Reconfigurable Manufacturing Systems and Transformable Factories

Transcription

1 Anatoli I. Dashchenko (Ed.) Reconfigurable Manufacturing Systems and Transformable Factories Sprin ger

2 Contents PART I: STATE OF THE ART Chapter 1 Globalization and Decentralization of Manufacturing E. Abele, J. Elzenheimer, T. Liebeck, T. Meyer 1.1 International Production and Trade is Becoming a Dominant Theme Criteria for Production Site Selection and the Importance of Flexibility in Factories and Machinery International Production Setup Categories Summary and Conclusion on the Globalization and Decentralization of Manufacturing 13 Chapter 2 New Trends in Production E. Westkämper 2.1 Introduction Strategies of Manufacturing New Paradigms for Manufacturing Life Cycle Orientation Product Integrated Knowledge Integration and Automation of Service Driving Transformation Processes by Innovative Manufacturing Technologies Technologies for the Future Advanced Industrial Engineering for Manufacturing NewTaylorism Summary 26 Chapter 3 General RMS Characteristics. Comparison with Dedicated and Flexible Systems Y. Koren 3.1 Introduction The Challenge Traditional Manufacturing Systems The Need for Responsiveness 30

3 XX Contents 3.3 RMS-A New Class of Systems RMS The Best of Both Worlds Comparison of Manufacturing Systems RMS Operation Enabling Technologies and Reconfiguration Characteristics RMS Enabling Technologies RMS Core Characteristics Sufficient and Necessary Conditions for RMS Reconfiguration Principles Reconfigurable Machines Reconfigurable Machine Tools Reconfigurable Inspection Machines Summary 43 Chapter 4 Progress in Reconfigurable Manufacturing Systems U. Heisel, M. Meitzner 4.1 Introduction Definition of Reconfigurability Benefits of RMS Delimitation Requirements of the Users Reconfigurability from the Producers' Point of View The Way to RMS Future Prospects 59 Chapter 5 Agile Manufacturing Systems - a Significant Quantum Leap for High Volume Production Approaches Flexibility Requirements as well as Fastest Reaction to Market Demands M. Berger 5.1 Definition Significant Features of Agile Manufacturing Systems Case Study - Agile Manufacturing System for Cylinder Heads Adaptor Plates for Agile Manufacturing Systems Summary 75

4 Contents PART II: MACHINES AND CONTROLS FORMS Chapter 6 Reconfigurable Manufacturing Equipment R. G. Landers, J. Ruan, F. Liou 6.1 Introduction Manufacturing Equipment Types Production and Operation Requirements Dedicated Manufacturing Equipment Flexible Manufacturing Equipment Reconfigurable Manufacturing Equipment Example Reconfigurable Machine Tools Hardware Characteristics Software Characteristics Prototype Reconfigurable Machine Tool Parallel Machine Tool Hybrid Deposition-Removal Processes Layer-Based Hybrid Systems Integrated Hybrid Systems Description of Hybrid Systems Integrated Hybrid Manufacturing System Example Applications 107 Chapter 7 Reconfigurable Machine Tool Design Y. M. Moon 7.1 Introduction Ill 7.2 Reconfigurable Machine Tool Design Design Process Overview Kinematic Modeling of Operation Requirements Graph Generation Function Mapping Module Selection Configuration Evaluation Introduction Work Envelope Degrees of Freedom Number of Modules Dynamic Stiffness Summary of RMT Design Methodology 133

5 XXII Contents 7.5 Future Direction of Reconfigurable Machine Tool Design Technology for RMT Logistics Issues Implementation Issues 137 Chapter 8 Challenges in the Design of Reconfigurable Machine Tools Z J. Pasek 8.1 Introduction Challenge #1: Defining Part Families Challenge #2: Mechanical Design Process Challenge #3: Control System Design Challenge #4: System Integration Challenge #5: Reconfiguration and Calibration Summary 153 Chapter 9 Reconfigurable Fixtures for Automotive Engine Machining and Assembly Applications C.-H. Shen, Y.-T. Lin, J. S. Agapiou, P. Bandyopadhyay 9.1 Introduction Previous Work Automotive Engine Machining and Assembly Environments Reconfigurable Engine Machining Fixture Examples of Engine Cylinder Head Machining Fixtures The Automated Reconfigurable Machining Fixture (ARMF) Characterization and Performance of the ARMF R&D Issues for ARMF System Production Implementation Reconfigurable Engine Assembly Pallet Examples of Engine Assembly Pallets Reconfigurable Pallet Design Requirements Modular Stanchion Design Options Summary Reconfigurable Machining Fixture Reconfigurable Engine Assembly Pallet 192 Chapter 10 Control Systems for RMS and Methods of their Reconfiguration G. Pritschow, C. Kircher, M. Kremer, M. Seyfarth 10.1 Challenges in the Range of Control Systems for RMS Requirements for Controllers in RMS Elements of a Reconfigurable, Self-adapting Control System for RMS 198

