Editorial

3 pages, 181 KiB

Open AccessEditorial

Design and Management of Manufacturing Systems

by Arkadiusz Gola

Appl. Sci. 2021, 11(5), 2216; https://doi.org/10.3390/app11052216 - 03 Mar 2021

Cited by 14 | Viewed by 1897

Although the design and management of manufacturing systems have been explored in the literature for many years now, they still remain topical problems in current scientific research [...] Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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23 pages, 2140 KiB

Open AccessArticle

The Use of Artificial Intelligence Methods to Assess the Effectiveness of Lean Maintenance Concept Implementation in Manufacturing Enterprises

by Katarzyna Antosz, Lukasz Pasko and Arkadiusz Gola

Appl. Sci. 2020, 10(21), 7922; https://doi.org/10.3390/app10217922 - 08 Nov 2020

Cited by 35 | Viewed by 4157

Abstract

The increase in the performance and effectiveness of maintenance processes is a continuous aim of production enterprises. The elimination of unexpected failures, which generate excessive costs and production losses, is emphasized. The elements that influence the efficiency of maintenance are not only the [...] Read more.

The increase in the performance and effectiveness of maintenance processes is a continuous aim of production enterprises. The elimination of unexpected failures, which generate excessive costs and production losses, is emphasized. The elements that influence the efficiency of maintenance are not only the choice of an appropriate conservation strategy but also the use of appropriate methods and tools to support the decision-making process in this area. The research problem, which was considered in the paper, is an insufficient means of assessing the degree of the implementation of lean maintenance. This problem results in not only the possibility of achieving high efficiency of the exploited machines, but, foremost, it influences a decision process and the formulation of maintenance policy of an enterprise. The purpose of this paper is to present the possibility of using intelligent systems to support decision-making processes in the implementation of the lean maintenance concept, which allows the increase in the operational efficiency of the company’s technical infrastructure. In particular, artificial intelligence methods were used to search for relationships between specific activities carried out under the implementation of lean maintenance and the results obtained. Decision trees and rough set theory were used for the analysis. The decision trees were made for the average value of the overall equipment effectiveness (OEE) indicator. The rough set theory was used to assess the degree of utilization of the lean maintenance strategy. Decision rules were generated based on the proposed algorithms, using RSES software, and their correctness was assessed. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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25 pages, 2490 KiB

Open AccessArticle

LCA as a Tool for the Environmental Management of Car Tire Manufacturing

by Piotrowska Katarzyna, Piasecka Izabela, Bałdowska-Witos Patrycja, Kruszelnicka Weronika and Tomporowski Andrzej

Appl. Sci. 2020, 10(20), 7015; https://doi.org/10.3390/app10207015 - 09 Oct 2020

Cited by 17 | Viewed by 4832

Abstract

Car tire manufacturing can be the cause of numerous environmental hazards. Harmful emissions from the production process are an acute danger to human health as well as the environment. To mitigate these unwanted consequences, manufacturers employ the eco-balance analysis at the product designing [...] Read more.

Car tire manufacturing can be the cause of numerous environmental hazards. Harmful emissions from the production process are an acute danger to human health as well as the environment. To mitigate these unwanted consequences, manufacturers employ the eco-balance analysis at the product designing and development stage, when formulating general development strategies, and increasingly when investigating the entire product lifecycle management process. Since the negative effects of products are considered in a broader range of implications, it has become necessary to extend the traditional scope of analytical interest onto the production, use, and end-of-life stages. This work investigates the manufacturing of passenger car tires executed with traditional and modern manufacturing technologies. The Life Cycle Assessment (LCA) of tires reported in this study involved three LCA methods: Eco-Indicator 99, Cumulative Energy Demand (CED) and the scientific assessment methods developed by the Intergovernmental Panel on Climate Change, Global Warming Potential (IPCC). LCA as a tool for environmental analysis can be carried out for the entire life cycle or its individual phases. The implementation of the work made it possible to demonstrate that as a result of the identification of the main sources of negative impacts, it is possible to propose ways to minimize these impacts in the car tire manufacturing process. The results indicate that the most damaging impact is the depletion of natural resources, which play a key role in the production process of car tires. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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16 pages, 1398 KiB

Open AccessArticle

Layout Guidelines for 3D Printing Devices

by Arkadiusz Kowalski and Robert Waszkowski

Appl. Sci. 2020, 10(18), 6333; https://doi.org/10.3390/app10186333 - 11 Sep 2020

Cited by 5 | Viewed by 2249

Abstract

3D printing methods are constantly gaining in popularity among investors, allowing for the production of products with a complex structure, and also used in the production of products with increasingly longer production series. It is planned to build factories (or those already under [...] Read more.

