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 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 Impact of climate change on first generation biofuels production in the 21st century(Cranfield University Press, 2013-09-19) Garba, Nasir; Duckers, Les; Hall, WilliamThis study assessed the potential (near, medium, and long term) impacts of climate change on first generation corn bioethanol and soybean biodiesel production in Gainesville, Florida, USA. The Decision Support System for Agrotechnology Transfer-Cropping System Model (DSSAT-CSM) was used to simulate biomass and grain yield under climate change scenarios in the 21st century with direct effect of CO2. Weather projection was made for each scenario using the 10 year weather data for the baseline period (1981–1990). Precipitation is projected to increase by +20, +10, -10, and -20% every month throughout the growing season. Daily minimum and maximum air temperatures are projected to increase by +1.5, +3, and +5oC. Atmospheric CO2 is projected to increase by +70 and +350ppm. Simulated yields (grains/seeds and by-products) were then used as inputs into the LCA models. Results show that while bioethanol from corn and biodiesel from soybean offers some potential for GHG emissions savings per cultivated ha of set-aside land, this is tempered by rising air temperature. However, increased atmospheric levels of CO2 relative to current condition would reduce the severe impact of warming. Only soybean biodiesel will be positively affected by climate changes.Item Open Access Configuration of robust manufacturing systems(Cranfield University Press, 2013-09-19) Heinicke, MatthiasConsidering the increasing turbulence in the markets, many companies are faced with the task of responding to changes in customer demand in a flexible and timely manner. A variety of current research projects in terms of configuration of production systems deals with the increasing flexibility of several elements of a production system or the entire system, to meet the need for flexible responses. Furthermore, there is the avoidance or reduction of any kind of waste, including the creation of standards for the information and material flow processes at the heart of the company's efforts. Against this background, also organisationally robust processes are increasingly becoming the focus of operational actors. This paper points out the possibilities of influencing production systems and what characteristics exist regarding the requirement of structural changes. In this context, production control by defined loops and checking structural performance are indicators relevant to the focus of following considerations.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 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.Item Open Access Simulation analysis of the sustainability performance of a supply chain subject to disruption(Cranfield University Press, 2013-09-19) Montoya-Torres, Jairo; Huaccho Huatuco, Luisa; Burgess, ThomasIn recent years, two main concerns have surfaced in relation to improving manufacturing supply chains; one is their sustainability and the other is their resilience to major disruptions. This first concern relates to the optimal use of ever-scarcer natural resources. Hence, supply chains need to be assessed and re-designed to accommodate this trend and take in to account the triple bottom line of environmental, economic and social measures. The second concern stems from the globalisation of supply chains which increases complexity and vulnerability to major disruptions. To survive, organisations within supply chains must be resilient in the face of such disruptions. This paper’s study addresses these two concerns, i.e. sustainability and resilience, by using computer simulations to explore the effects of disruptions on the sustainability performance of a supply chain.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 A modified AHP algorithm for network selection(Cranfield University Press, 2013-09-19) Huang, Xin; Jules, Guiovanni; Saadat, Mozafar; Rakhodaei, HamidThis paper addresses the concept of ranking networks to the multiple criteria of customers to find the best and alternative networks. The use of modified AHP algorithm has been shown to provide better network ranking for reasonable customer objectives than the traditional AHP method. Both the traditional method and the proposed method produced results subjective to the customer requirements. However, the proposed method is more intuitive to the customers through direct capture of their exact requirements rather than an interpretation of their requirements through pair-wise comparison alone. Also, the proposed method is less time-consuming and results are of higher quality.Item Open Access Risk analysis in manufacturing footprint decisions(Cranfield University Press, 2013-09-19) Rösiö, Carin; Bruch, Jessica; Wiktorsson, Magnus; Bellgran, MonicaA 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.Item Open Access Production localization factors: an industrial and literature based review(Cranfield University Press, 2013-09-19) Bjelkemyr, Marcus; Wiktorsson, Magnus; Bruch, Jessica; Rösiö, Carin; Bellgran, MonicaDecision are commonly based on the available or easily accessible information; this is also true for more complex assessments like production localization. Where to locate production is often a key strategic decisions that has great impact on a company’s profitability for a long time; insufficient business intelligence may therefore have grave consequences. Six production localization factor studies have been assessed to see if they are focusing on the same issues and if there are any gaps. A new approach for structuring localization factors and the localization process is then presented and assessed with regards to some previously identified critical issues.Item Open Access The bees algorithm: Modelling nature to solve complex optimisation problems(Cranfield University Press, 2013-09-19) Pham, Duc; Le-Thi, Hoai; Castellani, MarcoThe Bees Algorithm models the foraging behaviour of honey bees in order to solve optimisation problems. The algorithm performs a kind of exploitative neighbourhood search combined with random explorative search. This paper describes the Bees Algorithm and presents two application examples: the training of neural networks to predict the energy efficiency of buildings, and the solution of the protein folding problem. The Bees Algorithm proved its effectiveness and speed, and obtained very competitive modelling accuracies compared with other state-of-the-art methods.Item Open Access Engineering management of gas turbine power plant co2 for microalgae biofuel production(Cranfield University Press, 2013-09-19) Mathew, Domoyi; Pilidis, Pericles; Di Lorenzo, GiuseppinaFossil fuel accounts for over 80% of the world`s primary energy, particularly in areas of transportation, manufacturing and domestic heating. However, depletion of fossil reserves, frequent threats to the security of fossil fuel supply, coupled with concerns over emissions of greenhouse gases associated with fossil fuel use has motivated research towards developing renewable and sustainable sources for energy fuels. Consequently, the use of