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| موضوع: كتاب Changeable and Reconfigurable Manufacturing Systems الثلاثاء 19 سبتمبر 2023, 2:58 am | |
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أخواني في الله أحضرت لكم كتاب Changeable and Reconfigurable Manufacturing Systems Hoda A. ElMaraghy
و المحتوى كما يلي :
Editor Contents Part I Definitions and Strategies 1 Changeability – An Introduction H. ElMaraghy and H.-P. Wiendahl . 3 1.1 Motivation 3 1.2 Evolution of Factories . 7 1.3 Deriving the Objects of Changeability . 8 1.4 Elements of Changeable Manufacturing 10 1.5 Factory Levels . 11 1.6 Changeability Classes . 12 1.7 Changeability Objectives 13 1.7.1 Manufacturing Level . 14 1.7.2 Assembly Level . 14 1.7.3 Factory Level . 15 1.8 Changeability Enablers 15 1.8.1 Manufacturing Level . 16 1.8.2 Assembly Level . 17 1.8.3 Factory Level . 17 1.8.4 Reconfigurable Process Planning Level 18 1.8.5 Production Planning and Control Level 19 1.9 Changeability Process . 19 1.10 Conclusion 22 References . 23 2 Changing and Evolving Products and Systems – Models and Enablers H.A. ElMaraghy 25 2.1 Introduction and Motivation 26 2.2 The Hierarchy of Parts and Products Variants . 27 2.3 Evolving and Dynamic Parts and Products Families 32 xixii Contents 2.4 Modeling Products Evolution – A Biological Analogy 34 2.5 Design of Assembly Systems for Delayed Differentiation of Changing and Evolving Products . 35 2.6 Process Planning – The Link Between Varying Products and their Manufacturing Systems . 37 2.6.1 Existing Process Planning Concepts . 37 2.6.2 Process Plans Changeability . 38 2.6.3 Reconfiguring Process Plans (RPP) and Its Significance 40 2.6.4 Process Planning for Reconfigurable Machines . 41 2.7 Discussion and Conclusions 42 References . 44 3 Focused Flexibility in Production Systems W. Terkaj, T. Tolio and A. Valente 47 3.1 The Importance of Manufacturing Flexibility in Uncertain Production Contexts . 47 3.1.1 Focused Flexibility Manufacturing Systems – FFMSs 48 3.2 Literature Review 50 3.3 Proposal of an Ontology on Flexibility . 51 3.4 Analysis of Real Systems 55 3.4.1 Lajous Industries SA Case Study . 55 3.4.2 Riello Sistemi Case Study . 58 3.5 Using the Ontology on Flexibility to Support System Design 60 3.6 Conclusions and Future Developments . 63 References . 64 Part II Physical Enablers 4 Control of Reconfigurable Machine Tools G. Pritschow, K-H. Wurst, C. Kircher and M. Seyfarth . 71 4.1 Introduction . 71 4.1.1 Basic Idea for Reconfigurable Machine Tools and Systems . 72 4.1.2 Initial Situation in Machining Systems and Machine Tools 72 4.2 State of the Art . 75 4.3 Configurable and Reconfigurable Machine Tools 77 4.3.1 Development of (Re)configurable Machine Tools . 77 4.3.2 Conception of a Reconfigurable Machine Tool 80 4.4 Field Bus Systems Requirements . 81 4.5 Configurable Control Systems 83 4.5.1 Middle-Ware 84 4.5.2 Configuration . 85 4.5.3 Adjustment Mechanisms for Control Systems 85 4.5.4 Configuration Procedure 87 4.5.5 Development of a Control Configuration Tool 90Contents xiii 4.5.6 Configuration of a Control System by an Expert 90 4.6 Self-Adapting Control System for RMS 91 4.6.1 Elements of a Self-Adapting Control System . 91 4.6.2 Extensions of Self-Adapting Control Systems 92 4.6.3 Method for Reconfiguration of the Self-Adaptable Control System . 96 4.7 Summary and Conclusions . 98 References . 99 5 Reconfigurable Machine Tools for a Flexible Manufacturing System M. Mori and M. Fujishima 101 5.1 Introduction . 101 5.2 Reconfigurable Machine Tools Development 102 5.3 Application Examples . 107 5.4 Summary . 109 References . 109 6 Reconfigurable Machine Tools and Equipment E. Abele and A. Wörn 111 6.1 Introduction . 111 6.2 Flexibility Requirements 113 6.3 Reconfigurable Multi-Technology Machine Tool (RMM) . 116 6.3.1 Machine Tool Design . 116 6.3.2 Modules 117 6.3.3 System Interfaces 121 6.3.4 Expert Tool for System Configuration . 