3D printing methods are constantly gaining in popularity among investors, allowing for the production of products with a complex structure, and also used in the production of products with increasingly longer production series. It is planned to build factories (or those already under construction) in which 3D printing devices are the basic production devices. It is therefore important to develop guidelines and recommendations for layout design principles for additive technologies’ devices. A question should be asked: will the development of a layout for additive technology machines in future factories differ from the preparation of a layout plan, for example, removal machining devices? Is it safe to assume that the mathematical methods of optimizing the layout of Computerized Relative Allocation of Facilities Technique (CRAFT), Computerized Relationship Layout Planning (CORELAP), and Modified Spanning Tree (MST) workstations or Schmigalla triangles will also work for 3D printing machines and devices? In search of answers to these questions, the article will attempt to apply a selected mathematical method to optimize the layout of workstations when machines and devices of additive technology are deployed for the assumed technological process and implemented according to frequently used Selective Laser Sintering (SLS) and Selective Laser Melting (SLM) technologies. A sample layout will be prepared for the assumed production plan and selected 3D printing technologies. Requirements and guidelines relevant to the development of layout plans will be collected regarding the necessary space, installations, and connections. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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13 pages, 951 KiB

Open AccessArticle

Parametric Estimation and Constraint Programming-Based Planning and Simulation of Production Cost of a New Product

by Marcin Relich and Antoni Świć

Appl. Sci. 2020, 10(18), 6330; https://doi.org/10.3390/app10186330 - 11 Sep 2020

Cited by 16 | Viewed by 2501

Abstract

Currently-used decision support solutions allow decision makers to estimate the cost of developing a new product, its production, and promotion, and compare the estimated cost to the target cost. However, these solutions are inadequate for supporting simulations of identifying conditions, by which the [...] Read more.

Currently-used decision support solutions allow decision makers to estimate the cost of developing a new product, its production, and promotion, and compare the estimated cost to the target cost. However, these solutions are inadequate for supporting simulations of identifying conditions, by which the specific cost is reached. The proposed approach provides a framework for searching for possible variants towards reaching the target production cost. This paper is concerned with a prototyping problem of product development described in terms of a constraint satisfaction problem. The proposed method uses parametric estimation to identify relationships between variables, and constraint programming to search for project completion variants within the company’s resources and project requirements. The results of an experiment indicate that constraint programming provides effective search strategies for finding admissible solutions. Consequently, the proposed approach allows decision makers to obtain alternative scenarios within the limits imposed by the production process. In this, it outperforms current methods dedicated to the support of evaluating the total cost of a new product. The declarative approach presented in this paper is used to model the production cost; however, it can be effortlessly extended to other aspects of product development (e.g., product reliability). Full article

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18 pages, 2049 KiB

Open AccessArticle

Predictive Scheduling with Markov Chains and ARIMA Models

by Łukasz Sobaszek, Arkadiusz Gola and Edward Kozłowski

Appl. Sci. 2020, 10(17), 6121; https://doi.org/10.3390/app10176121 - 03 Sep 2020

Cited by 10 | Viewed by 2883

Abstract

Production scheduling is attracting considerable scientific interest. Effective scheduling of production jobs is a critical element of smooth organization of the work in an enterprise and, therefore, a key issue in production. The investigations focus on improving job scheduling effectiveness and methodology. Due [...] Read more.