microalgae culture to convert CO2 from power plants flue gases into biomass that are readily converted into biofuel offers a window of opportunities to enhance, compliment or replace fossil- fuel-use. Interest in the use of microalgae biomass for biofuel production is high as it affords the potential for power plant CO2 sequestration – (1kg of dry algae biomass uses about 1.83kg CO2). Similarly, its capacity to utilise nutrients from a variety of wastewater, sets it apart from other biomass resources. These outlined benefits all emphasis the need for extended R&D efforts to advance commercial microalgae biofuel production. The paper is aimed at investigating the environmental performance of the microalgae biofuel production process using LCA.Item Open Access A review of life cycle assessments of renewable energy systems(Cranfield University Press, 2013-09-19) Ozoemena, Matthew; Hasan, Reaz; Cheung, Wai; Hackney, PhilipA review of life cycle assessments (LCAs) of wind energy published in the past few years are presented in this paper. The aim is to identify the differences of the developed methodologies, in particular, the factors such as methods used, energy performance and influence of uncertainty. Each of the factors is addressed to highlight the shortcomings and strengths of various approaches. Potential issues were identified regarding the way LCA is used for assessing environmental impact and energy performance of wind energy. It is found that the potential of incorporating the quantification of uncertainty in the manufacturing phase has not been studied elaborately. A framework methodology has been proposed in this paper to address this issue.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 Industrial waste management within manufacturing: a comparative study of tools, policies, visions and concepts(Cranfield University Press, 2013-09-19) Shahbazi, Sasha; Kurdve, Martin; Bjelkemyr, Marcus; Jönsson, Christina; Wiktorsson, MagnusIndustrial waste is a key factor when assessing the sustainability of a manufacturing process or company. A multitude of visions, concepts, tools, and policies are used both academically and industrially to improve the environmental effect of manufacturing; a majority of these approaches have a direct bearing on industrial waste. The identified approaches have in this paper been categorised according to application area, goals, organisational entity, life cycle phase, and waste hierarchy stage; the approaches have also been assessed according to academic prevalence, semantic aspects, and overlaps. In many cases the waste management approaches have similar goals and approaches, which cause confusion and disorientation for companies aiming to synthesise their management systems to fit their waste management strategy. Thus, a study was performed on how waste management approaches can be integrated to reach the vision of zero waste in manufacturing.Item Open Access Towards a business model for sustainable supply chain management(Cranfield University Press, 2013-09-19) Pimenta, Handson; Ball, Peter D.Designers make decisions that ultimately impact on both the economic, environmental and social performance of the products and process, and many of these costs and impacts occur across the supply chain. This paper aims to show initials elements of a research which aims to develop an integrated business model for sustainable supply chain management in order to facilitate the business management process in terms of assessment of suppliers and collaboration addressed to the sustainable improvements across supply chain. It is noteworthy that it is an imperative in the current competitive market that companies must be able to manage their entire production chain taking into account sustainable issues as an important factor in their decision processes. Therefore, it is believed that this model can integrate and strengthen a company’s functions and assist its decision processes as well as implement improvements within its supply chain.Item Open Access Environmental impact assessment of the manufacturing of a commercial aircraft(Cranfield University Press, 2013-09-19) Kolios, Athanasios; Asproulis, Nikolaos; Howe, Stuart; Salonitis, KonstantinosThis paper documents the methodology and presents the results of a comprehensive LCA study of an Airbus A320 commercial airliner to determine the relative environmental impact of its manufacturing phase. The study was conducted in accordance with ISO 14040/44 using SimaPro LCA software, the EcoInvent inventory database and Eco-Indicator 99 weighting method, which allows the analysis to be outputted in a single score representing a number of damage models including damage to human health, ecosystem quality or resource depletion. Results indicate CFRP wings to have the most significant contribution to the overall environmental impact as a proportion to mass.Item Open Access Barriers to total quality management (tqm)-Implementation in the mauritian food industry(Cranfield University Press, 2013-09-19) Shameer, Danyen; Sing, CallychurnThis study was undertaken to determine some of the barriers to the implementation of total quality management (TQM) in the population of medium to large Mauritian food manufacturing companies (MFMC), which were then compared with those identified in Indian and USA manufacturing industries. For this purpose, a questionnaire was sent to the population via e-mail. After carrying out exploratory factor analysis and reliability test, all constructs/investigated barriers were found to be valid and reliable. On comparing the mean ratings for the barriers, the local companies obtained the lowest mean rating that was significantly different (p<0.05) from Indian and USA manufacturing companies. This showed that these barriers had not yet impacted greatly in MFMC. However, the two potential obstacles identified in the Mauritian context were: employee’s resistance to change and frequent turnover of employees.Item 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, AA 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.Item Open Access Discrete-event simulation of process control in low volume high value industries(Cranfield University Press, 2013-09-19) Cox, Steven; Garside, John; Kotsialos, ApostolosThis paper presents a new method of process control for set-up dominant processes. This new method known as Set-up Process Algorithm (SUPA) was compared with existing industrial practices and statistical techniques in the literature. To test the method’s robustness, a generic discrete-event simulation model was built. This model was used to test four different statistical approaches to process control. It was concluded that SUPA offers a method of process control for set-up dominant processes, which is easier to apply than classically derived SPC approaches, by using simple rules and a traffic light system based on design specification. Simulation analysis shows that SUPA: is more sensitive, at detecting an incapable process as it will monitor more units when a process is less capable; is more sensitive than PRE-Control at detecting mean shifts in a process. SUPA is also a nonparametric methodology and therefore robust against processes with non-Gaussian distributions.