Enabling Manufacturing Competitiveness and Economic Sustainability
Hoda A. ElMaraghy Editor Enabling Manufacturing Competitiveness and Economic Sustainability Proceedings of the 4th International Conference on Changeable, Agile, Reconfigurable and Virtual production (CARV2011), Montreal, Canada, 2 5 October 2011 123
Editor Professor Hoda A. ElMaraghy University of Windsor Intelligent Manufacturing Systems Center 204 Odette Building 401 Sunset Avenue Windsor, Ontario Canada N9B 3P4 hae@uwindsor.ca ISBN 978-3-642-23859-8 e-isbn 978-3-642-23860-4 DOI 10.1007/978-3-642-23860-4 Springer Heidelberg Dordrecht London New York Library of Congress Control Number: 2011938236 c Springer-Verlag Berlin Heidelberg 2012 This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable to prosecution under the German Copyright Law. The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Cover design: estudio Calamar S.L., Heidelberg Printed on acid-free paper Springer is part of Springer Science+Business Media (www.springer.com)
Preface Globalization, unpredictable markets, increased product customization and the quest for competitive advantages are but a few of the many challenges facing manufacturing enterprises now and in the foreseeable future. Frequent changes in product, production technologies and manufacturing systems are evident today along with their significant implementation costs. Increased competitiveness requires enhanced quality and value through increasingly innovative products, materials and production technologies. One key strategy for manufacturing success and economic sustainability is to satisfy the market demand for increased product variants while reducing the resulting variations in their manufacturing and associated cost and complexity. This trend is on the rise as evidenced by the paradigm shifts witnessed in manufacturing systems and their increased flexibility and responsiveness to cope with the evolution of both products and manufacturing systems. A host of external and internal change drivers exist that affect manufacturing enterprises at various levels from strategic planning for re-positioning the business, to tactical control of production plans and facilities to achieve a high degree of responsiveness. The changing manufacturing environment requires careful effort to prolong the life of manufacturing systems by making them easily adaptable and facilitating the integration of new technologies and new functions. This requires pre-designing effective paths for change and providing innovative change enablers and adaptation mechanisms. The availability of solutions that go beyond adaptability and flexibility will thus be crucial for enhancing productivity and ensuring competitiveness and economic sustainability in the manufacturing sector. The theme of the 4 th International Conference on Changeable, Agile, Reconfigurable and Virtual production (CARV2011) is Enabling Manufacturing Competitiveness and Economic Sustainability. The leading edge research and best implementation practices and experiences, which address these important issues and challenges, presented in the CARV2011conference are included in this book. It is organized in 5 Parts and contains 107 papers contributed by 242 authors from around the world. The topics cover leading edge advances in