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
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
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
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
A strategy for achieving manufacturing statistical process control within a highly complex aerospace environment
(Cranfield University Press, 2013-09-19) Veira, Adryan; Khan, Khurshid; Farrell, Ian
This paper presents a strategy to achieve process control and overcome the previously mentioned industry constraints by changing the company focus to the process as opposed to the product. The strategy strives to achieve process control by identifying and controlling the process parameters that influence process capability followed by the implementation of a process control framework that marries statistical methods with lean business process and change management principles. The reliability of the proposed strategy is appraised using case study methodology in a state of the art manufacturing facility on Multi-axis CNC machine tools.
Open Access
Production localization factors: an industrial and literature based review
(Cranfield University Press, 2013-09-19) Bjelkemyr, Marcus; Wiktorsson, Magnus; Bruch, Jessica; Rösiö, Carin; Bellgran, Monica
Decision are commonly based on the available or easily accessible information; this is also true for more complex assessments like production localization. Where to locate production is often a key strategic decisions that has great impact on a company’s profitability for a long time; insufficient business intelligence may therefore have grave consequences. Six production localization factor studies have been assessed to see if they are focusing on the same issues and if there are any gaps. A new approach for structuring localization factors and the localization process is then presented and assessed with regards to some previously identified critical issues.
Open Access
Studies on fatigue behaviour of weld-bonds of Al-Mn-Mg alloy
(Cranfield University Press, 2013-09-19) Mittal, Mayank; Dwivedi, Dheerendra
In the present paper, fatigue and metallurgical behaviour of weld-bonds and adhesive bonds developed using 2 mm thick aluminium alloys namely 5052 alloy have been reported. Weld-bonds were prepared using structural adhesive (Epoxy resin) and spot welding (20 kA welding current for 6 cycles welding time at welding pressure of 0.5 MPa). Curing after applying Epoxy resin for developing adhesive bonds and weld bonds was performed at a temperature of 100 oC for 90 min. Fatigue tests were conducted under tension–shear loading pattern with stress ratio of 0.5 and loading frequency of 5 Hz. The maximum tensile shear load for fatigue test was kept at different level i.e. 90%, 80%, 70% and 50% of the ultimate shear tensile strength of weld bond and adhesive bonds. The fatigue lives of both adhesive bond and weld-bond joints decreased with increase in maximum tensile shear load. Fatigue performance of weld bond was higher than adhesive bond especially at high load.
Open Access
Automating human skills : preliminary development of a human factors methodology to capture tacit cognitive skills
(Cranfield University Press, 2013-09-19) Caird-Daley, Antoinette; Fletcher, Sarah R.; Baker, William
Despite technological advances in intelligent automation, it remains difficult for engineers to discern which manual tasks, or task components, would be most suitable for transfer to automated alternatives. This research aimed to develop an accurate methodology for the measurement of both observable and unobservable physical and cognitive activities used in manual tasks for the capture of tacit skill. Experienced operators were observed and interviewed in detail, following which, hierarchical task analysis and task decomposition methods were used to systematically explore and classify the qualitative data. Results showed that a task analysis / decomposition methodology identified different types of skill (e.g. procedural or declarative) and knowledge (explicit or tacit) indicating this methodology could be used for further human skill capture studies. The benefit of this research will be to provide a methodology to capture human skill so that complex manual tasks can be more efficiently transferred into automated processes.
Open Access
An empirical analysis of lean six sigma implementation in SMEs – A migratory perspective
(Cranfield University Press, 2013-09-19) Thomas, Andrew; Ringwald, Kath; Parfitt, Scott; Byard, Paul
The purpose of this paper is to investigate the migratory nature of Lean Six Sigma (LSS) implementation in manufacturing based SMEs in the UK. The companies were surveyed at two points over a five year period. These periods were before and after the 2008 recession point and were identified in order to assess the level of LSS implementation as a result of the tougher economic climate that has prevailed in the manufacturing industry since 2008. Analysis is carried out on a sample of 96 manufacturing SMEs from a range of manufacturing sectors in the UK. Data was gathered from company CEOs via a triangulated method of questionnaire, direct observation and interviews. The findings show the dynamic nature of LSS implementation in SMEs. Further work will be required to extend the LSS categorisation system to provide a wider category set that further defines the dynamical nature of LSS implementation.
