International Conference on Manufacturing Research (ICMR 2013)

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https://dspace.lib.cranfield.ac.uk/handle/1826/9337

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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Now showing 1 - 20 of 108

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, Thomas
In 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.
Open Access
An improved cell controller for the aerospace manufacturing
(Cranfield University Press, 2013-09-19) Asif, Seemal; Webb, Philip
The aerospace manufacturing industry is unique in that production typically focuses on high variety and quality but low volume. Existing flexible manufacturing cells are limited to certain types of machines, robots and cells which makes it difficult to introduce any changes. In this paper idea of treating machines, robots, any hardware and software as resource has been introduced. It describes the development of the Flexa Cell Coordinator (FCC), a system that is providing a solution to manage cells and their resources in a new flexible manner. It can control, organise and coordinate between cells and resources and is capable of controlling remote cells because of its distributed nature. It also provides connectivity with company systems e.g., Enterprise Resource Planner (ERP). It is extendable and capable of adding multiple cells inside the system. In FCC resources (e.g., tracker) can also be shared between cells. The paper presents its development and results of initial successful testing.
Open Access
Mechanical properties of three-phase polyamide 6 nanocomposites
(Cranfield University Press, 2013-09-19) Gendre, Laura; Abhyankar, Hrushikesh; Njuguna, James; Ermini, Valentina
This work focus on the mechanical properties of three-phase nanocomposites using multiscale reinforcements. The influence of the nano-fillers content, as well as the temperature were studied. Polyamide-6 reinforced with short glass fibre 30 wt.% and with an addition of nanoclay (montmorillonite) and/or nanosilica (SiO2) were tested in order to characterise their tensile properties at room temperature and at 65oC just above the polyamide 6 glass transition temperature. SEM analysis were conducted on the fracture surface of the tensile bars. SEM investigations showed the importance of the interaction matrix/filler for the material behaviour. Our study also shows that the increase of OMMT percentage in polyamide-6/glass fibre composite made the material more brittle and had a negative effect on the tensile properties. Further, for the silica-based nanocomposites, an optimum was found for a nanofillers content of 1wt.%.
Open Access
Cost, benefit, and financial risk (COBEFR) of ERP implementation
(Cranfield University Press, 2013-09-19) Badewi, Amgad; Shehab, Essam
The purpose of this research is to develop Benefits, Costs, and Financial Risks (CoBeFR) model to show and measure the impact of ERP related decisions, such as degree of business process re-engineering and the level of hardware investment, on the organisational financial value (OFV). OFV is based on current time value of money (i.e. interest rate), financial risk, and net cash flows emerged from ERP system. Financial risk, the sensitivity of the organisation net profit to changes in market conditions, is affected by organisational adoption of ERP system. The main conclusion is that there are interrelated impacts of ERP implementation decisions to the organisational financial value. Therefore, decision maker should look at the implementation decision from a new perspective which is Organisational Financial Value (OFV) perspective
Open Access
Fighters pilot helmet design for 5th generation aircraft
(Cranfield University Press, 2013-09-19) McAndrew, Ian; Moran, Katherine; Little, Andrew
Fighter pilots’ helmets have become more complex and heavier resulting in long term implications to pilots musculoskeletal systems as they fly and experience high g-load. Current research has identified design changes to the helmet to accommodate the ancillary items fitted to assist pilots but at the expense of comfort and additional loading. Its manufacturing requirements and adaptations to offer bespoke solutions are addressed to allow for training and operational usage. To produce the next generation of helmets that reduce long-term injuries, from g-loads and asymmetrical ancillaries requires individual considerations, unique manufacturing requirements and the ability to support with service spares anywhere in the world at short notice. This paper will describe how manufacturing requirements are matched to ergonomic needs and bespoke components can support global demands.
Open Access
A novel methodology to ascertain the heating mechanism of steel wire during annealing in a tube furnace
(Cranfield University Press, 2013-09-19) Hasan, Reaz; Baddage, S; Perera, Noel; Persson, Martin
The paper describes a methodology to determine the heating mechanism of steel wire inside a tube furnace used for annealing. The approach is based on Lumped Heat Capacity method of heating where the ‘surface heat transfer coefficient’ is obtained from radiation considerations. The developed methodology calculates the temperature of the wire as it travels along the tube furnace whose surface temperature is kept at about 800 oC. The results obtained from the developed methodology have been compared with experimental data and the possible reasons for the discrepancies identified. The influence of surface emissivity and its consequence on the heating rate has also been documented. The approach highlights that the method may serve as a useful tool to predict temperatures for this kind of furnace in order to optimize the manufacturing process.