manufacturing systems design, planning, evaluation, control and evolving paradigms such as mass customization, personalization, changeability, reconfigurability and flexibility. It treats new and important concepts such as the dynamic product families and platforms, and co-evolution of products and systems, and methods for enhancing manufacturing systems economic sustainability and prolonging their life for use to produce more than one product generation. Enablers of change in manufacturing systems, production volume and capability scalability and managing the volatility of markets, competition among global enterprises and the increasing complexity of products, manufacturing systems and management strategies are discussed. An outline of industry challenges and future directions for research and development needed to help both practitioners and academicians are presented. Professor Hoda A. ElMaraghy, PhD, PEng, FCIRP, FSME, FCSME Canada Research Chair (CRC) in Manufacturing Systems Chair, CARV2011 Conference
Acknowledgements The 4th International Conference on Changeable, Adaptable, Reconfigurable and Virtual Production (CARV2011) was held in Montreal, Canada. The conference was organized by the Intelligent Manufacturing System (IMS) Centre, University of Windsor, Canada and the Institute for Machine Tools and Industrial Management (iwb), Technical University of Munich, Germany. It is sponsored by the International Production Engineering Academy (CIRP) and the Canadian Society for Mechanical Engineering (CSME). CARV2011 provided an excellent forum for engineers, scientists and researchers from academia and industry to discuss current practices and future challenges germane to the success and survival of manufacturing in a changing and globally competitive environment. It offered an environment conducive to networking and exchange among researchers and practitioners in academia and industry. On behalf of the conference Co-Chairs, Professor Michael Zaeh, Professor Gunther Reinhart and Professor Waguih ElMaraghy, I thank all authors for their high quality contributions and their cooperation in the manuscript preparation process. We also extend our thanks and appreciation to the International Scientific Committee members who provided valuable input and expert judgement during the review and evaluation process. We express our gratitude to all members of the teams (too many to list) of qualified and expert assistants from the Intelligent Manufacturing Systems (IMS) Centre, University of Windsor, Canada and the Institute for Machine Tools and Industrial Management (iwb), Technical University of Munich, Germany, who demonstrated a high level of dedication, professionalism and collaboration. I am particularly grateful to Dr. Tarek AlGeddawy and Dr. Sameh Badrous (IMS Centre) for their expert assistance in putting this document together in record time. Thanks also go out to Ms. Erica Lyons (IMSC) for her continued assistance throughout and to Mr. Michael Niehues (iwb) for his participation in the conference organization and logistical support. Dr. Hoda A. ElMaraghy