Production scheduling is attracting considerable scientific interest. Effective scheduling of production jobs is a critical element of smooth organization of the work in an enterprise and, therefore, a key issue in production. The investigations focus on improving job scheduling effectiveness and methodology. Due to simplifying assumptions, most of the current solutions are not fit for industrial applications. Disruptions are inherent elements of the production process and yet, for reasons of simplicity, they tend to be rarely considered in the current scheduling models. This work presents the framework of a predictive job scheduling technique for application in the job-shop environment under the machine failure constraint. The prediction methods implemented in our work examine the nature of the machine failure uncertainty factor. The first section of this paper presents robust scheduling of production processes and reviews current solutions in the field of technological machine failure analysis. Next, elements of the Markov processes theory and ARIMA (auto-regressive integrated moving average) models are introduced to describe the parameters of machine failures. The effectiveness of our solutions is verified against real production data. The data derived from the strategic machine failure prediction model, employed at the preliminary stage, serve to develop the robust schedules using selected dispatching rules. The key stage of the verification process concerns the simulation testing that allows us to assess the execution of the production schedules obtained from the proposed model. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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17 pages, 2771 KiB

Open AccessArticle

Simulation-Based Analysis on Operational Control of Batch Processors in Wafer Fabrication

by Pyung-Hoi Koo and Rubén Ruiz

Appl. Sci. 2020, 10(17), 5936; https://doi.org/10.3390/app10175936 - 27 Aug 2020

Cited by 4 | Viewed by 1900

Abstract

In semiconductor wafer fabrication (wafer fab), wafers go through hundreds of process steps on a variety of processing machines for electrical circuit building operations. One of the special features in the wafer fabs is that there exist batch processors (BPs) where several wafer [...] Read more.

In semiconductor wafer fabrication (wafer fab), wafers go through hundreds of process steps on a variety of processing machines for electrical circuit building operations. One of the special features in the wafer fabs is that there exist batch processors (BPs) where several wafer lots are processed at the same time as a batch. The batch processors have a significant influence on system performance because the repetitive batching and de-batching activities in a reentrant product flow system lead to non-smooth product flows with high variability. Existing research on the BP control problems has mostly focused on the local performance, such as waiting time at the BP stations. This paper attempts to examine how much BP control policies affect the system-wide behavior of the wafer fabs. A simulation model is constructed with which experiments are performed to analyze the performance of BP control rules under various production environments. Some meaningful insights on BP control decisions are identified through simulation results. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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26 pages, 7701 KiB

Open AccessArticle

Productivity Improvement through Reengineering and Simulation: A Case Study in a Footwear-Industry

by Rubén Calderón-Andrade, Eva Selene Hernández-Gress and Marco Antonio Montufar Benítez

Appl. Sci. 2020, 10(16), 5590; https://doi.org/10.3390/app10165590 - 12 Aug 2020

Cited by 9 | Viewed by 4480

Abstract

Process reengineering is a very useful tool, specifically in industrial engineering where technological advances, information systems, customer requirements, and more have led to the need for radical change in some or all areas of an organization. The objective of this work is to [...] Read more.

Process reengineering is a very useful tool, specifically in industrial engineering where technological advances, information systems, customer requirements, and more have led to the need for radical change in some or all areas of an organization. The objective of this work is to show the usefulness of applying reengineering in the case of the footwear industry to make a proposal to change the problem area and the production decoration line as well as compare it with the current process using models of simulation performed in the Arena™ software. The proposal consisted of merging two production lines and comparing the current design with the proposal as well as comparing different parameters such as the use of resources and the production rate. The results indicated that the production rate increases by approximately 29% with the new design, using the same resources. In addition, using the OptQuest tool of the Arena™ software, it was found that with the new process, the production rate could be increased by up to 41% compared to the current process. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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33 pages, 11903 KiB

Open AccessArticle

Automatic Supervisory Controller for Deadlock Control in Reconfigurable Manufacturing Systems with Dynamic Changes

by Husam Kaid, Abdulrahman Al-Ahmari, Zhiwu Li and Reggie Davidrajuh

Appl. Sci. 2020, 10(15), 5270; https://doi.org/10.3390/app10155270 - 30 Jul 2020

Cited by 14 | Viewed by 2066

Abstract

In reconfigurable manufacturing systems (RMSs), the architecture of a system can be modified during its operation. This reconfiguration can be caused by many motivations: processing rework and failures, adding new products, adding new machines, etc. In RMSs, sharing of resources may lead to [...] Read more.