122 6.4 Summary . 124 References . 124 7 Changeable and Reconfigurable Assembly Systems B. Lotter and H-P. Wiendahl 127 7.1 Introduction . 127 7.2 Flexible Manual Assembly Systems . 129 7.2.1 Single Station Assembly with Set-Wise Assembly Flow 130 7.2.2 Single Station Assembly According to the One-Piece-Flow Principle 131 7.2.3 Multi-Station Assembly According to the One-Piece-Flow Principle 132 7.3 Flexible Automated Systems . 134 7.4 Hybrid Assembly Systems . 136 7.4.1 Characteristics 136 7.4.2 Example of a Hybrid Assembly System . 136 7.4.3 Analysis of the Results for Automated and Hybrid Assemblies . 140xiv Contents 7.5 Conclusion 141 References . 141 Part III Logical Enablers 8 Unified Dynamic and Control Models for Reconfigurable Robots A.M. Djuric and W.H. ElMaraghy 147 8.1 Design of Reconfigurable Modules for the Reconfigurable Robotics, Automation and Intelligent Systems Industry . 147 8.1.1 Description of a Robot Model 148 8.1.2 Reconfigurable Aspects of Industrial Robotic Systems . 148 8.1.3 Reconfigurable Kinematic and Dynamic Modules . 149 8.2 Design of Reconfigurable Control Platform (RCP) . 152 8.2.1 DC Motor Reconfigurable Position Control Design 152 8.3 Design of Reconfigurable Robot Platform (RRP) 157 8.4 Reverse Modeling of Reconfigurable Robot Meta-Model . 158 8.5 Conclusions . 159 References . 160 9 Reconfigurable Control of Constrained Flexible Joint Robots Interacting with Dynamic and Changeable Environment Y. Cao, H. ElMaraghy and W. ElMaraghy . 163 9.1 Introduction . 163 9.2 Dynamic Model of Flexible Joint Robot in Contact with Different Environment . 166 9.3 Decoupled Controller Design . 167 9.3.1 Contact with Rigid Surface 167 9.3.2 Contact with Stiff Environment 169 9.3.3 Contact with Dynamic Environment 169 9.4 Reconfigurable Control Scheme 171 9.5 Simulation Study . 172 References . 176 10 Reconfiguring Process Plans: A New Approach to Minimize Change A. Azab, H. ElMaraghy and S.N. Samy 179 10.1 Introduction . 180 10.2 Related Work 181 10.3 Conceptual Basis . 183 10.4 Mathematical Modeling and Programming . 184 10.5 A New Criterion in Process Planning 186 10.6 Computational Time Complexity . 187 10.7 Application and Verification 187 10.7.1 Reconfigurable Assembly Planning of a Family of Household Products . 187Contents xv 10.7.2 Reconfigurable Process Planning for Machining of a Front Engine Cover Part Family 190 10.7.3 Concluding Remarks . 192 10.8 Summary . 192 References . 193 11 Adaptive Production Planning and Control – Elements and Enablers of Changeability H-H. Wiendahl . 197 11.1 Introduction . 197 11.2 The PPC Framework 199 11.2.1 Design Aspects of a Socio-Technical PPC System . 200 11.2.2 PPC Design Matrix 201 11.3 Changeability of PPC Tools 202 11.3.1 Change Elements of PPC 203 11.3.2 Enablers of PPC Changeability . 203 11.3.3 Building Blocks of PPC Changeability 204 11.4 Adaptive PPC Solutions . 204 11.4.1 Functional Models . 205 11.4.2 Planning and Control Methods . 206 11.4.3 Data Models 207 11.4.4 Data Interfaces 208 11.5 Change Process in PPC 209 11.6 Summary and Further Research . 210 References . 211 12 Component Oriented Design of Change-Ready MPC Systems M.A. Ismail and H.A. ElMaraghy 213 12.1 Introduction . 213 12.2 Related Review 215 12.3 The New MPC System Characteristics . 216 12.3.1 Component-Based Software Engineering (CBSE) . 218 12.3.2 Component-Oriented Versus Object-Oriented Programming 219 12.4 Mini-Case Study: Component-Based Aggregate Production Planning System Framework . 219 12.4.1 System Architecture 219 12.4.2 Change-Ready MPC Framework . 220 12.5 Discussion and Conclusions 224 References . 225 13 Dynamic Capacity Planning and Modeling Its Complexity A. Deif and H. ElMaraghy 227 13.1 Introduction . 227 13.1.1 The Dynamic Capacity Problem 227xvi Contents 13.1.2 Complexity vs. Uncertainty 228 13.1.3 Complexity in Dynamic Capacity Planning 229 13.2 Literature Review 229 13.3 System Dynamic Model for Multi-Stage Production . 