Conference Chair Professor Hoda A. ElMaraghy (Canada) Co-Chairs: Professor Michael F. Zaeh (Germany) Professor Waguih H. ElMaraghy (Canada) Professor Gunther Reinhart (Germany) INTERNATIONAL SCIENTIFIC COMMITTEE Prof. Abele, E (Germany) Prof. Azab, A. (Canada) Prof. Balazinski, M. (Canada) Prof. Bernard, A. (France) Prof. Bley, H. (Germany) Prof. Chryssolouris, G. (Greece) Prof. Cunha, P.F. (Portugal) Prof. Deif, A. (Egypt) Prof. ElMaraghy, H.A. (Canada) Prof. ElMaraghy, W.H. (Canada) Prof. Hu, S.J. (USA) Prof. Jovane, F. (Italy) Prof. Kuhlang, P. (Austria) Prof. Kuzgunkaya, O. (Canada) Prof. Laperrière, L. (Canada) Prof. Maropoulos, P.G. (UK) Prof. Monostori, L. (Hungary) Prof. Müller, E. (Germany) Prof. Nee, A. (Singapore) Prof. Newman, S. (UK) Prof. Nyhuis, P. (Germany) Prof. Pasek, Z. (Canada) Prof. Perrone, G. (Italy) Prof. Reinhart, G (Germany) Prof. Schönsleben, P. (Switzerland) Prof. Schuh, G. (Germany) Prof. Shea, K. (Germany) Prof. Sihn, W. (Austria) Prof. Soderberg, R. (Sweden) Prof. Teti, R. (Italy) Prof. Tichkiewitch, S. (France) Prof. Tolio, T. (Italy) Prof. Torvinen, S. (Finland) Prof. Tracht, K. (Germany) Prof. Tseng, M. (Hong Kong) Prof. Urbanic, J. (Canada) Prof. Vancza, J. (Hungary) Prof. van Houten, F. (Netherlands) Prof. Westkämper, E. (Germany) Prof. Windt, K. (Germany) Prof. Zaeh, M. F. (Germany)
Contents PARTI: VISIONANDFUTUREPRESPECTIVES...1 ChangeinManufacturing ResearchandIndustrialChallenges...2 H.ElMaraghy,T.AlGeddawy,A.Azab,W.ElMaraghy AdaptiveJobControlintheCognitiveFactory...10 M.F.Zaeh,M.Ostgathe,F.Geiger,G.Reinhart MassCustomisationasaCompetitiveFactorforSustainability...18 A.Bernard,J.Daaboul,F.Laroche,C.DaCunha PARTII: MANUFACTURINGSYSTEMS...27 MANUFACTURINGSYSTEMDESIGN,PLANNING,OPERATION,ANDCONTROL...28 LinnaeanandCladisticClassificationsofManufacturingSystems...29 J.S.Baldwin,C.RoseAnderssen,K.Ridgway IntegratingAbilityLimitationsintoAssemblySystemDesign...35 G.Reinhart,J.Egbers SelectionCatalogueofKinematicConfigurationforPickandPlaceApplication...41 K.Chandrasekaran,A.Djuric,W.H.ElMaraghy ATransitioninProductionandPlanningforaChangeableMicroManufacturingSystem...47 B.Röhlig,J.P.Wulfsberg Usingformalmethodstomodelhybridmanufacturingprocesses...52 AydinNassehi,StephenNewman,VimalDhokia,ZichengZhu,RezaImaniAsrai ConsideringReconfigurabilityCharacteristicsinProductionSystemDesign...57 CarinRösiö OntologydrivenRequirementsElicitationinProductConfigurationSystems...63 Wicaksono,H.;Schubert,V.;Rogalski, S.;AitLaydi, Y.;Ovtcharova, J. EarlyAlertCockpitsforChangeableManufacturingSystems...68 Spath,D.;Gerlach,S.;Scholtz,O.;Hämmerle,M.;Krause,T. NewMethodstoCreateVariantsof3DSimulationModelsofManufacturingSystems...74 R.Wischnewski,J.Rossmann,O.Stern Productvariety,flexibilityandenergyuseinhotrollingmills...80 J.Storck LostValueMapping AFastMethodtoTrackLostValueinaProductionFlow...86 PawelPawlewski,ZbigniewJ.Pasek CHANGEABILITY,FLEXIBILITY,RECONFIGURABILITYANDTHEIRMETRICS...92 Asurveyonchangeabilityofmachinetools...93 PhilipHollstein;HeinerLasi;HansGeorgKemper QuantifyingtheEffectofEnterpriseStrategicFlexibility...99 A.Arafa,W.H.ElMaraghy DecisionMakingDuringDesignandReconfigurationofModularAssemblyLines...105 K.Tracht,S.Hogreve Developmentofmanufacturingprocesschainsconsideringuncertainty...111 S.O.Schmitt,J.Avemann,P.Groche OptimalSequencingofMachiningOperationsforChangeableManufacturing...117 AhmedAzab,AttiaH.Gomaa ManufacturingConceptsoftheFuture UpcomingTechnologiesSolvingUpcomingChallenges...123 R.Hadar,A.Bilberg
