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System dynamics analysis of energy usage: Case studies in automotive manufacturing
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology. KTH.ORCID iD: 0000-0002-8597-2604
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.
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.

Place, publisher, year, edition, pages
2014. Vol. 9, no 2, p. 131-156
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:kth:diva-161011DOI: 10.1504/IJMR.2014.062440Scopus ID: 2-s2.0-84902212487OAI: oai:DiVA.org:kth-161011DiVA, id: diva2:795643
Note

QC 20150317

Available from: 2015-03-17 Created: 2015-03-06 Last updated: 2018-06-04Bibliographically approved
In thesis
1. Manufacturing Dynamics and Performance Evaluation
Open this publication in new window or tab >>Manufacturing Dynamics and Performance Evaluation
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
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:nbn:se:kth:diva-229400 (URN)978-91-7729-841-0 (ISBN)
Public defence
2018-06-15, M311, Brinellvägen 68, Stockholm, 13:00 (English)
Opponent
Supervisors
Funder
VINNOVA, 2012-00933
Available from: 2018-06-04 Created: 2018-06-01 Last updated: 2018-06-04Bibliographically approved

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Adane, Tigist FeteneNicolescu, Mihai

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