In reconfigurable manufacturing systems (RMSs), the architecture of a system can be modified during its operation. This reconfiguration can be caused by many motivations: processing rework and failures, adding new products, adding new machines, etc. In RMSs, sharing of resources may lead to deadlocks, and some operations can therefore remain incomplete. The objective of this article is to develop a novel two-step solution for quick and accurate reconfiguration of supervisory controllers for deadlock control in RMSs with dynamic changes. In the first step, the net rewriting system (NRS) is used to design a reconfigurable Petri net model under dynamic configurations. The obtained model guarantees boundedness behavioral property but may lose the other properties of a Petri net model (i.e., liveness and reversibility). The second step develops an automatic deadlock prevention policy for the reconfigurable Petri net using the siphon control method based on a place invariant to solve the deadlock problem with dynamic structure changes in RMSs and achieve liveness and reversibility behavioral properties for the system. The proposed approach is tested using examples in the literature and the results highlight the ability of the automatic deadlock prevention policy to adapt to RMSs configuration changes. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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23 pages, 3774 KiB

Open AccessArticle

Identification of Optimal Process Parameter Settings Based on Manufacturing Performance for Fused Filament Fabrication of CFR-PEEK

by Kijung Park, Gayeon Kim, Heena No, Hyun Woo Jeon and Gül E. Okudan Kremer

Appl. Sci. 2020, 10(13), 4630; https://doi.org/10.3390/app10134630 - 03 Jul 2020

Cited by 13 | Viewed by 3678

Abstract

Fused filament fabrication (FFF) has been proven to be an effective additive manufacturing technique for carbon fiber reinforced polyether–ether–ketone (CFR-PEEK) due to its practicality in use. However, the relationships between the process parameters and their trade-offs in manufacturing performance have not been extensively [...] Read more.

Fused filament fabrication (FFF) has been proven to be an effective additive manufacturing technique for carbon fiber reinforced polyether–ether–ketone (CFR-PEEK) due to its practicality in use. However, the relationships between the process parameters and their trade-offs in manufacturing performance have not been extensively studied for CFR-PEEK although they are essential to identify the optimal parameter settings. This study therefore investigates the impact of critical FFF parameters (i.e., layer thickness, build orientation, and printing speed) on the manufacturing performance (i.e., printing time, dimensional accuracy, and material cost) of CFR-PEEK outputs. A full factorial design of the experiments is performed for each of the three sample designs to identify the optimal parameter combinations for each performance measure. In addition, multiple response optimization was used to derive optimal parameter settings for the overall performance. The results show that the optimal parameter settings depend on the performance measures regardless of the designs, and that the layer thickness plays a critical role in the performance trade-offs. In addition, lower layer thickness, horizontal orientation, and higher speed form the optimal settings to maximize the overall performance. The findings from this study indicate that FFF parameter settings for CFR-PEEK should be identified through multi-objective decision making that involves conflicts between the operational objectives for the parameter settings. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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24 pages, 7958 KiB

Open AccessArticle

Modeling and Simulation of Processes in a Factory of the Future

by Patrik Grznár, Milan Gregor, Martin Krajčovič, Štefan Mozol, Marek Schickerle, Vladimír Vavrík, Lukáš Ďurica, Martin Marschall and Tomáš Bielik

Appl. Sci. 2020, 10(13), 4503; https://doi.org/10.3390/app10134503 - 29 Jun 2020

Cited by 41 | Viewed by 5627

Abstract

Current trends in manufacturing, which are based on customisation and gradually customised production, are becoming the main initiator for the development of new manufacturing approaches. New manufacturing approaches are counted as the application of new behavioural management patterns that calculate the retained competencies [...] Read more.