AnalysisofReconfigurable2DOFMachineryforIntelligentManufacturingSystems...129 AnaDjuric;WaguihH.ElMaraghy MobileSystemsforMachiningLargeWorkPieces...135 Neugebauer,R.,Priber,U.,Rentzsch,H.,Ihlenfeldt,S.,Hoffmann,D. MethodologyforFlexibilityMeasurementinSemiautomaticProduction...141 Rogalski,S.;Wicaksono,H. AutomaticConfiguration(Plug&Produce)ofRobotSystems DataInterpretationandExchange...147 G.Reinhart,S.Krug ADAPTABILITYANDEMERGENCE...153 EnhancedSurvivabilityaFrameworkofSelfHealingMechanisms InstallationUsingAxiomaticDesign...154 T.M Dealingwiththeunpredictable:AnEvolvableRoboticAssemblyCell...160 M.Onori,P.Neves,H.Akillioglu,A.Maffei,A.Hofmann,N.Siltala TheManufacturingAdaptabilityScorecardatooltoanalyzethebenefitofautonomousproductionprocesses...166 CorinnaFohrholz,NorbertGronau FrameworkforDistributedManufacturingSystems...172 H.Nylund,K.Salminen,P.H.Andersson Conceptionandevaluationofanagedifferentiatedtaskanalysisandscreeningmethod...178 Keil,SpannerUlmer AdaptiveProcessChainOptimisationofManufacturingSystems...184 B.Denkena,J.Henjes,L.E.Lorenzen MappingtheTaskTimePerformanceofHumanCentredAssemblySystems...189 R.Folgado,E.Henriques,P.Peças PARTIII: PRODUCTANDPRODUCTIONDEVELOPMENTANDCODEVELOPMENT...195 COEVOLUTIONOFPRODUCTS,PROCESSESANDMANUFACTURINGSYSTEMS...196 FromDedicatedtoPlatformBasedCoDevelopmentofProductsandManufacturingSystems...197 M.T.Michaelis,H.Johannesson NatureInspiredCoevolutionintheManufacturingWorldofArtefacts...203 T.AlGeddawy,H.A. ElMara Fromproductarchitecturetoassemblysequence:amethodtodevelopconceptualDesignforAssemblybasedon interfaceanalysis...209 C.Favi,M.Germani Networkedproductandproductiondevelopmentforlithiumionbatteries...215 Kampker,A.;Franzkoch,B.;Nowacki,C. RequirementsManagementasaSuccessFactorforSimultaneousEngineering...221 G.Reinhart,J.F.Meis VARIANTORIENTEDMODELLINGANDMANAGEMENTOFVARIATION...227 BottomUpComponentOrientedFEModellingofMachineTools...228 A.Dadalau,A.Verl Assessmentoftheproductbasedtimeexpandingeffect...234 Jander,H.,SpannerUlmer,B. Featurebasedcomponentdescriptionforfunctionalgradedparts...239 F.Bauer,D.Dettmer,J.Gausemeier TowardsaFeatureBasedandFineGrainProductRepositoryforHeterogeneousComputerAidedSystems...245 M.M.Uddin,Y.S.Ma SustainableSystemRiskAnalysis:ATripleBottomLineApproach...251 Z. A.AliQrehi,W.ElMaraghy PRODUCT,PROCESSANDSYSTEMSMODELLING,PROTOTYPINGANDDEVELOPMENT...257 ConstructionofaDigitalFacebow...258 E.Solaberrieta,A.Arias,O.Etxaniz,R.Minguez EvaluationofRFIDTechnologyApplicationinProductionofFiberReinforcedPlastics...263 T.R.Philipp,G.Reinhart Contents
Contents SelectingVirtualRealityToolsinrelationwiththeirusecontext...269 R.G.J.Damgrave,D.Lutters,J.P.Thalen AFrameworkEnablingDataIntegrationforVirtualProduction...275 Reinhard,R.;Meisen,T.;Beer,T.;Schilberg,D.;Jeschke,S. AFoundationforIntegratingHandHeldMobileDevicesinaComputerAidedManufacturingEnvironment...281 R.Hedrick,J.Urbanic ParametricInternalMatrixStructuresforComponentsBuiltbyFusedDepositionModelling...287 L.Villalpando,J.Urbanic AnExperimentalStudytoDetermineGeometricandDimensionalAccuracyImpactFactorsforFusedDeposition..293 S.Saqib,J.Urbanic FlexibleToolpathGenerationforVariableGeometry...299 Sawula,D.A.,Lin,Y.P.,Fleisig,R.V.,Spence,A.D. ASystemforProvidingVisualFeedbackofMachineFaults...305 K.Hughes,G.Szkilnyk,B.Surgenor Aninnovativecrosswedgerollingpreformingoperationforwarmforging...310 