Process Planning - The Link Between Varying Products and their Manufacturing Systems p. 37

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1 Definitions and Strategies Changeability - An Introduction p. 3 Motivation p. 3 Evolution of Factories p. 7 Deriving the Objects of Changeability p. 8 Elements of Changeable Manufacturing p. 10 Factory Levels p. 11 Changeability Classes p. 12 Changeability Objectives p. 13 Manufacturing Level p. 14 Assembly Level p. 14 Factory Level p. 15 Changeability Enablers p. 15 Manufacturing Level p. 16 Assembly Level p. 17 Factory Level p. 17 Reconfigurable Process Planning Level p. 18 Production Planning and Control Level p. 19 Changeability Process p. 19 Conclusion p. 22 References p. 23 Changing and Evolving Products and Systems - Models and Enablers p. 25 Introduction and Motivation p. 26 The Hierarchy of Parts and Products Variants p. 27 Evolving and Dynamic Parts and Products Families p. 32 Modeling Products Evolution - A Biological Analogy p. 34 Design of Assembly Systems for Delayed Differentiation of Changing and Evolving Products p. 35 Process Planning - The Link Between Varying Products and their Manufacturing Systems p. 37 Existing Process Planning Concepts p. 37 Process Plans Changeability p. 38 Reconfiguring Process Plans (RPP) and Its Significance p. 40 Process Planning for Reconfigurable Machines p. 41 Discussion and Conclusions p. 42 References p. 44 Focused Flexibility in Production Systems p. 47 The Importance of Manufacturing Flexibility in Uncertain Production Contexts p. 47 Focused Flexibility Manufacturing Systems - FFMSs p. 48 Literature Review p. 50 Proposal of an Ontology on Flexibility p. 51 Analysis of Real Systems p. 55

2 Lajous Industries SA Case Study p. 55 Riello Sistemi Case Study p. 58 Using the Ontology on Flexibility to Support System Design p. 60 Conclusions and Future Developments p. 63 References p. 64 Physical Enablers Control of Reconfigurable Machine Tools p. 71 Introduction p. 71 Basic Idea for Reconfigurable Machine Tools and Systems p. 72 Initial Situation in Machining Systems and Machine Tools p. 72 State of the Art p. 75 Configurable and Reconfigurable Machine Tools p. 77 Development of (Re)configurable Machine Tools p. 77 Conception of a Reconfigurable Machine Tool p. 80 Field Bus Systems Requirements p. 81 Configurable Control Systems p. 83 Middle-Ware p. 84 Configuration p. 85 Adjustment Mechanisms for Control Systems p. 85 Configuration Procedure p. 87 Development of a Control Configuration Tool p. 90 Configuration of a Control System by an Expert p. 90 Self-Adapting Control System for RMS p. 91 Elements of a Self-Adapting Control System p. 91 Extensions of Self-Adapting Control Systems p. 92 Method for Reconfiguration of the Self-Adaptable Control System p. 96 Summary and Conclusions p. 98 References p. 99 Reconfigurable Machine Tools for a Flexible Manufacturing System p. 101 Introduction p. 101 Reconfigurable Machine Tools Development p. 102 Application Examples p. 107 Summary p. 109 References p. 109 Reconfigurable Machine Tools and Equipment p. 111 Introduction p. 111 Flexibility Requirements p. 113 Reconfigurable Multi-Technology Machine Tool (RMM) p. 116 Machine Tool Design p. 116 Modules p. 117 System Interfaces p. 121

