International Conference on Manufacturing Research (ICMR 2013)
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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
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Item Open Access Lean product development performance measurement tool(Cranfield University Press, 2013-09-19) Al-Ashaab, Ahmed; Petritsch, Christoph; Gourdin, Mathilde; Urrutia, Usue Aliende; Andino, Alberto; Varro, Brigitta; Rigatti, Carlotta; Golob, Matic; Summers, Mark; El-Nounu, AbdulrahmanThe need of applying lean thinking to product development is becoming a must for the organisations to success in the current industry. This paper presents a tool that helps to define the actual status of the organisations in relation to the lean principles. Extensive literature highlighted the need of developing a tool focused on assessing the implementation of lean principles themselves, rather than quantitate metrics. Based on the Balanced Scorecard, four perspectives, with corresponding set of questions, were defined reflecting the enablers of the product development model proposed by the LeanPPD European project. A five-level scale was customised to score the different readiness levels that define the transformation into a full lean implementation. The tool was used to assess the current and desired lean situation of an aerospace company within the research environment and resulted to be accurate to define the starting condition of the company to adopt leaner practices.Item Open Access Mixed-model production system design for aircraft assembly(Cranfield University Press, 2013-09-19) Briggs, James; Jin, Yan; Price, Mark; Burke, RobertWith the advancement of flexible fixture and flexible tooling, mixed production has become possible for aircraft assembly as the manufacturing processes of different aircraft/sub-assembly models are similar. However, due to the low volume and complex constraints of aircraft assemblies, how to model the problem and produce a practical solution has been a great challenge. To tackle this challenge, this work proposes a methodology for designing the mixed production system, and a new scheduling approach is proposed by using combined backward and forward scheduling methods. These methods are validated through a real-life industrial example. As a result, the number of workstations is reduced by 50%, and the cycle time for making a fuselage is reduced by 38% by using the new mixed-model system.Item 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, MehdiIn 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.Item Open Access Making automation pay - cost & throughput trade-offs in the manufacture of large composite components(Cranfield University Press, 2013-09-19) Mullan, M; Price, M; Murphy, A; Quinn, D; Butterfield, J; Cowan, S; McElroy, P; Hawthorne, P; Robertson, SThe automation of complex manufacturing operations can provide significant savings over manual processes, and there remains much scope for increasing automation in the production of large scale structural composites. However the relationships between driving variables are complex, and the achievable throughput rate and corresponding cost for a given design are often not apparent. The deposition rate, number of machines required and unit production rates needed are interrelated and consequently the optimum unit cost is difficult to predict. A detailed study of the costs involved for a series of composite wing cover panels with different manufacturing requirements was undertaken. Panels were sized to account for manufacturing requirements and structural load requirements allowing both manual and automated lay-up procedures to influence design. It was discovered that the introduction of automated tape lay-up can significantly reduce material unit cost, and improve material utilisation, however higher production rates are needed to see this benefit.Item Open Access Cost, benefit, and financial risk (COBEFR) of ERP implementation(Cranfield University Press, 2013-09-19) Badewi, Amgad; Shehab, EssamThe purpose of this research is to develop Benefits, Costs, and Financial Risks (CoBeFR) model to show and measure the impact of ERP related decisions, such as degree of business process re-engineering and the level of hardware investment, on the organisational financial value (OFV). OFV is based on current time value of money (i.e. interest rate), financial risk, and net cash flows emerged from ERP system. Financial risk, the sensitivity of the organisation net profit to changes in market conditions, is affected by organisational adoption of ERP system. The main conclusion is that there are interrelated impacts of ERP implementation decisions to the organisational financial value. Therefore, decision maker should look at the implementation decision from a new perspective which is Organisational Financial Value (OFV) perspectiveItem Open Access Studies on fatigue behaviour of weld-bonds of Al-Mn-Mg alloy(Cranfield University Press, 2013-09-19) Mittal, Mayank; Dwivedi, DheerendraIn the present paper, fatigue and metallurgical behaviour of weld-bonds and adhesive bonds developed using 2 mm thick aluminium alloys namely 5052 alloy have been reported. Weld-bonds