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An Optimized Production Technology Approach to Design for Throughput 面向产量设计的优化生产技术方法
Pub Date : 1999-11-14 DOI: 10.1115/imece1999-0785
S. B. Billatos, Gregg Wolffarth
Many manufacturing organizations are losing their competitive position due to a large number of reasons discussed in this paper. To regain a competitive position, organizations must clearly understand their goals. The Goal for a manufacturing organization should be making money now and in the future [1,2]. Producing products, high utilization, keeping people busy, high quality, good customer service, etc., are means to the Goal but not ‘The Goal’ itself. To achieve an organization’s goal, management must turn to OPT. OPT (Optimized Production Technology) is the original and most advanced constraint based advanced planning and scheduling system [3,4]. It is the practical implementation of the Theory of Constraints in the modeling, planning and scheduling of activity based business. OPT has proven its applicability in job shop, repetitive manufacturing and process industries all over the world. Therefore, shop floor issues, such as bottlenecks, setups, lot sizes, priorities, random fluctuations and performance measurements, are treated in great depth. The OPT philosophy incorporates nine rules which, when followed, can help move the organization towards the goal of making money. Underlying each of the rules is the understanding that effective management of an organization takes a global perspective of all resources and their interrelationship to achieve the goal. These rules coupled with a set of measurements: Throughput, Inventory and Operating Expenses, would lead any manufacturing organization to fulfilling the goal. Since few literatures have covered the general application of these measures, this paper will focus only on Throughput. The paper will discuss the step-by-step implementation procedures that would help industry in designing their systems for throughput.
由于本文讨论的大量原因,许多制造组织正在失去其竞争地位。为了重新获得竞争地位,组织必须清楚地了解他们的目标。制造组织的目标应该是现在和将来赚钱[1,2]。生产产品、高利用率、让人们忙碌、高质量、良好的客户服务等等,都是实现目标的手段,而不是“目标”本身。为了实现组织的目标,管理必须转向OPT。OPT (Optimized Production Technology,优化生产技术)是最早的、最先进的基于约束的先进计划和调度系统[3,4]。它是约束理论在基于活动的业务建模、计划和调度中的实际应用。OPT已经在世界各地的作业车间、重复制造和加工工业中证明了它的适用性。因此,车间问题,如瓶颈,设置,批量大小,优先级,随机波动和性能测量,都得到了深入的处理。OPT哲学包含了9条规则,如果遵循这些规则,可以帮助组织朝着赚钱的目标前进。每条规则的基础都是对组织的有效管理需要从全局角度看待所有资源及其相互关系以实现目标的理解。这些规则加上一组度量:吞吐量、库存和运营费用,将使任何制造组织实现目标。由于很少有文献涵盖了这些措施的一般应用,本文将只关注吞吐量。本文将讨论逐步实施的程序,这将有助于工业界设计他们的系统吞吐量。
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引用次数: 0
Innovative Design in Quality Engineering 质量工程中的创新设计
Pub Date : 1999-11-14 DOI: 10.1115/imece1999-0789
Z. Bzymek, S. B. Billatos
Industry is currently evaluating hundreds of applications to innovate their products. The Theory of Inventive Problem Solving (TIPS) can help industry achieve this goal. It provides principles of standard thinking called inventive standards that are based on a limited number of physics phenomena and mathematics theories. Applying these principles of thinking would avoid generating undesirable solutions and approach desirable ones. The theory is very powerful and almost unlimited. The basic concept of TIPS is understanding the process of describing a product that would then leads to its development. It is best applied when there are strong conflicts that the designer has to resolve. For example, to design a tailor needle, we have to solve the eye conflict. The needle’s eye should be small enough to secure comfortable sewing and big enough to put the thread through. The objective of this paper is to discuss TIPS, describe its five levels of inventive tasks and develops a systematic procedure for its application. A case study is described that details the application from the conceptual design stage to the final inventive design stage.