Open Access
Constrained bayesian inference of project performance models
(Cranfield University Press, 2013-09-19) Sunmola, Funlade
Project performance models play an important role in the management of project success. When used for monitoring projects, they can offer predictive ability such as indications of possible delivery problems. Approaches for monitoring project performance relies on available project information including restrictions imposed on the project, particularly the constraints of cost, quality, scope and time. We study in this paper a Bayesian inference methodology for project performance modelling in environments where information about project constraints is available and can be exploited for improved project performance. We apply the methodology to probabilistic modelling of project S-curves, a graphical representation of a project’s cumulative progress. We show how the methodology could be used to improve confidence bounds on project performance predictions. We present results of a simulated process improvement project in agile setting to demonstrate our approach.
Open Access
A study into continuous improvement initiative sustainability
(Cranfield University Press, 2013-09-19) Szwejczewski, Marek; Sweeney, Michael; Butler, Michael
The idea of continuous improvement is familiar to most managers and there are many examples of how its use can increase a company’s overall performance. However, while numerous companies have adopted the approach, very few have seen the long term sustainability of such programmes. This paper reports on research that was carried out into the sustainability of continuous improvement initiatives. A case study was carried out in a manufacturing company that had been using the approach for five years. The case study identified several factors that helped to sustain the initiative but it also revealed some elements that had a negative impact.
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, Benny
ICMR2013 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.
Open Access
The effect of temperature changes on to quasi-static tensile and flexural performance of glass fibre reinforced PA66 composites
(Cranfield University Press, 2013-09-19) Butterworth, Ian; Abhyankar, Hrushikesh; Westwood, Keith; Njuguna, James; Brighton, James; Mouti, Zakaria
A significant method of reducing CO2 emissions in road vehicles is to reduce the vehicle mass. One means in which this can be achieved is to adopt lightweight materials such as thermoplastic composites. Thermoplastics offer advantages in term of weight when compared to conventional steel and aluminium casting. In this study thermal mechanical testing has been conducted on two types of commercial polyamide 66 (PA66) with 35 wt.% short glass fibre reinforcement. One of the materials was impact modified with an elastomer to increase material toughness. Experimental results showed both the reinforced PA66 materials to be temperature dependent. All test results demonstrated the trade-off in the mechanical properties of the two materials especially the impact modified. PA66 with 35 wt.% short glass fibre exhibits the best tensile strength, flexural strength and modulus for each temperature tested. Whereas the impact modified PA66 with 35 wt.% short glass fibre exhibits the higher strain and toughness for each temperature tested.
Open Access
Requirements analysis in the implementation of integrated PLM, ERP and CAD systems
(Cranfield University Press, 2013-09-19) Muni Prasad, Giddaluru; James, Gao; Raj, Bhatti; Satya, Shah
Product Lifecycle Management (PLM) system implementation is a major investment when the technology is used in manufacturing companies. This paper provides an analysis of the requirements for the integration of PLM systems with Enterprise Resource Planning (ERP) systems incorporating the design aspects of Computer Aided Design and Manufacturing (CAD/CAM) within the product development process. PLM implementation deals with various existing product data and information generated over years both from CAD and ERP systems. Data integration is very challenging and has important impact on future decisions while creating new processes. The information management plays very important role not only in PLM implementation but also in the way this will be used in future production. Therefore it is very important to analyse how product information is transferred to PLM system. It also need to be investigated that what, when and how the data will flow from and to PLM systems.
Open Access
Fabrication of binder-free ultrafine WC-6CO composites by coupled multi-physical fields activation technology
(Cranfield University Press, 2013-09-19) Huang, Kunlan; Qin, Yi; Yin, Deqiang; Yang, Yi; Yang, Gang
A novel sintering method, named as coupled multi-physical fields activation technology, has been introduced for the forming of various material powder systems. Compared with the conventional ones, this technique presents more advantages: lower sintering temperature, shorter forming time, and remarkable inhibition of the grains coarsening. In the study, the cylinders of Φ4.0mm×4.0mm had been formed with ultrafine WC-6Co powders. The relative properties of sintered WC-6Co cemented carbides, such as hardness and the microstructures, had been obtained. The study has shown that a relative density, 97.80%, of the formed samples, could been achieved when the case of temperature 850℃, heating rate 50℃/s, pressure 75MPa and Electro-heating loop 6 times, were used. More importantly, the circumscription for the growth of grain size of WC, attributed to the effect of electrical field, renders coupled multi-physical fields activation technology applicable for getting WC-6Co cemented carbides with fine grain size and good properties.
Open Access
Risk analysis in manufacturing footprint decisions
(Cranfield University Press, 2013-09-19) Rösiö, Carin; Bruch, Jessica; Wiktorsson, Magnus; Bellgran, Monica
A 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.