6 Contents XXIII Open Controller Architecture as a Basis for Self-adapting Control Systems Extensions for Self-adapting Control Systems Method for the Reconfiguration of Self-adaptable Control Systems The Model Based Configuration Process The Model Based Reconfiguration Process An Exemplary Reconfiguration Sequence Summary 209 Chapter 11 Closed-loop, Fieldbus-based Clock Synchronisation for Decentralised Control Systems R. Koninckx, H. Van Brüssel 11.1 Introduction Definition of Concepts Synchronisation Requirements for Distributed Motion Controllers Approaches to Synchronisation A Centralised Oscillator Clock Discipline Clock Characterisation Frequency Domain Characterisation Time Domain Characterisation Clock Discipline Phase Locked Loop Consequences of a Bus System Frequency Domain Analysis Implementation Details Measuring the Synchronisation Error Augmented Plant Model and Choice of States Controller Design Experimental Results Conclusion 233 PART III: SYSTEM-LEVEL ISSUES IN RMS Chapter 12 Production System Modelling for the Evaluation of the Degree of Reconfigurability A. Urbcmi, S. P. Negri 12.1 Introduction A Comprehensive Modelling Method for Reconfigurability Analysis Functional Decomposition Assessment of the Modification Effort Reconfigurability Assessment Application to One System Component: Machine 243

7 XXIV Contents 12.3 Application of the Modelling Method Functional Decomposition Structural Decomposition: Assessment of the Functional Units and of the Modules Index of Reconfigurability of the Morpheum PKM Analysis of the Results 255 Chapter 13 The Robot Cell as a Re-configurable Machining System S. Sakakibara 13.1 Introduction Intelligent Robot Basic Technologies of Intelligent Robot Robot Cell - a Long Time Unmanned Machining Cell Introduction of the Robot Cell Configuration of the Robot Cell Challenges to Robotize Mounting/Dismounting Processes Accurate Grasping of Work-piece Accurate Positioning of Work-piece Mounting the Work-piece onto the Machining Fixture Effects Conclusion 272 Chapter 14 Development of a Standard Reconfigurable Assembly Cell for Agile Manufacturing M. F. Molnar, R. Fernandez, B. Huff 14.1 Introduction Reconfigurable System Concepts Early SAC Developments The NCMS - LFMA Consortium LFMA Reconfigurable Flexibility The Demonstration Reconfigurable SAC NCMS LFMA Lessons Learned SAC Technology Commercialization Assembly Flex QuickCell Flexible Feeding Technologies End-User SAC Implementations Light-Duty Aerospace: Honeywell Space Systems Division Medium-Duty Aerospace: Lockheed Martin Missiles & Fire Control Business Implications Conclusions 293

8 Contents Chapter 15 Computer Supported Decision Making System that Generates and Optimizes Layouts of Reconfigurable Manufacturing Equipment at the Early Stage of Design O. A. Dashchenko 15.1 Synthesis and Optimization Method for Configuration of Manufacturing Systems Strategic Basis for RMS Design Main Functions of the CSS (Computer Support System) Classification of MS Structure Scheme for Directed Search Method of Optimal Variants Guided Search for Optimal Variant Reconfiguration of MS for Part N 1 into MS for Part N Optimization of Machine Tools in RMS Structures Conclusion 323 Chapter 16 Reconfigurable Machining System (RMS) for Machining of Case and Similar Parts in Machine Building E. Abele, A. Versace, A. Worn 16.1 Development Trend Machine Concept Requirements Adaptivity of the Machine Chaining Alternative Adaptive Clamping Systems Module Interfaces Measuring Systems Economic Aspects Research Activities Outlook 338 Chapter 17 Cellular Manufacturing System Capable of Responding to Changes in Demand H. Ebara, D. Hirotani, K. Takahashi, K. Morikawa 17.1 Introduction Cell Formation Formulation Flexible Cell Formation Redesigning Cell Formation Rolling Planning Period 347

9 XXVI Contents 17.4 The Proposed Solution Method The Basic Outline of GA Chromosome Expression Initialization Evaluation of Fitness Selection and Reproduction Crossover Mutation Numerical Experiments Experimental Conditions Results and Discussion Conclusion 353 Chapter 18 Example of Reconfigurable Manufacturing System in Mold Design and Manufacturing M. Nakao 18.1 Innovations in Mold Design and Manufacturing Proposal of Decision-Based Process Design Process Design of One-Mold Production Operation Design of Multi-Mold Production Summary of Reconfigurable Manufacturing System in Mold Design and Manufacturing 367 PART IV: TRANSFORMABLE FACTORY STRUCTURES Chapter 19 Factory Transformability: Adapting the Structures of Manufacturing E. Westkämper 19.1 Introduction Transformation of Factories Adapting to Changes in a Turbulent Environment Restructuring of Factories Activating the Human Potential Autonomous (Self) Organization Permanent Adaptation of Factory Structures Advanced Industrial Engineering Adoption of Complex Systems in Engineering Phases Re-Structuring and Re-Configuring Factories More Rapidly Adaptivity Made by Industrial Engineers Summary 381