业界目前正在评估数百个应用程序,以创新他们的产品。创造性问题解决理论(TIPS)可以帮助工业界实现这一目标。它提供了被称为创造性标准的标准思维原则,这些标准是基于有限数量的物理现象和数学理论。运用这些思考原则可以避免产生不理想的解决方案,并接近理想的解决方案。这个理论非常强大,几乎是不受限制的。TIPS的基本概念是理解描述产品的过程,然后导致产品的开发。它最适用于设计师必须解决的强烈冲突。例如,要设计裁缝针,我们必须解决眼睛冲突。针眼应该足够小,以确保舒适的缝纫,并足够大,以使线穿过。本文的目的是讨论TIPS,描述其五个层次的发明任务,并制定了一个系统的应用程序。通过案例分析,详细介绍了从概念设计阶段到最终发明设计阶段的应用过程。
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引用次数: 0
Modeling and Optimization of Fixture for Handling Compliant Sheet Metal Parts 柔性钣金件加工夹具的建模与优化
Pub Date : 1999-11-14 DOI: 10.1115/imece1999-0791
D. Ceglarek, H. F. Li, Y. Tang
Material handling of compliant parts is one of the most critical and underresearched problems in the sheet metal stamping industry. The fundamental shortcoming of currently studied material handling systems for sheet metal stamping is the lack of analysis of its impact on part dimensional quality and production throughput. This paper addresses this problem by development of a generic methodology for modeling and optimization of part holding end-effector fixture layout in order to minimize part dimensional deformation during handling operations. The methodology extends the design of “N-2-1” fixturing layout by adding part movability conditions. It considers part CAD model, handling direction and motion kinematic parameters to determine the best end effector layout. This methodology is realized by integrating FEM part and loading modeling with the optimization algorithm. It can be implemented into the design stage of a stamping line so that the trial and error process, which is current industrial practice, can be greatly shortened and the production throughput increased. Experimental results verify the proposed part holding end-effector layout methodology.
柔性零件的材料处理是钣金冲压工业中最关键和研究不足的问题之一。目前研究的钣金冲压物料搬运系统的根本缺点是缺乏对零件尺寸质量和生产吞吐量影响的分析。本文通过开发一种通用方法来解决这一问题,该方法用于零件保持末端执行器夹具布局的建模和优化,以便在处理操作期间最大限度地减少零件尺寸变形。该方法通过增加零件可动性条件,扩展了“N-2-1”夹具布局的设计。考虑零件CAD模型、搬运方向和运动运动学参数,确定最佳末端执行器布局。该方法通过将零件和载荷有限元建模与优化算法相结合来实现。它可以实施到冲压生产线的设计阶段,从而大大缩短了目前工业实践中的试错过程,并提高了生产吞吐量。实验结果验证了所提出的零件保持末端执行器布局方法。
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引用次数: 3
Innovative Design of Manufacturing Systems 制造系统创新设计“,
Pub Date : 1999-11-14 DOI: 10.1115/imece1999-0786
V. Tsourikov, Igor Devoino
This paper focuses on a knowledge-based approach to innovative design of manufacturing systems and processes. Innovative design includes three major steps: Functional Analysis of the manufacturing process; Innovative Concept Search in the semantic knowledge base of technical and scientific effects and New Concept selection using quantitative as well as qualitative data.
本文的重点是基于知识的方法来创新设计的制造系统和过程。创新设计包括三个主要步骤:制造过程的功能分析;在科技效果的语义知识库中进行创新概念搜索,利用定量和定性数据进行新概念选择。
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引用次数: 0
Concurrent Cost Calculations With a Feature-Based CAD System 基于特征的CAD系统并行成本计算
Pub Date : 1999-11-14 DOI: 10.1115/imece1999-0790
Peter Leibi, G. Hoehne, M. Hundal
The paper describes a procedure for calculating costs concurrent with the design process. The different modules of the computer program “IKF” are described. The modules include those for cost calculation, comparison and forecast. Form features are used for cost determination by classifying each feature and storing it in the detailed production plan. The production processes then follow from the list of stored features. The cost program takes the individual geometric data, e.g., part length, from the CAD program. The latter contains data sets, that describe the feature’s dimensions. The production time for the form feature is then calculated. From the time expenditures and the machine rates the program calculates the production costs for the given feature. Prior to developing the computer program a manual procedure was designed and developed. Upon testing, the group not using IKF took 40–50% more time and designed products that were about 80% costlier than the group using the IKF system. This procedure was then used as the model for the cost modules in a feature-based CAD program. Test cases dealing with sheet-metal design are described which demonstrate and quantify the advantages of this system.