were prepared using structural adhesive (Epoxy resin) and spot welding (20 kA welding current for 6 cycles welding time at welding pressure of 0.5 MPa). Curing after applying Epoxy resin for developing adhesive bonds and weld bonds was performed at a temperature of 100 oC for 90 min. Fatigue tests were conducted under tension–shear loading pattern with stress ratio of 0.5 and loading frequency of 5 Hz. The maximum tensile shear load for fatigue test was kept at different level i.e. 90%, 80%, 70% and 50% of the ultimate shear tensile strength of weld bond and adhesive bonds. The fatigue lives of both adhesive bond and weld-bond joints decreased with increase in maximum tensile shear load. Fatigue performance of weld bond was higher than adhesive bond especially at high load.Item Open Access Benefit realisation modelling for ERP systems using system dynamics(Cranfield University Press, 2013-09-19) Badewi, Amgad; Shehab, Essam; Peppard, JoeAchieving 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.Item Open Access Advanced periodic maintenance scheduling methods for aircraft lifecycle management(Cranfield University Press, 2013-09-19) Fedotova, Alena; Taratoukhine, Victor; Ovsyannikov, MikhailThis paper reviews existing methods and techniques addressing the problem of maintenance support throughout the life cycle for high value manufacturing products such as aircrafts. As part of this doctorate research the analysis of current methods of maintenance scheduling was conducted. In order to contribute to a more comprehensive solution, an advanced approach (algorithm) of periodic maintenance is presented. The authors believe that this approach will reduce the cost of maintenance of high value manufacturing products. The algorithm based on constraint programming methods is briefly presented and the future research directions are discussed.Item Open Access Factory modelling: data guidance for analysing production, utility and building architecture systems(Cranfield University Press, 2013-09-19) Davé, Aanand; Ball, Peter D.Work on energy and resource reduction in factories is dependent on the availability of data. Typically, available sources are incomplete or inappropriate for direct use and manipulation is required. Identifying new improvement opportunities through simulation across factory production, utility and building architecture domains requires analysis of model feasibility, particularly in terms of system data composition, input resolution and simulation result fidelity. This paper reviews literature on developing appropriate model data for assessing energy and material flows at factory level. Gaps are found in guidance for analysis and integration of resource-flows across system boundaries. The process for how data was prepared, input and iteratively developed alongside conceptual and simulation models is described. The case of a large-scale UK manufacturer is presented alongside discussions on challenges associated with factory level modelling, and the insights gained from understanding the effect of data clarity on system performance.Item 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, ZakariaA 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.Item Open Access Advances in Manufacturing Technology XXVII: Proceedings of the 11th International Conference on Manufacturing Research (ICMR2013)(Cranfield University, 2013-09-19) Shehab, Essam; Ball, Peter D.; Tjahjono, BennyICMR2013 was organised by Cranfield University on the 19-20 September 2013. The conference focuses on any aspects of product development, manufacturing technology, manufacturing systems, information systems and digital technologies. It provides an excellent avenue for researchers to present state-of-the-art multidisciplinary manufacturing research and exchange ideas. In addition to the four keynote speeches from Airbus and Rolls-Royce and three invited presentations, there are 108 papers in these proceedings. These papers are split into 24 technical sessions. The International Conference on Manufacturing Research is a major event for academics and industrialists engaged in manufacturing research. Held annually in the UK since the late 1970s, the conference is renowned as a friendly and inclusive environment that brings together a broad community of researchers who share a common goal; developing and managing the technologies and operations that are key to sustaining the success of manufacturing businesses. For over two decades, ICMR has been the main manufacturing research conference organised in the UK, successfully bringing researchers, academics and industrialists together to share their knowledge and experiences. Initiated a National Conference by the Consortium of UK University Manufacturing Engineering Heads (COMEH), it became an International Conference in 2003. COMEH is an independent body established in 1978. Its main aim is to promote manufacturing engineering education, training and research. To achieve this, the Consortium maintains a close liaison with government bodies concerned with the training and continuing development of professional engineers, while responding to the appropriate consultative and discussion documents and other initiatives. COMEH is