3 Expert Tool for System Configuration p. 122 Summary p. 124 References p. 124 Changeable and Reconfigurable Assembly Systems p. 127 Introduction p. 127 Flexible Manual Assembly Systems p. 129 Single Station Assembly with Set-Wise Assembly Flow p. 130 Single Station Assembly According to the One-Piece-Flow Principle p. 131 Multi-Station Assembly According to the One-Piece-Flow Principle p. 132 Flexible Automated Systems p. 134 Hybrid Assembly Systems p. 136 Characteristics p. 136 Example of a Hybrid Assembly System p. 136 Analysis of the Results for Automated and Hybrid Assemblies p. 140 Conclusion p. 141 References p. 141 Logical Enablers Unified Dynamic and Control Models for Reconfigurable Robots p. 147 Design of Reconfigurable Modules for the Reconfigurable Robotics, Automation and Intelligent Systems Industry p. 147 Description of a Robot Model p. 148 Reconfigurable Aspects of Industrial Robotic Systems p. 148 Reconfigurable Kinematic and Dynamic Modules p. 149 Design of Reconfigurable Control Platform (RCP) p. 152 DC Motor Reconfigurable Position Control Design p. 152 Design of Reconfigurable Robot Platform (RRP) p. 157 Reverse Modeling of Reconfigurable Robot Meta-Model p. 158 Conclusions p. 159 References p. 160 Reconfigurable Control of Constrained Flexible Joint Robots Interacting with Dynamic and Changeable Environment p. 163 Introduction p. 163 Dynamic Model of Flexible Joint Robot in Contact with Different Environment p. 166 Decoupled Controller Design p. 167 Contact with Rigid Surface p. 167 Contact with Stiff Environment p. 169 Contact with Dynamic Environment p. 169 Reconfigurable Control Scheme p. 171 Simulation Study p. 172 References p. 176 Reconfiguring Process Plans: A New Approach to Minimize Change p. 179 Introduction p. 180

4 Related Work p. 181 Conceptual Basis p. 183 Mathematical Modeling and Programming p. 184 A New Criterion in Process Planning p. 186 Computational Time Complexity p. 187 Application and Verification p. 187 Reconfigurable Assembly Planning of a Family of Household Products p. 187 Reconfigurable Process Planning for Machining of a Front Engine Cover Part Family p. 190 Concluding Remarks p. 192 Summary p. 192 References p. 193 Adaptive Production Planning and Control - Elements and Enablers of Changeability p. 197 Introduction p. 197 The PPC Framework p. 199 Design Aspects of a Socio-Technical PPC System p. 200 PPC Design Matrix p. 201 Changeability of PPC Tools p. 202 Change Elements of PPC p. 203 Enablers of PPC Changeability p. 203 Building Blocks of PPC Changeability p. 204 Adaptive PPC Solutions p. 204 Functional Models p. 205 Planning and Control Methods p. 206 Data Models p. 207 Data Interfaces p. 208 Change Process in PPC p. 209 Summary and Further Research p. 210 References p. 211 Component Oriented Design of Change-Ready MPC Systems p. 213 Introduction p. 213 Related Review p. 215 The New MPC System Characteristics p. 216 Component-Based Software Engineering (CBSE) p. 218 Component-Oriented Versus Object-Oriented Programming p. 219 Mini-Case Study: Component-Based Aggregate Production Planning System Framework p. 219 System Architecture p. 219 Change-Ready MPC Framework p. 220 Discussion and Conclusions p. 224 References p. 225 Dynamic Capacity Planning and Modeling Its Complexity p. 227

5 Introduction p. 227 The Dynamic Capacity Problem p. 227 Complexity vs. Uncertainty p. 228 Complexity in Dynamic Capacity Planning p. 229 Literature Review p. 229 System Dynamic Model for Multi-Stage Production p. 231 Multi Stage Production System p. 231 Model Nomenclature p. 232 Mathematical Model p. 233 Numerical Simulation of Industrial Case Study p. 236 Overview of the Multi-Stage Engine Block Production Line p. 236 Input Data p. 236 Numerical Simulation Results p. 238 Conclusions p. 243 References p. 244 Managing and Justifying Change in Manufacturing Design for Changeability p. 251 Production Trends in High-Wage Countries p. 252 Introduction of a Target System for Complex Production Systems p. 253 Holistic Definition of Production Systems p. 253 Target System for Complex Production Systems p. 254 Differentiation Between Complicated Systems and Complex Systems p. 256 Approach to Mastering Complexity in Production Systems p. 257 Object-Oriented Design p. 257 Object-Oriented Management of Production Systems p. 258 Case Studies p. 261 A: Object-Oriented Production Design p. 262 B: Release-Engineering in the Automotive Industry p. 263 Summary p. 265 References p. 266 Changeability Effect on Manufacturing Systems Design p. 267 Introduction p. 267 Synthesis of Manufacturing Systems p. 268 Enabling Changeability in Systems Frameworks p. 268 Effect of Changeability Enablers on the Factory Level Design p. 271 Changeability Effect on Machine Level Design p. 273 Product Design Directions p. 274 Changeability Integration into the Design Process p. 276 The System-Product Changeability Design Loop p. 276 Biological Evolution/Co-Evolution Analogy p. 278 Final Remarks p. 279