Current trends in manufacturing, which are based on customisation and gradually customised production, are becoming the main initiator for the development of new manufacturing approaches. New manufacturing approaches are counted as the application of new behavioural management patterns that calculate the retained competencies of decision-making by the individual members of the system agent; the production becomes decentralised. The interaction of the members of such a system creates emergent behaviour, where the result cannot be accurately determined by ordinary methods and simulation must be applied. Modelling and simulation will, therefore, be an integral part of the planning and control of the processes of factories of the future. The purpose of the article is to describe the use of modelling and simulation processes in factories of the future. The first part of the article describes new manufacturing concepts that will be used in factories of the future, with a description of modelling and simulation routing in the frame of Industry 4.0. The next section describes how simulation is used for the control of manufacturing processes in factories of the future. The included subsection describes the implementation of this suggested pattern in the laboratory of ZIMS (Zilina Intelligent Manufacturing System), with an example of a metamodeling application and the results obtained. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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30 pages, 1990 KiB

Open AccessArticle

Eco-Design of Energy Production Systems: The Problem of Renewable Energy Capacity Recycling

by Svetlana Ratner, Konstantin Gomonov, Svetlana Revinova and Inna Lazanyuk

Appl. Sci. 2020, 10(12), 4339; https://doi.org/10.3390/app10124339 - 24 Jun 2020

Cited by 20 | Viewed by 4621

Abstract

Due to the rapid development of recycling technologies in recent years, more data have appeared in the literature on the environmental impact of the final stages of the life cycle of wind and solar energy. The use of these data in the eco-design [...] Read more.

Due to the rapid development of recycling technologies in recent years, more data have appeared in the literature on the environmental impact of the final stages of the life cycle of wind and solar energy. The use of these data in the eco-design of modern power generation systems can help eliminate the mistakes and shortcomings when planning wind and solar power plants and make them more eco-efficient. The aim of this study is to extend current knowledge of the environmental impacts of most common renewables throughout the entire life cycle. It examines recent literature data on life cycle assessments of various technologies for recycling of wind turbines and photovoltaic (PV) panels and develops the recommendations for the eco-design of energy systems based on solar and wind power. The study draws several general conclusions. (i) The contribution of further improvements in PV’s recycling technologies to environmental impacts throughout the entire life cycle is insignificant. Therefore, it is more beneficial to focus further efforts on economic parameters, in particular, on achieving the economic feasibility of recycling small volumes of PV-waste. (ii) For wind power, the issue of transporting bulky components of wind turbines to and from the installation location is critical for improving the eco-design of the entire life cycle. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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27 pages, 5207 KiB

Open AccessArticle

Assessment of the Design for Manufacturability Using Fuzzy Logic

by Józef Matuszek, Tomasz Seneta and Aleksander Moczała

Appl. Sci. 2020, 10(11), 3935; https://doi.org/10.3390/app10113935 - 05 Jun 2020

Cited by 5 | Viewed by 2689

Abstract

The study proposes a procedure for assessing the designed manufacturing process for a new products. The purpose of the developed procedure is to evaluate the production process from the point of view of product design manufacturability of a unit and the small-lot production [...] Read more.

The study proposes a procedure for assessing the designed manufacturing process for a new products. The purpose of the developed procedure is to evaluate the production process from the point of view of product design manufacturability of a unit and the small-lot production process. Evaluation of the design for the production process of a new product is based on criteria like process performance efficiency. Fuzzy logic-based methods were used to assess the designed process at different stages of its implementation—processing, assembly and organization of production. The developed method was illustrated by an example. The method presented in the study may be used by designers of production processes and employees of companies involved in the rationalization of already implemented production processes. The proposed method applies specifically to small-lot and unit production. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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16 pages, 1658 KiB

Open AccessArticle

Analytic Hierarchy Process and Multilayer Network-Based Method for Assembly Line Balancing

by László Nagy, Tamás Ruppert and János Abonyi

Appl. Sci. 2020, 10(11), 3932; https://doi.org/10.3390/app10113932 - 05 Jun 2020

Cited by 10 | Viewed by 2404

Abstract

Assembly line balancing improves the efficiency of production systems by the optimal assignment of tasks to operators. The optimisation of this assignment requires models that provide information about the activity times, constraints and costs of the assignments. A multilayer network-based representation of the [...] Read more.