represented on the Engineering Professor’s council (EPC) and it organises and supports national manufacturing engineering education research conferences and symposia.Item Open Access On the profile intensive BiW design and optimization –the front module case study-(Cranfield University Press, 2013-09-19) Chantzis, Dimitrios; Salonitis, Konstantinos; Paralikas, John; Chryssolouris, GeorgeThe European automotive industry is known world-wide as the technically most advanced and innovative. Based on the competitiveness of global market, it is an emerging challenge and puts forward the need of flexibility for automobile OEMs and the product’s ability to meet the demands of the continuously changing customer’s behaviour. Therefore flexible processes have to be implemented during the design process of a BiW in order to achieve a flexible and modular product. In this paper profile intensive design of a front module has been developed under the prism of lightweight design. Profile intensive design offers to the manufacturer higher levels of flexibility and ability to adapt to the market needs efficiently and more quickly. Evaluation of the proposed design has been made through Design of Experiments. Finally Response Surface Method has been used for predicting the response of the front module when design variables are being changed.Item Open Access Statistical process control implementation in the food industry: A systematic review and implications for future research(Cranfield University Press, 2013-09-19) Lim, Sarina; Antony, JijuThis study is to illustrate a systematic review application in investigating common issues emerging from Statistical Process Control (SPC) implementation in the food industry. A total of 34 journal articles were rigorously selected from four databases and reviewed. The most common themes emerge in SPC implementation in the food industry is the benefits while the remaining themes are motivation, barriers and critical success factors (CSF). This review found that the evidence of SPC implementation in the food industry is beneficial; however, a lack of both awareness and guidelines relating to SPC implementation in the food industry has resulted in a slow adoption. This systematic review concluded that there is a crucial need for further research into the SPC deployment aspect addressing how to deploy SPC in the food industry in a systematic manner.Item Open Access Design of an innovation platform for manufacturing SMES(Cranfield University Press, 2013-09-19) Singh, Lakhvir; Ziarati, Martin; Ziarati, RezaThis paper reports on the conception of a collaborative, internet-based innovation platform with semantic capabilities, which implements a new methodology for the adoption of a systematic innovation process in globally-acting networked SMEs. The main objective of the innovation platform is to stimulate the generation of ideas, the selection of good ideas and their ultimate implementation. The platform will support SMEs to manage and implement the complex innovation processes arisen in a networked environment, taking into account their internal and external links, by enabling an open multi-agent focused innovation system, facilitating customer, provider, supplier and employee- focused innovation. The solution is specifically focused on the needs of manufacturing SMEs and will observe product, process and management innovation. The paper presents the key elements of the innovation model and makes references to a novel approach concerning the development of a robust and flexible Central Knowledge Repository for the innovation platform.Item Open Access Influence of processing parameters on forming quality of non-circular spinning(Cranfield University Press, 2013-09-19) Xia, Qinxiang; Qu, Juxin; Lai, Zhouyi; Xiu-quan, ChengProcessing parameters have great influence on forming quality of non-circular spinning. Finite element simulation model of non-circular spinning for the three straight-edge round-corner cross-section (TSRC) hollow-part was established. Variation rules of thickness and springback of TSRC spun workpiece under different processing parameters were obtained by means of orthogonal test as well as the software MSC.MARC. The results show that the influences of the relative clearance ΔC and the feed ratio of roller fz on the maximum wall thickness thinning ratio δt are obvious, and the influences of n and Dr are slight; the influences of the nose radius of roller rρ on the springback angle Δα is the most obvious, and the influences of ΔC and Dr are slight.Item Open Access Towards a framework for predicting whole life-cycle cost for long-term digital preservation(Cranfield University Press, 2013-09-19) Badawy, Mohamed; Sanya, Isaac; Shehab, Essam; Baguley, PaulEstimating the costs for the whole lifecycle of long-term digital preservation (LTDP) activities ena-bles decision makers to choose carefully what data to preserve, duration of preservation and type of preservation techniques best applied for their information. To address this need, a framework is de-veloped to generate a cost model that will estimate costs for long-term digital preservation activities using storage in the cloud and taking into consideration the impact of mitigating