10 Contents XXVII Chapter 20 The Transformable Factory - Strategies, Methods and Examples H.-P. Wiendahl, R. Hernandez 20.1 Factories - Production Sites in Production Networks Systematic of Changeability Types of Factory Changeability Transformability Objects of Transformability Enablers of Transformability Methods and Principles for the Planning of Transformability Case Study Conclusion 392 Chapter 21 Analysis of Modern Factory Structures and Their Transformability O. Dashchenko 21.1 Introduction What is Transformability? Modern Factory Structure Trends Examples of Today's Factory Structures Concept of the Method for the Evaluation of Production Structures and Their Transformation Ability Development of a Transformable Automobile Factory Layout (Example) Conclusion 422 Chapter 22 Innovative Logistics is a Vital Part of Transformable Factories in the Automotive Industry H. Graf 22.1 Overview of the Automotive Industry Introduction Customer Orientation and Product Complexity Outsourcing of Value Added Scopes to the Suppliers Location Transfers and Globalization Logistical Built-to-Order Business Process Model of a Premium Vehicle Manufacturer Integration and Synchronization of Core Processes Process Description Customer Order-Managed Program Planning and Order Processing Customer Ordering Process Order Scheduling and Management Using the In-line Sequencing (Perlenkette) Principle 432

11 XXVIII Contents 22.4 Process-oriented Material Procurement Standard Systems in the Automobile Industry Standard Delivery Forms Supplier Location Synchronous Management of Networks in Production and Procurement Introduction Innovative Methods for Managing Production and Procurement Networks Management of Inventories, Requirements and Capacities Control-Loop-Oriented Management through Integration of Innovative Methods Flexibility Management in Production Program Planning Outlook 454 PART V: PRODUCT AND PROCESS OPTIMIZATION FOR RECONFIGURABLE MANUFACTURING Chapter 23 Products Design and Analysis for Transformable Production and Reconfigurable Manufacturing M. Abdi, A. Labib 23.1 Introduction Reconfiguration Link Product Design Products Analysis Using the AHP The AHP Theory The AHP Model A Case Study Analysis of Solutions Conclusions 477 Chapter 24 Optimal Design of the Vehicle S. V. Bakhmutov, A. L. Karunin 24.1 Introduction Theoretical Principles for Optimization of the Vehicle Design by the Specified Complex of Quality Criteria Total Algorithm for Statement of the Two-Stage Optimization Problem The First Stage of the Optimization Problem Development of the Vehicle Mathematical Model Adapted for Multicriterion Parameter Optimization Method for Solution of Multicriterion Optimization Problems The Second Stage of the Optimization Problem 510

12 Contents XXIX Estimation of the Two-Stage Optimization Efficiency General Conclusions 518 Chapter 25 New Generation of Engines with Controlled Pistons Movement for Reconfigurable Manufactures G. G. Ter-Mkrtichjan 25.1 Introduction Traverse Engines with Piston Movement Control Idea - Traverse Power Mechanism Possible Production of Traverse Engines at Reconfigured Motor Factories Mathematical Model of the Conversion Mechanism of Engines with Controlled Movement of Pistons Introduction Matrix Research of the Traverse Conversion Mechanism Kinematics Calculation and Design of the Conversion Mechanism for Engines with Controlled Movement of Pistons Optimization of the Traverse Mechanism Parameters Combined Regulation of Compression Ratio and Displacement in Traverse Engines Inference 533 Chapter 26 Experience of Rapid Prototyping Technologies Usage for Moulding Case Parts A. A. Ipatov, M. A. Zlenko 26.1 Introduction Types of RP Technologies Examples of Implementation 537 Chapter 27 Theory and Practice of Technology for Machining Non-Rigid Smooth Shafts in Reconfigurable Production Yu. V. Maksimov, A. V. Ankin 21Л Solution of the Problem Analysis of Combined Machining Processes Analysis of Errors in Parts' Combined Machining Simulation and Optimization of Processes Conclusion 567