231 13.3.1 Multi Stage Production System . 231 13.3.2 Model Nomenclature . 232 13.3.3 Mathematical Model . 233 13.4 Numerical Simulation of Industrial Case Study 236 13.4.1 Overview of the Multi-Stage Engine Block Production Line 236 13.4.2 Input Data 236 13.4.3 Numerical Simulation Results 238 13.5 Conclusions . 243 References . 244 Part IV Managing and Justifying Change in Manufacturing 14 Design for Changeability G. Schuh, M. Lenders, C. Nussbaum and D. Kupke . 251 14.1 Production Trends in High-Wage Countries . 252 14.2 Introduction of a Target System for Complex Production Systems 253 14.2.1 Holistic Definition of Production Systems 253 14.2.2 Target System for Complex Production Systems 254 14.2.3 Differentiation Between Complicated Systems and Complex Systems 256 14.3 Approach to Mastering Complexity in Production Systems 257 14.3.1 Object-Oriented Design . 257 14.3.2 Object-Oriented Management of Production Systems 258 14.4 Case Studies . 261 14.4.1 A: Object-Oriented Production Design 262 14.4.2 B: Release-Engineering in the Automotive Industry . 263 14.5 Summary . 265 References . 266 15 Changeability Effect on Manufacturing Systems Design T. AlGeddawy and H. ElMaraghy 267 15.1 Introduction . 267 15.2 Synthesis of Manufacturing Systems 268 15.2.1 Enabling Changeability in Systems Frameworks 268 15.2.2 Effect of Changeability Enablers on the Factory Level Design . 271 15.2.3 Changeability Effect on Machine Level Design . 273 15.2.4 Product Design Directions . 274 15.3 Changeability Integration into the Design Process . 276 15.3.1 The System-Product Changeability Design Loop 276Contents xvii 15.3.2 Biological Evolution/Co-Evolution Analogy . 278 15.4 Final Remarks . 279 References . 280 16 Managing Change and Reconfigurations of CNC Machine Tools R. Hedrick and J. Urbanic 285 16.1 Introduction . 285 16.1.1 Reconfiguration Considerations 287 16.2 The Change or Reconfiguration Management Methodology . 289 16.3 Pneumatic Flow Control Valve Case Study . 294 16.4 Summary and Conclusions . 299 References . 300 17 Economic and Strategic Justification of Changeable, Reconfigurable and Flexible Manufacturing O. Kuzgunkaya and H.A. ElMaraghy . 303 17.1 Introduction . 303 17.2 Literature Review 304 17.3 Proposed RMS Justification Model 305 17.3.1 Financial Objective 308 17.3.2 System Complexity 309 17.3.3 System Responsiveness . 310 17.3.4 Overall Model . 310 17.4 Illustrative Example 313 17.4.1 Comparison of Reconfigurable and Flexible Scenarios over the System Life Cycle 315 17.4.2 FMS and RMS Comparison Through Life-Cycle Simulation 317 17.5 Conclusions . 318 References . 319 18 Quality and Maintainability Frameworks for Changeable and Reconfigurable Manufacturing W.H. ElMaraghy and K.T. Meselhy . 321 18.1 Introduction . 322 18.2 Quality and the Manufacturing System Design 322 18.3 Changeable Manufacturing and Quality 325 18.4 Effect of Reconfigurable Manufacturing System Design on Quality . 328 18.5 The Changeability and Maintainability Relationship . 330 18.6 Conclusion 333 References . 334xviii Contents 19 Maintenance Strategies for Changeable Manufacturing A.W. Labib and M.N. Yuniarto . 337 19.1 Introduction . 337 19.2 Recent Developments . 338 19.3 Current Research and Trends . 338 19.3.1 Model of Integration Between Intelligent Manufacturing Control System and Intelligent Maintenance System . 339 19.3.2 Fuzzy Logic Controller I and II (FLC I and II) 341 19.3.3 Fuzzy Maintenance and Decision Making Grid . 344 19.4 Case Study 348 19.5 Conclusions and Future Research . 349 References . 350 Part V Future Directions 20 The Cognitive Factory M.F. Zäh, M. Beetz, K. Shea, G. Reinhart, K. Bender, C. Lau, M. Ostgathe, W. Vogl, M. Wiesbeck, M. Engelhard, C. Ertelt, T. Rühr, M. Friedrich and S. Herle 355 20.1 Introduction . 356 20.2 Intelligence in Automated Systems 356 20.3 Cognitive Technical Systems . 