H.Kache,R.Nickel,B.A.Behrens SystemDynamicModelsandRealtimeSimulationofComplexMaterialFlowSystems...316 S.Hoher,P.Schindler,S.Göttlich,V.Schleper,S.Röck Earlyidentificationofmanufacturingprocessinfluencesonproductfailurebehaviour...322 StefanBracke,StephanHaller TheaspectsofenergyintheBodyinWhiteprocessregardingproductdevelopmentandproductionplanning...328 M.Schacht,R.Schulte,F.Mantwill RefiningProcessLogicFromCNCPartProgrammesforIntegratedSTEPNCCompliantManufacturing...333 X.Zhang,A.Nassehi,V.G.Dhokia,S.T.Newman ENABLERSOFCHANGE...339 SynchronisationofDistributedConfigurationToolsusingFeaturesModels...340 Brecher,C.;Karlberger,A.;Herfs,W. ChangeManagementasanEnablerofEmployeeKnowledgeIntegrationintotheDesignofPlanningProcedures...346 Tracht,K.,Weikert,F.,Funke,L. Areconfigurationconcepttoenableversatileproductionintheautomotivefactories...352 SarfrazUlHaqueMinhas,UlrichBerger MethodologyfortheSupportofReconfigurationProcessesintheAutomotiveBodyShop...358 Reinhart,G.;Meling,F. GripperwithIntegratedThreeDimensionalForceDetection...364 K.Tracht,S.Hogreve,F.Borchers ChangeBeneficialProcessArchitecturesandtheHumanasaChangeEnabler...370 DennisGossmann;CarstenWagner;TimKlemke;PeterNyhuis Adaptive and Selective Assembling of Microscope Objectives............376 K.-P. Zocher PARTIV: GLOBALCOMPETITIVENESSANDSUSTAINABILITY...383 DRIVERS,ENABLERS,STRATEGIESANDINDICES...384 AnAsianPerspectiveonGlobalSourcing...385 Schneider,C.,Finke,G.,Sproedt,A.,Alard,R.,Schönsleben,P. StrategicEvaluationofTechnologyChainsforProducingCompanies...391 Reinhart,G.,Schindler,S. StrategicImpactofGlobalProduction HowtoFindtheSuccessMeasures...397 HeinrichBürstner Coopetitionasafacilitatorofmanufacturingcompetitiveness:opportunitiesandthreats...403 F.Ehrenmann,M.Reiss EnablingCompetitiveDesignofNextGenerationReconfigurableManufacturingEnterprises...409 T.Masood,R.H.Weston ECONOMICSUSTAINABILITYFORMANUFACTURINGSYSTEMSANDPRODUCTS...415 IntegratedEnvironmentalandEconomicAssessmentofProductionSystems...416 A.Sproedt,J.Plehn,C.Schneider,P.Schönsleben
TowardsSustainableDevelopmentandSustainableProductioninFinnishManufacturingIndustry...422 MikkoKoho,MikkoTapaninaho,SeppoTorvinen EmployeeParticipationintheImplementationofLeanProductionSystems...428 U.Dombrowski;T.Mielke;S.Schulze ChallengesFacingManufacturingtoMovetowardsaGreenSocietywithCleanEnergyVehicles...434 MasaruNakano QualitativeGrowthandSustainabilityinOrganizations AnOverview...439 B.Seeberg,M.Monauni MANAGINGCOMPLEXITYOFPRODUCTS,PROCESSESANDMANUFACTURINGSYSTEMS...445 EnablingCarBodyCustomizationthroughAutomotiveFramingSystemsDesign...446 A.AlZaher,W.ElMaraghy,Z.J.Pasek PartsandAssemblyEquipmentComplexityDependencyMatrix...452 S.N.Samy,H.ElMaraghy AnalysisofMarketDemandParametersfortheEvaluationofFlexibilityinFormingTechnology...458 Avemann,J.;Schmitt,S.O.;Ederer,T.;Lorenz,U.;Groche,P. PRODUCTIONANDCOOPERATIONWITHINGLOBALNETWORK...464 EnsuringHumanSafetywithOfflineSimulationandRealtimeWorkspaceSurveillanceforWeldingofAssemblies.465 C.Thomas,F.Busch,B.Kuhlenkoetter,J.Deuse AMethodforMultiScaleModelingofProductionSystems...471 NeumannM.,ConstantinescuC.,WestkämperE. Efficientanalysis,handlinganduseofcustomercomplaints...476 Effey,T.;Schmitt,R. Adaptive,LocationbasedShopFloorControl...482 