uncertainties, espe-cially obsolescence issues on future costs. This cost estimating framework is part of the European pro-ject entitled ‘Enabling kNowledge Sustainability Usability and Recovery for Economic value’ which aims to provide a total long-term digital preservation solution for companies and public sector organi-sations interested in keeping their digital information alive for the long-term within the healthcare, fi-nancial and the clinical trials business sectors.Item Open Access Sustainable machining - correlation of the optimization by minimum energy, minimum manufacturing time and cost of production(Cranfield University Press, 2013-09-19) Pascoal, Filipa; Silveira, JoséThe machining process leads the indices of productivity and employability in a world level and has an enormous influence at social and economics standards, however it requires machinery that consume high levels of energy, chemical fluids and has great emissions of greenhouse gases. In our days as governments and clients increase their demands for the degradation of ecosystems, also increase the need for companies to implement sustainable policies and improve their environmental performances. The reduction of energy consumption and consequently the reduction of fossil supplies are a major source of concern at this level. This article establish a bridge between the classical approaches of optimization models of machining processes (Maximizing Production Rate and Minimizing Production Cost), and reduction of electricity. For a single pass turning it was used a mathematical model to analyse the data taken as a reference, optimizing the critical parameters of consumption of time, money and energy.Item Open Access Requirements analysis in the implementation of integrated PLM, ERP and CAD systems(Cranfield University Press, 2013-09-19) Muni Prasad, Giddaluru; James, Gao; Raj, Bhatti; Satya, ShahProduct Lifecycle Management (PLM) system implementation is a major investment when the technology is used in manufacturing companies. This paper provides an analysis of the requirements for the integration of PLM systems with Enterprise Resource Planning (ERP) systems incorporating the design aspects of Computer Aided Design and Manufacturing (CAD/CAM) within the product development process. PLM implementation deals with various existing product data and information generated over years both from CAD and ERP systems. Data integration is very challenging and has important impact on future decisions while creating new processes. The information management plays very important role not only in PLM implementation but also in the way this will be used in future production. Therefore it is very important to analyse how product information is transferred to PLM system. It also need to be investigated that what, when and how the data will flow from and to PLM systems.Item Open Access A framework for identifying uncertainties in long-term digital preservation(Cranfield University Press, 2013-09-19) Shehab, Essam; Chuku, Glory; Badawy, MohamedWith the current expansion in digital information comes an increasing need to preserve such assets. The ENSURE (Enabling knowledge Sustainability, Usability and Recovery for Economic value) pro-ject, a research project under the European Community's Seventh Framework Programme, is the par-ent project to this research area and its aim is to conduct advanced research to address the challenges of Long Term Digital Preservation (LTDP) to ensure the successful preservation, availability and ac-cessibility of preserved data in the future. Focusing on identifying uncertainties in the LTDP activities and their impact on cost and economic performance of digital preservation systems, this paper dis-cusses a framework to identify uncertainties in LTDP for business sectors interested.Item Open Access Novel nanocomposite automotive temperature sensing technology(Cranfield University Press, 2013-09-19) Kelly, Andrew; Impey, Susan A.; Mitsev, Petar; Nicholls, John R.In recent years, automotive emissions legislation has been introduced and is rapidly becoming more stringent. With alternative vehicular propulsion methods far from becoming mainstream reality, leading automotive providers have intensified efforts in the direction of reducing the harmful footprint of their products. This is being accomplished via smaller, more optimally designed internal-combustion engines. A crucial means to that end is exhaust gas temperature monitoring and control. To enable such control, a mass-produced sensor, capable of operating reliably in the harsh automotive combustion environment, comprising a broad spectrum of high temperatures, severe shocks and a chemically aggressive ambient, has been used widely in the past decade, with performance demands growing constantly in line with advances in engine performance. This paper presents a technology overview of the potential of novel nano composite sensor design and manufacture using materials in an innovative way towards industrialising such a sensing solution. The presented sensor design implements the state-of-the-art in thick and thin film technology incorporating nano materials for improved strength, fabrication and performance properties.