本文描述了在设计过程中同时计算成本的方法。描述了计算机程序“IKF”的不同模块。包括成本计算、成本比较和成本预测三个模块。通过对每个特征进行分类并将其存储在详细的生产计划中,形状特征用于成本确定。然后,生产过程按照存储的特征列表进行。成本程序从CAD程序中获取单个几何数据,例如零件长度。后者包含描述特征维度的数据集。然后计算表单特征的生产时间。程序根据时间花费和机器速率计算给定特性的生产成本。在开发计算机程序之前,设计并开发了一个手动程序。经过测试,不使用IKF系统的小组比使用IKF系统的小组多花了40-50%的时间,设计的产品成本约为80%。然后将该程序作为基于特征的CAD程序中成本模块的模型。描述了处理钣金设计的测试用例,证明并量化了该系统的优点。
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引用次数: 0
Robust Design: Tolerance Design Method 稳健设计:公差设计方法
Pub Date : 1999-11-14 DOI: 10.1115/imece1999-0792
Hanxiang Yang, Pah I. Chen
There are three phases involved in Robust Design — conceptual design, parameter design, and tolerance design. Parameter design aims to specify the variations of the design parameters in order to meet the design requirement, and the tolerance design further specifies the optimized parameters in order to reduce the performance variation near the design target. A robust design requires that tolerance design to be preceded by parameter design. In this paper, our effort will be focused on presenting an iterative method to perform the tolerance design phase. Two hypothetical examples (whose parameter designs have been completed) will be used to illustrate the tolerance design methodology. The first example involves the design of a pneumatic cylinder whose piston movement can be expressed by a theoretical equation containing five parameters. With the equation, it becomes a simple task for determining the tolerances of the optimized parameters to constrain the design target. The second example involves the production of a agrochemical by mixing two chemicals to achieve a specific yield. A set of test data is available but the equation relating the parameters is not. In this case, we shall adopt the linear regression technique to obtain an experimental equation to represent the test data. Based on this equation, we can proceed to determine the tolerances of different parameters in order to achieve a specific variation of the yield. The step-by-step procedure outlined in the hypothetical examples demonstrates that this iterative method is a simple and effective way to conduct the tolerance design.
稳健设计包括三个阶段:概念设计、参数设计和公差设计。参数设计旨在指定设计参数的变化,以满足设计要求,公差设计进一步指定优化参数,以减少设计目标附近的性能变化。稳健设计要求公差设计先于参数设计。在本文中,我们的工作将集中在提出一种迭代方法来执行公差设计阶段。将使用两个假设的例子(其参数设计已经完成)来说明公差设计方法。第一个例子涉及一个气缸的设计,其活塞运动可以用包含五个参数的理论方程来表示。利用该方程,确定优化参数的公差以约束设计目标成为一项简单的任务。第二个例子涉及到通过混合两种化学品来达到特定产量的农用化学品的生产。一组试验数据是可用的,但没有有关参数的方程。在这种情况下,我们将采用线性回归技术得到一个实验方程来表示测试数据。根据这个方程,我们可以继续确定不同参数的公差,以实现特定的产量变化。在假设的例子中概述的逐步过程表明,这种迭代方法是进行公差设计的一种简单有效的方法。
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引用次数: 2
A Model for Conceptual Design Methodology 概念设计方法论模型
Pub Date : 1999-11-14 DOI: 10.1115/imece1999-0788
S. Condoor, Richard G. Weber
Conceptual design is the seminal phase in the design process. This phase determines the level of product innovation, the efficiency of the product, and the effectiveness of the down-stream stages of the design process. It has tremendous leverage on the final product performance, cost, and time-to-market. To improve the efficiency of the conceptual design process, the paper combines the parameter analysis methodology with a fundamental insight from robust design. Parameter analysis is a generic design methodology that aids in systematically developing an idea into a viable design. It is particularly useful in creating innovative conceptual designs. Robust design is, often, used after finalizing the conceptual design. Robust design improves the product quality by first reducing the variability in product performance and then, tuning the low variability performance onto the target. The paper presents guidelines for executing the parameter analysis methodology which in turn provides consistent or low variability performance by considering robustness in the very early phases of the design process. The paper illustrates this process with two case studies. The case studies also show how to qualitatively optimize a conceptual design by developing the overall concept before details.
概念设计是设计过程中的萌芽阶段。这个阶段决定了产品创新的水平,产品的效率,以及设计过程的下游阶段的有效性。它对最终产品的性能、成本和上市时间有着巨大的影响。为了提高概念设计过程的效率,本文将参数分析方法与稳健设计的基本见解相结合。参数分析是一种通用的设计方法,有助于系统地将一个想法发展成可行的设计。它在创建创新的概念设计时特别有用。稳健设计通常在概念设计完成后使用。稳健设计通过首先减少产品性能的可变性,然后将低可变性性能调整到目标上,从而提高产品质量。本文提出了执行参数分析方法的指导方针,通过考虑设计过程的早期阶段的鲁棒性,反过来提供一致或低可变性的性能。本文通过两个案例来说明这一过程。案例研究还展示了如何通过在细节之前开发整体概念来定性地优化概念设计。
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引用次数: 0
Some Limitations of TRIZ Tools and Possible Ways of Improvement TRIZ工具的一些局限性和可能的改进途径
Pub Date : 1999-11-14 DOI: 10.1115/imece1999-0793
V. Kosse
The Ideation/TRIZ Methodology has grown into the most powerful engineering problem solving methodology. However, experienced users may discover some limitations of TRIZ tolls, such as empty cells in the Contradiction Matrix, missing physical effects in the library of physical effects. In this paper possible ways of improvement of the Contradiction Matrix as well as special physical effects to complement the list of physical effects and phenomena are discussed.