Reinhart,G.;Niehues,M.;Ostgathe,M. RelocationinProductionnetworksofaMultiNationalEnterprise...488 Ponton,P.;Jaehne,M.;Mueller,E AModelingApproachtoAnalyzeRedundancyinManufacturingSystems...493 K.Windt,M.T.Hütt,M.Meyer InfluenceoftheEuropeanEmissionsTradingSchemeonMROProvideroftheCivilAviationIndustry...499 Tracht,K.;Funke,L.;Weikert,F DYNAMICANDGLOBALM NUFACTURINGCAPACITYANDCAPABILITIES...505 ShiftingBottlenecksinProductionControl...506 Schuh,G.;Potente,T.;Fuchs,S. SimulationBasedDetailedPlanningforAgileManufacturing...512 BerendDenkena,LeifErikLorenzen,MaxKrüger,JustinSchmidt ProductVarietyManagementinDesignandManufacturing:ChallengesandStrategies...518 TAlGeddawy,HElMaraghy CapabilityAssessmentandValuationoftheImplementationofLeanProductionMethods...524 Lanza,G.,Jondral,A.,Book,J. PARTV: ENTERPRISEANDKNOWLEDGEMANAGEMENT...531 MANUFACTUREANDORGANIZATIONALSTRUCTURES...532 ANovelToolforAssessingandImprovingMaketoOrderandAssembletoOrderProductionSystems...533 M.Koho,S.Torvinen ReferencePlanningProcessesforSeriesProduction...539 N.Macke,S.Rulhoff,J.Stjepandic Theeffectofmanufacturingresponsetimeonmitigatingthedemandriskandfacilitydisruption...544 Niroomand,I.;Baygi,M.B.;Kuzgunkaya,O.;Bulgak,A.A. TRANSFORMATIONANDCHANGEMANAGEMENT...550 CladisticClassificationofAncientManufacturingFormsandTechnologies...551 C. RoseAnderssen,J. Baldwin,K.Ridgway RealtimecapableProductionPlanningandControlintheOrderManagementofbuilttoorderCompanies...557 G.Schuh,T.Brosze,S.Kompa,C.Meier Contents.. A
Contents CrosscompanycoordinationinBuilttoOrderProductionNetworksinMachineryandEquipmentIndustry...563 V.Stich,C.Schmidt,C.Meier,S.Cuber,S.Kompa TypeOrientedFactoryPlanningwithSolutionSpaceManagement...569 A.Kampker,B.Franzkoch,R.Hilchner OptimumRestorationoftheSharedPalletsDistributionAmongFactoriesandWarehouses...574 TakafumiMatsuura,SatomiWada,KazumitiNumata AConsortiumLeveragedLearningNetwork...580 V. Townsend,J.Urbanic ExtensionofValueStreamDesignfortheSimulationofAutonomousProductionSystems...586 Theuer,H. BuildingBlocksinanExperimentalandDigitalFactory...592 E.Müller,S.Horbach AnewApproachtoSimulationinProductionManagement...598 Lass,S. COMPLEX/DYNAMICSUPPLYCHAINSANDLOGISTICS...604 APlanningApproachforInplantMilkRunProcessestoOptimizeMaterialProvisioninAssemblySystems...605 MarkusDroste,JochenDeuse ImpactofMachineDrivenCapacityConstellationsonPerformanceandDynamicsofJobShopSystems...611 C.Toonen,D.Lappe,R.V.Donner,B.ScholzReiter OperatorSchedulingUndertheLeanManufacturingPrinciplesinOverSizeProductManufacturingFacilities...617 KadirErtogral,AliAkgunduz KNOWLEDGEMANAGEMENTANDLEARNING...623 TrainingconceptandstructureoftheLearningFactoryadvancedIndustrialEngineering...624 Dinkelmann,M.;Riffelmacher,P.;Westkämper,E. SupportingProjectExecutionforAdaptableProductionSystemsusingaflexiblesoftwaretool...630 E.Müller,U.Wagner Productionpilotforcooperationinfactorydevelopment...636 D.Chen,T.Kjellberg,R.Svensson,G.Sivard SurrogateModellingasanEnablerforSelfOptimisationforProductionProcesses...642 ReisgenU.,BeckersM.,BuchholzG.,WillmsK.,LoseJ.,Perge,J.,Schmitt,R. ApplicationProtocolsforStandardisingofProcessesandDatainDigitalManufacturing...648 SchallowJ.,MagenheimerK.,DeuseJ.,ReinhartG. PartnerSelectioninInnovationAlliance...654 Chen,X.;Riedel,R.;Mueller,E. HumanCentredModelforApplicationofLeanProductionSystemsinNetworks...660 Uygun, Y.; Straub, N.