13 XXX Contents Chapter 28 Application of Non-Traditional Assembly Methods in Reconfigurable Manufacturing O. A. Dashchenko, P. E. Elchov, A. I, Dashchenko 28.1 Introduction Assembly as the Main Application Domain for the Reconfigurable Equipment Impact of New Technologies on Reconfigurability Parametric Optimization of the Processes Reconfigurable Assembly Line based on Multi-Position Pneumovortical Automates Conclusion 580 Chapter 29 Laser Technologies K. V. Frolov, A. K. Skvorchevsky 29.1 Introduction Physical Fundamentals of Laser Methods Connection between Measured Parameters and Assembling Exterior Technological Conditions Mathematical Model of Connection of the Optical Parameters of Transformation of a Signal with Design and Technological Parameters of Assembling Theory of Conjugation and Transformation Functions Restoration of a Signal of Assembling Measurements under Vacuum Assembling Laser Assembly Algorithm 602 Chapter 30 Selecting an Optimal Production Order and Its Corresponding Configuration in a Reconfigurable Manufacturing System with Multiple Product Groups K. Takahashi, K. Morikawa, Myreshka, T. Ohiro, A. Takubo 30.1 Introduction Background Modeling RMS Assumptions The Selection Policy Optimal System Configuration Problem The Previous Method The Proposed Method Modelling the Proposed Method Algorithms for Selecting System Configuration Numerical Examples 619

14 Contents 30.6 Simulation Algorithms for Selecting System Configuration by Using Simulation Experiments Concluding Remarks 625 PART VI: ECONOMICS OF RMS Chapter 31 Economical Models for Reconfigurable Manufacturing Systems M. Bruccoleri, G. Perrone 31.1 Introduction The DML Model The Parametric Approach The FMS Model The RMS Model The Factors Constraints Numerical Example Conclusions and Further Developments 640 Chapter 32 Life Cycle Cost Calculation for Manufacturing Systems by Means of Reconfigurability Analysis A. Urbani 32.1 Introduction Overview of the Approach Model and Method for Lifecycle Analysis Generation of Production Alternatives Life Cycle Analysis of Each Generated Alternative A Model for the Life Cycle Analysis of Production Solutions Based on the Assessment of their Reconfigurability Modification of the Production Mix Change in Available Production Time Reconfigurations Method for Life Cycle Cost (LCC) Analysis 656 Chapter 33 An Analytical Comparison on Cost and Performance among DMS, AMS, FMS and RMS G. Zhang, R. Liu, L. Gong, Q. Huang 33.1 Evolution in Manufacturing Systems Dedicated Manufacturing Systems (DMS) Adjustable Manufacturing Systems (AMS) 660

15 XXXII Contents Flexible Manufacturing Systems (FMS) Reconfigurable Manufacturing Systems (RMS) Description of the Method Adaptability for Multiple Products System Complexity Production Rate Reconfiguration Time and Ramp-up Time Life Cycle Cost Discussion Analysis on SDIs Ramp-up Time Application of SMED Methodology Combination and Adjustment Standardization Conclusion 672 Chapter 34 Real Options: an Application to RMS Investment Evaluation M. Amico, F. Asl, Z. Pasek, G. Perrone 34.1 Introductions Real Option Framework The Payoff Function The Manufacturing Scenario Conclusions 691 PART VII: FUTURE TRENDS Chapter 35 Future Scenarios, Describing Consistent Networks of Influences from Markets, Technologies and Business Environment with a Time Horizon of 2020 /. Gausemeier, G. Stollt, C. Wenzelmann 35.1 The Product Innovation Process - the Path from an Idea to a Successful Product Launch Scenario Technique - Systematic Recognition of Future Success Potentials Identification of Influence Factors Systems Analysis and Determination of Key Factors Description of Alternative Developments in Future (Future Projections) Development of Consistent and Plausible Scenarios Comprehensible Description (Prose) of Scenarios Identification of Opportunities and Threats Determination of Options for Actions 705

16 Contents XXXIII 35.3 Developing Market and Business Environment Scenarios Considering the European Machine-Tool Industry as Example Systematic Development of Business-, Product-, and Technology-Strategies Conclusion 716 Chapter 36 Intelligent Systems, Self-optimizing Concepts and Structures J. Gausemeier, U. Frank, D. Steffen 36.1 From Mechatronics to Self-Optimization Architecture of the Information Processing of Self-Optimizing Systems Basic Constructs for the Development of Self-Optimizing Systems The Early Phases of the Development Process for Self-Optimizing Systems Summary 741 Chapter 37 Virtual Production - Computer Model-Based Planning and Analyzing of Manufacturing Systems J. Gausemeier, P. Ebbesmeyer, R. Eckes 37.1 The Product Creation Process Current Focal Points in Virtual Product Creation Process Planning Layout Planning Manufacturing Cell Planning Material Flow Simulation Simulation of Manufacturing Technology A Reference Model for the Development of Production Systems Conclusion 757