Assembly line balancing improves the efficiency of production systems by the optimal assignment of tasks to operators. The optimisation of this assignment requires models that provide information about the activity times, constraints and costs of the assignments. A multilayer network-based representation of the assembly line-balancing problem is proposed, in which the layers of the network represent the skills of the operators, the tools required for their activities and the precedence constraints of their activities. The activity–operator network layer is designed by a multi-objective optimisation algorithm in which the training and equipment costs as well as the precedence of the activities are also taken into account. As these costs are difficult to evaluate, the analytic hierarchy process (AHP) technique is used to quantify the importance of the criteria. The optimisation problem is solved by a multi-level simulated annealing algorithm (SA) that efficiently handles the precedence constraints. The efficiency of the method is demonstrated by a case study from wire harness manufacturing. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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21 pages, 1204 KiB

Open AccessArticle

On Solving Large-Size Generalized Cell Formation Problems via a Hard Computing Approach Using the PMP

by Youkyung Won

Appl. Sci. 2020, 10(10), 3478; https://doi.org/10.3390/app10103478 - 18 May 2020

Cited by 4 | Viewed by 2132

Abstract

In this paper, we show that the hard computing approach using the p-median problem (PMP) is a very effective strategy for optimally solving large-size generalized cell formation (GCF) problems. The soft computing approach, relying on heuristic or metaheuristic search algorithms, has been [...] Read more.

In this paper, we show that the hard computing approach using the p-median problem (PMP) is a very effective strategy for optimally solving large-size generalized cell formation (GCF) problems. The soft computing approach, relying on heuristic or metaheuristic search algorithms, has been the prevailing strategy for solving large-size GCF problems with a short computation time at the cost of the global optimum in large instances of GCF problems; however, due to recent advances in computing technology, using hard computing techniques to solve large-sized GCF problems optimally is not time-prohibitive if an appropriate mathematical model is built. We show that the hard computing approach using the PMP-type model can even solve large 0–1 GCF instances optimally in a very short computation time with a powerful mixed integer linear programming (MILP) solver adopting an exact search algorithm such as the branch-and-bound algorithm. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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26 pages, 6087 KiB

Open AccessArticle

Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company

by Arturo Realyvásquez-Vargas, Karina Cecilia Arredondo-Soto, Jorge Luis García-Alcaraz and Emilio Jiménez Macías

Appl. Sci. 2020, 10(7), 2433; https://doi.org/10.3390/app10072433 - 02 Apr 2020

Cited by 12 | Viewed by 6335

Abstract

Customer satisfaction is a key element for survival and competitiveness in industrial companies. This paper describes a case study in a manufacturing company that deals with several customer complaints due to defective custom cable assemblies that are integrated in an engine. The goal [...] Read more.

Customer satisfaction is a key element for survival and competitiveness in industrial companies. This paper describes a case study in a manufacturing company that deals with several customer complaints due to defective custom cable assemblies that are integrated in an engine. The goal of this research is to find a solution to this problem, as well as prevent its recurrence by implementing the eight disciplines (8Ds) method in order to: (1) develop a team, (2) describe the problem, (3) develop an interim containment action, (4) determine and verify root causes, (5) develop permanent corrective actions, (6) define and implement corrective actions, (7) prevent recurrences, and (8) recognize and congratulate teamwork as well as individual contributions. Therefore, a software tool is proposed to conduct a functional test on assembly lines. After the test, the problem was successfully reduced and detected, because from 67 engines that were identified with problems, 51 were redesigned before being sent to customers, consequently decreasing the number of defective products by 75%, whereas the remaining 16 engines were replaced by new engines. In conclusion, the research goal was accomplished, and the 8Ds method proved to be a helpful model with which to increase employees’ motivation and involvement during the problem-solving process. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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15 pages, 1655 KiB

Open AccessArticle

Evaluation of Machinery Readiness Using Semi-Markov Processes

by Andrzej Świderski, Anna Borucka, Małgorzata Grzelak and Leszek Gil

Appl. Sci. 2020, 10(4), 1541; https://doi.org/10.3390/app10041541 - 24 Feb 2020

Cited by 22 | Viewed by 2941

Abstract

This article uses Markov and semi-Markov models as some of the most popular tools to estimate readiness and reliability. They allow to evaluate of both individual elements as well as entire systems—including production systems—as multi-state structures. To be able to distinguish states with [...] Read more.

