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Manufacturing Dynamics and Performance Evaluation
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology. KTH. (Manufacturing and Metrology Systems)ORCID iD: 0000-0002-8597-2604
2018 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Manufacturing companies are striving to remain competitive in the market and maintain their economic growth and productivity. Uncertainties regarding the changes in product demand, workpiece material, product design, and technological advancement, have imposed pressure on manufacturing systems. Market uncertainties force manufacturing companies to be flexible and responsive in producing different parts, by adapting the existing system without the need for a substantial investment. The market is characterized by time variations in product quantities and varieties while manufacturing systems remain inherently fixed. To sustain competitive manufacturing, a company has to adopt to new production requirements and be responsive to market changes quickly. Conscious decisions have to be made for a system to respond to market fluctuations. In order to respond to the dynamic changes, there is a need for developing methodologies that analyse, evaluate and control performance of manufacturing system at the system and/or process levels.

The primary focus of the thesis is to develop a novel generic framework for modelling and controlling manufacturing systems intending for improvement of the performance of manufacturing and make companies more competitive. The framework incorporates the complex interrelations between the process and system parameters, i.e., the dynamics of the system. Thus, provides a quantitative and qualitative analysis for performance evaluation and for optimizing performance of manufacturing system. The generic framework can further be adapted for studying specific manufacturing systems in discrete manufacturing. Three case studies are presented. The case studies are performed in an automotive company where the effect of various levels of control is investigated in manufacturing systems configured as transfer line or as a flexible manufacturing system.

Two aspects of the dynamic nature of manufacturing system are investigated in this thesis: (1) The engineering nature of the system, i.e., the selection of appropriate process parameters to manufacture a product according to the design specification, and (2) The business nature of the system, i.e., the selection of system parameters with respect to the way the product is manufactured. At the process level, the parameters are controlled within the process capability limits to adapt to the changes of the system parameters in response to the market dynamics. At the system level, operational parameters are controlled to satisfy performance criteria.

A case study for resource use analysis during primary processes has also been investigated and presented. The critical operations and the operations that have the highest energy consumptions and the potential for energy savings have been identified.

The methodology developed for analysing the performance of the dynamic manufacturing system is based on a system dynamics modelling approach. Results obtained from different modelling approaches are presented and compared based on the selected performance metrics.

Place, publisher, year, edition, pages
Stockholm: Kungliga Tekniska högskolan, 2018. , p. 107
Series
TRITA-ITM-AVL ; 2018:33
Keywords [en]
Manufacturing system and strategy; performance evaluation; manufacturing dynamics; decision-making; system dynamics; sustainable and energy efficient manufacturing
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production Engineering
Identifiers
URN: urn:nbn:se:kth:diva-229400ISBN: 978-91-7729-841-0 (print)OAI: oai:DiVA.org:kth-229400DiVA, id: diva2:1212487
Public defence
2018-06-15, M311, Brinellvägen 68, Stockholm, 13:00 (English)
Opponent
Supervisors
Funder
VINNOVA, 2012-00933Available from: 2018-06-04 Created: 2018-06-01 Last updated: 2018-06-04Bibliographically approved
List of papers
1. System dynamics analysis of energy usage: Case studies in automotive manufacturing
Open this publication in new window or tab >>System dynamics analysis of energy usage: Case studies in automotive manufacturing
2014 (English)In: International Journal of Manufacturing Research, ISSN 1750-0591, Vol. 9, no 2, p. 131-156Article in journal (Refereed) Published
Abstract [en]

Our life is strongly linked with the usage of natural resources. With increase in world population and welfare there is an increasing global demand for raw material. Energy is a necessity in everyday life and is often generated using non-renewable natural resources which are finite. Manufacturing is one of the largest energy and material resource consumers. There is great concern about minimising consumption of energy in manufacturing industry to sustain the natural carrying capacity of the ecosystem. This is one of the challenges in today’s industrial world. The paper presents the application of system dynamics theory for modelling and simulation of complex manufacturing processes. The simulations help to understand the intricate nature of the interrelation of process parameter and to make sound decision about minimising the energy losses. Two case studies are presented, one in cylinder head casting processes and the other in crankshaft machining. The developed models provide an insight into how to select critical operations and to identify the effect of various parameters on the energy consumption. Also, the models help to understand how changes of parameters over time affect the behaviour of energy changes. The outcome of this research enables the company to identify potential avenues to minimise energy usage and offers a decision support tool.