Open Access
An integrative lean assessment model for distribution centres
(Cranfield University Press, 2013-09-19) Mahfouz, Amr; Smith, Laura; Arisha, Amr
It is hard to benefit fully from lean manufacturing without having an efficient distribution centre. Applying lean distribution concept helps to reduce distribution centres waste while maintains customer service level high. The purpose of this study is to develop a lean assessment model that enables distribution managers to measure and improve the leanness levels of their companies. A data driven analytical approach (i.e. factor analysis) is used to assess leanness quantitatively. A lean index score is calculated to benchmark the leanness level of four distribution companies based in Ireland and UK. Results recommend that special attention should be taken on simplifying distribution network structure, establishing long term suppliers’ collaboration, managing customer demand, improving storage space utilisation, and managing distribution operations more efficiently.
Open Access
Towards an ontology-based platform-independent framework for developing KBE systems in the aerospace industry
(Cranfield University Press, 2013-09-19) Sanya, Isaac; Shehab, Essam
Aerospace engineering is considered to be one of the most complex and advanced branches of engineering. The use of knowledge based engineering (KBE) technologies has played a major role in automating routine design activities in view of supporting the cost-effective and timely development of a product. However, technologies employed within KBE systems are usually platform-specific. The nature of these platform-specific models has significantly limited knowledge abstraction and reusability in KBE systems. This research paper presents a novel approach that illustrates the use of platform-independent knowledge models for the development of KBE systems in the aerospace industry. The use of semantic technologies through the definition of generic-purposed ontologies has been employed to support the notion of independent knowledge models that strengthens knowledge reusability in KBE systems. This approach has been validated qualitatively through experts’ opinion and its benefit realised in the abstraction, reusability and maintainability of KBE systems.
Open Access
A framework of industrial sustainability good practices
(Cranfield University Press, 2013-09-19) Al-Ashaab, Ahmed; Flores, Myrna; Hernando Anta, Pablo; Varro, Brigitta
Global environmental problems, energy and raw material prices as well as their availability, increasingly demanding legislation and environmental taxes are some of the reasons that drive the consideration of sustainability concepts and practices into company operations. This paper presents the research carried out in order to capture industrial sustainability good practices and represent them into a framework to help companies increase their awareness and adopt practices to embed them within their operational processes.
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, William
This 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.
Open Access
Comparison of the environmental impact of the crimson process with normal sand casting process
(Cranfield University Press, 2013-09-19) Zeng, Binxu; Salonitis, Konstantinos; Jolly, Mark R.
The CRIMSON process is an alternative process to conventional casting that can be used for small to medium batch sizes. The aim of this process are to improve the casting quality and reduce the energy consumption within light-metal casting industry. Nowadays, the energy efficiency becomes more and more important. This is not only about the cost of the production, but also about the environmental effect. In this paper, the CRIMSON process will be compared with the conventional sand casting process. The Life cycle assessment (LCA) method will be used to assess the environmental impact of both casting processes.
Open Access
Achieving workplace inclusiveness by using ergonomics risk assessment
(Cranfield University Press, 2013-09-19) Hussain, Amjad; Case, Keith; Marshall, Russell; Summerskill, Steve
Traditional manufacturing work practices do not consider human variability issues during the design process. However, most manual assembly activities demand high levels of repetition and speed without compromising product quality and work productivity. Individual factors including age, gender, skill, experience and anthropometry cause variations in task strategies that lead to variations in individual and organizational work performance. The ergonomics-based risk assessment methods OWAS, REBA and RULA have been used to evaluate risk levels associated with working methods. This paper discusses the need for these methods to understand and highlight the key issues generated by these variations with the objective of minimizing these variations. Methods that can be used to promote working strategies that minimize the level of risk are described. The proposed research method potentially reduces work-related musculoskeletal disorders, injuries, pain, and promotes safe, healthy, productive and more inclusive working strategies suitable for a diverse working population.
Open Access
Human centred manufacturing: methodology for ergonomic previsional evaluation of manual assembly operations
(Cranfield University Press, 2013-09-19) Di Pardo, Massimo; Monferino, Rossella; Spada, Stefania; Costantino, Marco
The challenge of flexibility and productivity for manufacturing operations needs a new concept based on “human-centered manufacturing process”. This concept must consider basically the ergonomics of workplaces and workload balancing. The application of this concept is achievable through the detailed knowledge of the interaction between human and workplace, in particular as far as the mechanical load (or work load) arising from product design and from manufacturing process definition (included tools and equipment). The measurement of workload then is a fundamental for new (and existing) workplaces. In this paper is described the methodology that considers the procedure and instruments for measuring ergonomic parameters and the use of EAWS method to assess the ergonomic risk level of the workplace summarized by a score. EAWS considers postural aspects and dynamics of work activity. Design or modification of the workplace can be defined on base of the results obtained by the methodology application.