This article uses Markov and semi-Markov models as some of the most popular tools to estimate readiness and reliability. They allow to evaluate of both individual elements as well as entire systems—including production systems—as multi-state structures. To be able to distinguish states with varying degrees of technical readiness in complicated and complex objects (systems) allows to determine their individual impact on the tasks performed, as well as on the total reliability. The application of the Markov process requires, for the process dwell times in the individual states, to be random variables of exponential distribution and the fulfilling Markov’s property of the independence of these states. Omitting these assumptions may lead to erroneous results, which was the authors’ intention to show. The article presents a comparison of the results of the examination of the process of non-parametric distribution with an analysis in which its exponential form was (groundlessly) assumed. Significantly different results were obtained. The aim was to draw attention to the inconsistencies obtained and to the importance of a preliminary assessment of the data collected for examination. The diagnostics of the machine readiness operating in the studied production company was additionally performed. This allowed to evaluate its operational potential, especially in the context of solving process optimization problems. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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20 pages, 5210 KiB

Open AccessArticle

The Level of the Additive Manufacturing Technology Use in Polish Metal and Automotive Manufacturing Enterprises

by Justyna Patalas-Maliszewska, Marcin Topczak and Sławomir Kłos

Appl. Sci. 2020, 10(3), 735; https://doi.org/10.3390/app10030735 - 21 Jan 2020

Cited by 27 | Viewed by 4049

Abstract

(1) Background: Products, manufactured using additive manufacturing technologies (AM) are increasingly present on the market. The research was undertaken to determine the possibilities of increasing the use of AM technology in Polish manufacturing companies. The aim of the paper is to determinate the [...] Read more.

(1) Background: Products, manufactured using additive manufacturing technologies (AM) are increasingly present on the market. The research was undertaken to determine the possibilities of increasing the use of AM technology in Polish manufacturing companies. The aim of the paper is to determinate the level of the AM technology use of Polish Metal and Automotive Manufacturing and the influence of AM technology use on the increase of manufacturing company’s competitiveness–in the context of Polish Manufacturing Companies. (2) Methods: This paper uses literature studies to determinate the AM technology used within the production processes in the automotive and metal industry companies (so called dimensions) and a questionnaire survey, which was carried out on a sample of 250 Polish Metal and Automotive Manufacturing Enterprises. (3) Results: The results were verified by a statistical analysis, using correlation coefficients. Based on the data obtained, it was determined that both metal and automotive Polish companies use, or have in their investment plans, the implementation of AM technology, due to the need to reduce production costs and increase speed and flexibility when responding to customer needs. Moreover, the relationship between applied additive manufacturing technologies and the effects of their use, in enterprises, was analysed. The novelty of our work is defining the dimensions of the AM technology use for our empirical research and determining the influence of AM technology use on the increase Polish manufacturing company’s competitiveness. (4) Conclusions: The possibilities of using the results of research in economic practice were demonstrated. We also highlighted the impracticality for managers to support the selection and implementation of AM technology in the context of obtaining possible benefits for a manufacturing company. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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23 pages, 569 KiB

Open AccessArticle

Game-Theoretic Analysis to Examine How Government Subsidy Policies Affect a Closed-Loop Supply Chain Decision

by Izabela Ewa Nielsen, Sani Majumder and Subrata Saha

Appl. Sci. 2020, 10(1), 145; https://doi.org/10.3390/app10010145 - 23 Dec 2019

Cited by 34 | Viewed by 3943

Abstract

The pros and cons of government subsidy policies in a closed-loop supply chain (CLSC) setting on optimal pricing, investment decisions in improving product quality, and used product collection under social welfare (SW) optimization goal have not been examined comprehensively. This study compares the [...] Read more.