构思/TRIZ方法已经成长为最强大的工程问题解决方法。然而,有经验的用户可能会发现TRIZ收费的一些局限性,例如矛盾矩阵中的空单元,物理效果库中缺少物理效果。本文讨论了改进矛盾矩阵的可能途径以及特殊的物理效应,以补充物理效应和现象列表。
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引用次数: 0
Robust Tolerance Design Considering Process Capability and Quality Loss 考虑加工能力和质量损失的鲁棒公差设计
Pub Date : 1999-11-14 DOI: 10.1115/imece1999-0783
Chang-Xue Feng, Ravi Balusu
Tolerance design bridges design and manufacturing. Concurrent design of tolerances and manufacturing processes may ensure the manufacturability, reduce the manufacturing and other related costs, decrease the number of fraction nonconforming (or defective rate), and shorten the production lead time. Since process capability indices relate tolerance specifications to manufacturing process capabilities, it is quite natural to apply them to concurrent design of tolerances and processes. As process shifts often exist in a manufacturing process, using Cp does not yield a good estimation of fraction nonconforming. Index Cpk does not precisely measure process shift either, but Cpm does. Therefore, this research compares the applications of Cp, Cpk and Cpm based on a numerical example of non-linear mechanical tolerance synthesis. In addition, the Taguchi quality loss function is used together with the manufacturing cost as the objective function.
桥梁公差设计设计与制造。公差和制造工艺的并行设计可以保证产品的可制造性,降低制造成本和其他相关成本,减少不合格率(或不良率),缩短生产周期。由于过程能力指标将公差规范与制造过程能力联系起来,因此将其应用于公差和过程的并行设计是很自然的。由于工艺转移经常存在于制造过程中,使用Cp不能很好地估计不合格率。指数Cpk也不能精确地衡量过程转移,但Cpm可以。因此,本研究以非线性力学公差综合为例,比较了Cp、Cpk和Cpm的应用。此外,采用田口质量损失函数与制造成本作为目标函数。
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引用次数: 5
A Study of the Impact of Knurling Parameters on Knurl Quality With the Design of Experiments Approach 用试验设计方法研究滚花参数对滚花质量的影响
Pub Date : 1999-11-14 DOI: 10.1115/imece1999-0784
Chang-Xue Feng, Chinh Tran
A local company produces various types of connecting cables for a number of military and civilian customers. A key part of these cables is the knurled component to provide proper frictional force for easy assembly and maintenance. In the past, the company has usually faced a problem of inconsistent knurl quality. There has been no report in the literature about knurling process design. Vendors of knurling tools could only recommend the traditional try-and-error method. This research uses the design of experiments (or 2n-k fractional factorial design) approach to examine the impact of different knurling process parameters on the knurl quality. Our purpose is to determine the key factors and factor interactions that have significant effect on the knurl quality so that we could set the process parameters in such a way that the process is robust (or insensitive) to any uncontrollable factors. As a result, a robust knurl quality is achieved. A case study illustrates our approach.
当地一家公司为许多军事和民用客户生产各种类型的连接电缆。这些电缆的关键部分是滚花组件,以提供适当的摩擦力,便于组装和维护。过去,该公司经常面临滚花质量不一致的问题。目前尚无关于滚花工艺设计的文献报道。滚花工具的供应商只能推荐传统的试错方法。本研究采用实验设计(或2n-k分数因子设计)的方法,考察不同滚花工艺参数对滚花质量的影响。我们的目的是确定对滚花质量有重大影响的关键因素和因素相互作用,以便我们可以设置工艺参数,使工艺对任何不可控因素都具有鲁棒性(或不敏感)。因此,实现了坚固的滚花质量。一个案例研究说明了我们的方法。
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引用次数: 1
期刊
Conceptual and Innovative Design for Manufacturing
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