vibration strength. Other parameters considered were temperature variation, efficiency and lifetime of the products.
Open Access
The implementation of uncertainty evaluation model in manufacturability analysis system for miniature machine tool
(Cranfield University Press, 2013-09-19) Abdul Shukor, Syaimak
The development of Manufacturability Analysis System for micro-machining domain (MicroMAS) is intended to address the need of the 4-axis Miniature Machine Tool (MMT) that require such system to assist the user in generating micro-component through manufacturability evaluation. One of the manufacturability aspects being assessed is the impacts from Uncertainty Evaluation Model (UEM) analysis that analyse the influence of the errors stemmed from the MMT construction on the geometrical accuracy of the machined micro-parts. The model has allowed a methodology for the errors in a custom-made MMT to be predicted and to further understand the origin of the errors on the machined micro-part. This paper reports on the implementation of UEM in the development of MicroMAS. Therefore, the results from uncertainty evaluation towards the MMT were integrated in the database which are interactively searched based on IF-THEN clauses in order to determine which rules satisfy the requirements expressed via inputs.
Open Access
Benefit realisation modelling for ERP systems using system dynamics
(Cranfield University Press, 2013-09-19) Badewi, Amgad; Shehab, Essam; Peppard, Joe
Achieving success for ERP systems is not only concerned with deploying the technology on time and on budget but also concerned with the level of achieving targeted benefits from the system. This level of achieving targeted benefits can be managed indirectly through managing the organisational attitude toward the new system. Thus, the aim of this paper is to use the System Dynamics (SD) to reveal how managing organisational attitude leads to an increase in the level of system use and, therefore, leads to a decrease in the level of resistance to change to new system for achieving high level of performance. SD is used to investigate the causal loops of organisational attitude, perceptions, behaviours, and policies taken to achieve desired benefits. The ability to manage an organisational attitude toward ERP is an important factor for achieving desired levels of benefits is the main conclusion of this research.
Open Access
Towards the development of a manufacturing failure mode avoidance framework for aerospace manufacturing
(Cranfield University Press, 2013-09-19) Goodland, J; Campean, I; Victory, J; Caunce, A
A process based management strategy is crucial to enable productivity and cost effectiveness enhancement in high value manufacturing. This paper introduces a Manufacturing Failure Mode Avoidance (MFMA) framework based on four high level steps, underpinned by a series of structured tools to support a structured function-based decomposition of complex manufacturing processes and a continuous flow of information towards the development of robust control plans. The approach draws from experience from the automotive industry where Failure Mode Avoidance (FMA) has been adopted as a strategy to achieve a step change in the effectiveness of business and engineering processes associated with the product creation process. The paper illustrates a pilot implementation of the MFMA framework on a case study for the manufacturing of an aerospace component, followed by a discussion of the broader applicability of the framework and directions for further work.
Open Access
A cost engine system for estimating whole-life cycle cost of long-term digital preservation activities
(Cranfield University Press, 2013-09-19) Sanya, Isaac; Shehab, Essam; Badawy, Mohamed
This research paper presents a cost engine system that estimates the whole life cycle cost of long-term digital preservation (LTDP) activities using cloud-based technologies. A qualitative research methodology has been employed and the activity based costing (ABC) technique has been used to develop the cost model. The unified modelling language (UML) notation and the object oriented paradigm (OOP) are utilised to design the architecture of the software system. In addition, the service oriented architecture (SOA) style has been used to deploy the function of the cost engine as a web service in order to ensure its accessibility over the web. The cost engine is a module that is part of a larger digital preservation system and has been validated qualitatively through experts’ opinion. Its benefits are realised in the accurate and detailed estimation of cost for companies wishing to employ LTDP activities.
Open Access
Delivery management of industrial product-service systems – challenges for a performance measurement
(Cranfield University Press, 2013-09-19) Meier, Horst; Dorka, Thomas; Morlock, Friedrich
In the manufacturing industry, competitors are continuously struggling to differentiate themselves from other companies in the market. Industrial product-service systems (IPS²) offer this differentiation by representing a paradigm shift from traditional product selling and service offering to providing customer value. During the use phase of IPS², the organisation and planning are executed and managed by the IPS² execution system (IPS²-ES). To ensure and improve the effectiveness and efficiency of the IPS²-ES during the use phase, a performance measurement is needed. This paper presents a motivation for a performance measurement during the delivery phase and based on this the requirements for the performance measurement are introduced. An outlook for further research will be given.