Open Access
Discrete-event simulation of process control in low volume high value industries
(Cranfield University Press, 2013-09-19) Cox, Steven; Garside, John; Kotsialos, Apostolos
This paper presents a new method of process control for set-up dominant processes. This new method known as Set-up Process Algorithm (SUPA) was compared with existing industrial practices and statistical techniques in the literature. To test the method’s robustness, a generic discrete-event simulation model was built. This model was used to test four different statistical approaches to process control. It was concluded that SUPA offers a method of process control for set-up dominant processes, which is easier to apply than classically derived SPC approaches, by using simple rules and a traffic light system based on design specification. Simulation analysis shows that SUPA: is more sensitive, at detecting an incapable process as it will monitor more units when a process is less capable; is more sensitive than PRE-Control at detecting mean shifts in a process. SUPA is also a nonparametric methodology and therefore robust against processes with non-Gaussian distributions.
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
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
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
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
Position control of an industrial robot using an optical measurement system for machining purposes
(Cranfield University Press, 2013-09-19) Schneider, Ulrich; Drust, Manuel; Diaz Posada, Julian; Verl, Alexander
A series of mechanical properties and disturbances limit the accuracy achievable in robotic applications. External control of the end effector position is commonly known as being an appropriate mean to increase accuracy. This paper presents an approach for position control of industrial robots using the pass-through between an industrial CNC and servomotors. A CNC-controlled robot is used together with an external optical measurement system to close the feedback loop of robot end effector and robot controller in order to improve robot accuracy. For short cycle times and implementation reasons a PLC is used for signal processing and control implementation. The relevance of the approach is outlined in experiments. The robot behaviour in free space motion and in machining application is analysed with the optical measurement system and a CMM.
Open Access
Towards a business model for sustainable supply chain management
(Cranfield University Press, 2013-09-19) Pimenta, Handson; Ball, Peter D.
Designers make decisions that ultimately impact on both the economic, environmental and social performance of the products and process, and many of these costs and impacts occur across the supply chain. This paper aims to show initials elements of a research which aims to develop an integrated business model for sustainable supply chain management in order to facilitate the business management process in terms of assessment of suppliers and collaboration addressed to the sustainable improvements across supply chain. It is noteworthy that it is an imperative in the current competitive market that companies must be able to manage their entire production chain taking into account sustainable issues as an important factor in their decision processes. Therefore, it is believed that this model can integrate and strengthen a company’s functions and assist its decision processes as well as implement improvements within its supply chain.
Open Access
Surrogate modelling for reliability assessment of cutting tools
(Cranfield University Press, 2013-09-19) Kolios, Athanasios; Salonitis, Konstantinos
Currently, cutting tool life for machining operations is correlated to process parameters through the widely applied Taylor functions. The latter are valuable expressions in established practice however their generalised nature does not allow accurate prediction of the tool’s service life or optimization of the manufacturing process due to effects of uncertainties in various input variables. These variables should be treated in a stochastic way in order to avoid employment of safety factors for quantification of uncertainty. This paper documents a procedure that allows derivation of analytical expressions for cutting tools performance employing advanced approximation methods and concepts of reliability analysis. Due to the complexity of manufacturing processes surrogate modelling (SM) methods are applied, starting from a few sample points obtained through lab or soft experiments and extending them to models able to predict/estimate the values of control values/indicators as a function of the key design variables, often referred to as limit states.
Open Access
Towards a framework for predicting whole life-cycle cost for long-term digital preservation
(Cranfield University Press, 2013-09-19) Badawy, Mohamed; Sanya, Isaac; Shehab, Essam; Baguley, Paul
Estimating the costs for the whole lifecycle of long-term digital preservation (LTDP) activities ena-bles decision makers to choose carefully what data to preserve, duration of preservation and type of preservation techniques best applied for their information. To address this need, a framework is de-veloped to generate a cost model that will estimate costs for long-term digital preservation activities using storage in the cloud and taking into consideration the impact of mitigating uncertainties, espe-cially obsolescence issues on future costs. This cost estimating framework is part of the European pro-ject entitled ‘Enabling kNowledge Sustainability Usability and Recovery for Economic value’ which aims to provide a total long-term digital preservation solution for companies and public sector organi-sations interested in keeping their digital information alive for the long-term within the healthcare, fi-nancial and the clinical trials business sectors.
Open Access
Statistical process control implementation in the food industry: A systematic review and implications for future research
(Cranfield University Press, 2013-09-19) Lim, Sarina; Antony, Jiju
This study is to illustrate a systematic review application in investigating common issues emerging from Statistical Process Control (SPC) implementation in the food industry. A total of 34 journal articles were rigorously selected from four databases and reviewed. The most common themes emerge in SPC implementation in the food industry is the benefits while the remaining themes are motivation, barriers and critical success factors (CSF). This review found that the evidence of SPC implementation in the food industry is beneficial; however, a lack of both awareness and guidelines relating to SPC implementation in the food industry has resulted in a slow adoption. This systematic review concluded that there is a crucial need for further research into the SPC deployment aspect addressing how to deploy SPC in the food industry in a systematic manner.