National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-161011 (URN)10.1504/IJMR.2014.062440 (DOI)2-s2.0-84902212487 (Scopus ID)
Note

QC 20150317

Available from: 2015-03-17 Created: 2015-03-06 Last updated: 2018-06-04Bibliographically approved
2. Performance evaluation of machining strategy for engine-block manufacturing
Open this publication in new window or tab >>Performance evaluation of machining strategy for engine-block manufacturing
2015 (English)In: Performance evaluation of machining strategy for engine-block manufacturing, ISSN 1895-7595, Vol. 15, no 4, p. 81-102Article in journal (Refereed) Accepted
Abstract [en]

This paper will introduce a novel methodology for the performance evaluation of machining strategies of engine block manufacturing. The manufacturing of engine components is vital to the automotive and vehicle manufacturing industries. Machining is critical processes in the production of these parts. To survive and excel in the competitive manufacturing environment, companies need to improve as well as update their machining processes and evaluate the performance of their machining lines. Moreover, the lines and processes have to be robust in handling different sources of variation over time that include such examples as demand fluctuations, work-piece materials or even any changes in design specifications. A system dynamics modelling and simulation approach has been deployed to develop a methodology that captures how machining system parameters from the machining process are interacted with each other, how these connections drive performance and how new targets affect process and machine tool parameters through time. The developed model could provide an insight of how to select the crucial machining system parameters and to identify the effect of those parameters on the output of the system. In response to such an analysis, this paper provides (offers) a framework to examine machining strategies and has presented model that is useful as a decision support system for the evaluation and selection of machining strategies. Here a system dynamics methodology for modelling is applied to the milling operation and the model is based on an actual case study from the engine-block manufacturing industry.

National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-229289 (URN)
Note

QC 20180604

Available from: 2018-06-01 Created: 2018-06-01 Last updated: 2018-06-04Bibliographically approved
3. Towards a Generic Framework for the Performance Evaluation of Manufacturing Strategy: An Innovative Approach
Open this publication in new window or tab >>Towards a Generic Framework for the Performance Evaluation of Manufacturing Strategy: An Innovative Approach
2018 (English)In: Towards a Generic Framework for the Performance Evaluation of Manufacturing Strategy: An Innovative Approach, Vol. 9, no 2, p. 131-156Article in journal (Refereed) Published
Abstract [en]

To be competitive in a manufacturing environment by providing optimal performance in terms of cost-effectiveness and swiftness of system changes, there is a need for flexible production systems based on a well-defined strategy. Companies are steadily looking for methodology to evaluate, improve and update the performance of manufacturing systems for processing operations. Implementation of an adequate strategy for these systems’ flexibility requires a deep understanding of the intricate interactions between the machining process parameters and the manufacturing system’s operational parameters. This paper proposes a framework/generic model for one of the most common metal cuttingoperations—the boring process of an engine block machining system. A system dynamics modelling approach is presented for modelling the structure of machining system parameters of the boring process, key performance parameters and their intrinsic relationships. The model is based on a case study performed in a company manufacturing engine blocks for heavy vehicles. The approach could allow for performance evaluation of an engine block manufacturing system condition. The presented model enables a basis for other similar processes and industries producing discrete parts.

Keywords
performance evaluation; machining strategies; manufacturing system; manufacturing strategy; machining process interaction; dynamic modelling; performance criteria; system dynamics
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:kth:diva-229086 (URN)
Note

QC 20180604

Available from: 2018-06-01 Created: 2018-06-01 Last updated: 2019-09-04Bibliographically approved
4. System dynamics as a decision support system for machine tool selection
Open this publication in new window or tab >>System dynamics as a decision support system for machine tool selection
2016 (English)In: Journal of Machine Engineering, ISSN 1895-7595, Vol. 16, no 3, p. 102-125Article in journal (Refereed) Published
Abstract [en]

The worldwide competitive economy, the increase in sustainable issue and investment of new production line is demanding companies to choose the right machine from the available ones. An improper selection can negatively affect the overall performance of the manufacturing system like productivity, quality, cost and company’s responsive manufacturing capabilities. Thus, selecting the right machine is desirable and substantial for the company to sustain competitive in the market. The ultimate objective of this paper is to formulate a framework for machining strategy and also provide methodology for selecting machine tool from two special purpose machine tools in consideration of interaction of attributes. A decision support system for the selection of machine tool is developed. It evaluates the performance of the machining process and enhances the manufacturer (decision maker) to select the machine with respect to the performance and the pre-chosen criteria. Case study was conducted in a manufacturing company. A system dynamics modelling and simulation techniques is demonstrated towards efficient selection of machine tool that satisfy the future requirement of engine-block production.

Place, publisher, year, edition, pages
Editorial Institution of Wrocaw Board of Scientific, 2016
Keywords
Decision making, Machine selection, Performance analysis, System dynamics modelling
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:kth:diva-195549 (URN)2-s2.0-84990997629 (Scopus ID)
Note

QC 20161109

Available from: 2016-11-09 Created: 2016-11-03 Last updated: 2018-06-04Bibliographically approved

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