6 References p. 280 Managing Change and Reconfigurations of CNC Machine Tools p. 285 Introduction p. 285 Reconfiguration Considerations p. 287 The Change or Reconfiguration Management Methodology p. 289 Pneumatic Flow Control Valve Case Study p. 294 Summary and Conclusions p. 299 References p. 300 Economic and Strategic Justification of Changeable, Reconfigurable and Flexible Manufacturing p. 303 Introduction p. 303 Literature Review p. 304 Proposed RMS Justification Model p. 305 Financial Objective p. 308 System Complexity p. 309 System Responsiveness p. 310 Overall Model p. 310 Illustrative Example p. 313 Comparison of Reconfigurable and Flexible Scenarios over the System Life Cycle p. 315 FMS and RMS Comparison Through Life-Cycle Simulation p. 317 Conclusions p. 318 References p. 319 Quality and Maintainability Frameworks for Changeable and Reconfigurable Manufacturing p. 321 Introduction p. 322 Quality and the Manufacturing System Design p. 322 Changeable Manufacturing and Quality p. 325 Effect of Reconfigurable Manufacturing System Design on Quality p. 328 The Changeability and Maintainability Relationship p. 330 Conclusion p. 333 References p. 334 Maintenance Strategies for Changeable Manufacturing p. 337 Introduction p. 337 Recent Developments p. 338 Current Research and Trends p. 338 Model of Integration Between Intelligent Manufacturing Control System and Intelligent Maintenance System p. 339 Fuzzy Logic Controller I and II (FLCI and II) p. 341 Fuzzy Maintenance and Decision Making Grid p. 344 Case Study p. 348 Conclusions and Future Research p. 349 References p. 350

7 Future Directions The Cognitive Factory p. 355 Introduction p. 356 Intelligence in Automated Systems p. 356 Cognitive Technical Systems p. 359 The Cognitive Factory p. 360 Vision and Goals p. 360 Core Aspects to Achieve the Cognitive Factory p. 362 Summary and Outlook p. 368 References p. 369 Migration Manufacturing - A New Concept for Automotive Body Production p. 373 Initial Situation p. 373 Development of the Basic Concept p. 376 Operating Phases of the Migration Concept p. 380 Practical Evaluation and Implementation p. 382 Conclusion and Outlook p. 385 References p. 387 Changeable Factory Buildings - An Architectural View p. 389 The Factory Planners View p. 390 The Challenge: Multi-User, Changeable and Scalable Buildings p. 392 Performance and Constituent Components of Factory Buildings p. 394 Form Follows Performance p. 394 Building Components p. 395 Synergetic Planning of Processes, Logistics and Buildings p. 397 Industrial Example of a Transformable Factory p. 398 Conclusion p. 400 References p. 401 Index p. 403 Table of Contents provided by Blackwell's Book Services and R.R. Bowker. Used with permission.

Hoda ElMaraghy Sample List of Publications

Hoda ElMaraghy Sample List of Publications 1 Book Publication: The outcome of several of Dr. ElMaraghy s research activities that were carried out as part of the CRC program was documented as a basis for a new reference book on Changeable and Reconfigurable