The pros and cons of government subsidy policies in a closed-loop supply chain (CLSC) setting on optimal pricing, investment decisions in improving product quality, and used product collection under social welfare (SW) optimization goal have not been examined comprehensively. This study compares the outcomes of three government policies under manufacturer-Stackelberg (MS) and retailer-Stackelberg (RS), namely (i) direct subsidy to the consumer, (ii) subsidy to the manufacturer to stimulate used product collection, and (iii) subsidy to the manufacturer to improve product quality. Results demonstrate that the greening level, used product collection, and SW are always higher under the RS game, but the rate of a subsidy granted by the government is always higher under the MS game. Profits for the CLSC members and SW are always higher if the government provides a subsidy directly to the consumer, but productivity of investment in the perspective of the manufacturer or government are less. In a second policy, the government organizations grant a subsidy to the manufacturer to stimulate used product collection, but it does not necessarily yield the desired outcome compared to others. In a third policy, the manufacturer receives a subsidy on a research and development (R&D) investment, but it yields a sub-optimal greening level. This study reveals that the outcomes of subsidy policies can bring benefit to consumers and add a degree of complication for CLSC members; government organizations need to inspect carefully among attributes, mainly product type, power of CLSC members, and investment efficiency for the manufacturer, before implementing any subsidy policies so that it can lead to an environmentally and economically viable outcome. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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15 pages, 1453 KiB

Open AccessArticle

Bootstrap Analysis of the Production Processes Capability Assessment

by Patrycjusz Stoma, Monika Stoma, Agnieszka Dudziak and Jacek Caban

Appl. Sci. 2019, 9(24), 5360; https://doi.org/10.3390/app9245360 - 08 Dec 2019

Cited by 9 | Viewed by 3136

Abstract

The high customer requirements for appropriate product quality pose a challenge for manufacturers and suppliers and also cause them many problems related to ensuring a sufficiently high product quality throughout the entire production cycle. For the above reasons, it is so important to [...] Read more.

The high customer requirements for appropriate product quality pose a challenge for manufacturers and suppliers and also cause them many problems related to ensuring a sufficiently high product quality throughout the entire production cycle. For the above reasons, it is so important to assess the capability of monitored processes, and shaping, analyzing and controlling the capability of processes is an important aspect of managing an organization that uses a process approach to management. The use of an appropriate method to analyze the course of production processes is a necessity imposed by quality standards, e.g., ISO 9001: 2015. That is why it is so important to propose a quick and low-cost method of assessing production processes. For this purpose, a method of assessing the capability of the manufacturing process using bootstrap analysis was used. The article presents the analysis of inherent properties of the production process based on the results of measurements of the characteristic features of the process or the characteristics of the manufactured products (process variables) for the shafts with grooves. The main goals of the work are to develop a procedure for determining process capability based on the bootstrap method, including criteria for the classification of production process capability; to develop the criterion values for confidence intervals of production process capability; as well as to demonstrate the practical application of bootstrap analysis in manufacturing. Moreover, comparative analyses of process capabilities using bootstrap and classic methods were carried out. They confirm both the narrowing of the confidence interval when using the bootstrap method and the possibility of determining a better estimator of the lower limit of this range compared to the results obtained using the classic method. The tests carried out for the unit production of shafts with grooves showed that the analysis of the process capability for measuring tests n = 10 is possible. Finally, new criterion values for the assessment of process capability for the bootstrap method were proposed. The model for assessing the capability of production processes presented in the paper was implemented in low-volume production in the defense industry. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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16 pages, 1103 KiB

Open AccessArticle

Application of Logistic Regression for Production Machinery Efficiency Evaluation

by Anna Borucka and Małgorzata Grzelak

Appl. Sci. 2019, 9(22), 4770; https://doi.org/10.3390/app9224770 - 08 Nov 2019

Cited by 14 | Viewed by 2888

Abstract

Production companies operate in a complex economic, technological, social and political environment. There are a number of factors contributing to a satisfactory market position, the most important one being a properly defined and implemented strategy. It needs, however, to be continuously monitored and, [...] Read more.

Production companies operate in a complex economic, technological, social and political environment. There are a number of factors contributing to a satisfactory market position, the most important one being a properly defined and implemented strategy. It needs, however, to be continuously monitored and, if necessary, modified. One of the elements subject to such evaluation is the efficiency of the production processes, which has become the genesis of this article. In response to the methods presented in the literature, a proposal using the logistic regression method for this purpose is presented. The dichotomous form of the dependent variable makes it possible to make such an evaluation in an unambiguous manner and to determine the significance and influence of selected factors on the result thereof. Full article

(This article belongs to the Special Issue Design and Management of Manufacturing Systems)

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