359 20.4 The Cognitive Factory 360 20.4.1 Vision and Goals 360 20.4.2 Core Aspects to Achieve the Cognitive Factory . 362 20.5 Summary and Outlook 368 References . 369 21 Migration Manufacturing – A New Concept for Automotive Body Production T.P. Meichsner 373 21.1 Initial Situation 373 21.2 Development of the Basic Concept 376 21.3 Operating Phases of the Migration Concept . 380 21.4 Practical Evaluation and Implementation . 382 21.5 Conclusion and Outlook . 385 References . 387 22 Changeable Factory Buildings – An Architectural View J. Reichardt and H-P. Wiendahl 389 22.1.1 The Factory Planners View 390 22.1.2 The Challenge: Multi-User, Changeable and Scalable Buildings 392 22.2 Performance and Constituent Components of Factory Buildings 394Contents xix 22.2.1 Form Follows Performance 394 22.2.2 Building Components 395 22.3 Synergetic Planning of Processes, Logistics and Buildings 397 22.4 Industrial Example of a Transformable Factory 398 22.5 Conclusion 400 References . 401 Index . 403 Index A Adaptability 3, 26, 71, 73, 75, 115, 198, 205, 206, 210, 268, 305, 355, 356, 359, 361, 379, 394, 395, 397 Adjustability 18, 19 Aggregate Planning 213 Agile Manufacturing 213, 214 Architecture 49, 63, 84, 91, 92, 97–99, 113, 116, 215, 218, 219, 228, 270, 271, 274, 357, 358, 360, 362, 368, 389, 390, 394, 397 Assembly 6, 7, 11–15, 17, 25, 27, 29, 30, 36–39, 41, 43, 76, 77, 91, 116, 121, 123, 182–185, 187–190, 192, 236, 270, 271, 323, 326, 365, 366, 374, 377, 390, 391, 399 Assembly System 26, 35 Assembly System Design 26 Automated Assembly 182 Automotive Manufacture 373 B Biological 25, 34, 275, 278, 279 Body-in-White Production 373 C Capacity Planning 227, 229, 234, 241, 271 Change Management 285 Changeability 3, 8–13, 15–22, 26, 38, 40, 51, 54, 63, 75, 180, 193, 197, 201–205, 207–210, 213–217, 227, 267–269, 271, 273–280, 304, 321, 326, 330, 337, 349, 356, 368, 373, 376, 389, 391, 393, 394 Changeability Enablers 3, 15, 202, 273, 275, 376, 389 Changeability Objects 3, 19 Changeability Strategy 3 Changeable Manufacturing 10, 13, 16, 27, 32, 179, 213–216, 222, 224, 227–229, 243, 244, 303, 304, 322, 323, 331, 337, 341 Cladistic 25, 34–36, 43 Classification 14, 25, 26, 32, 35, 50, 63, 87, 94, 148, 149, 275, 330, 361, 363 CNC Machine 285 CNC Machine Tool 101, 285 Co-evolution 43, 279 Code 56, 89, 218, 297, 309, 346, 349, 364, 366 Cognition 355, 359, 368 Cognitive 330, 355, 356, 359–363, 368 Compatibility 32, 121, 217, 275, 287–294, 296–300, 376, 377, 382 Competitiveness 3, 390 Complexity 187, 218, 227–229, 240, 241, 303, 309, 315, 316, 321, 333 Component-Based MPC System 213 Computer Integrated Manufacturing 213 Concurrency 84 Configurable Control System 71, 83 Configuration 18, 27, 48, 60, 63, 71–77, 80, 83, 85–91, 93–97, 99, 101, 103–106, 115, 121–124, 181, 191, 205, 209, 210, 270–272, 275, 276, 280, 285–288, 290–292, 294–296, 299, 300, 303, 304, 307–310, 313–315, 317–319, 321, 324, 327–329, 331, 334, 358, 377, 382 Configuration Procedure 71, 124 403404 Index Control 11, 14, 19, 71, 83, 85, 88, 90–92, 96, 99, 147, 152, 159, 160, 197, 199, 206, 213, 216, 234, 235, 271, 294, 339, 341, 360, 362 Convertability 325, 327 Customization 4, 16, 25, 30, 31, 33, 43, 48, 49, 179, 180, 214, 268, 373 D Decision Theory 47, 337 Design 35, 51, 52, 60–63, 109, 116, 147, 152, 157, 187, 200, 201, 213, 215, 267–269, 271, 273, 274, 276–280, 346, 389, 391–393, 395 Design Field 389 Design Synthesis 267 Differentiation 4, 25, 30, 31, 33, 37, 38, 43 Dynamics 147, 230 E Economic Justification 303 Enablers 3, 4, 9, 14, 16–19, 22, 25–27, 44, 54, 197, 202–204, 216, 228, 272, 273, 276, 280, 356 Equipment 7, 111, 304, 374 Evolution 7, 33, 34, 278 Evolving Family 25, 32, 275 Evolving Part 26 Evolving Parts 32, 34, 43, 181 Evolving Parts and Products Families 26 F Family 7, 13, 25–27, 29–40, 43, 48, 49, 56, 64, 117, 179, 183, 187, 190, 274, 275, 280, 290 Feature 12, 50, 90, 105, 113, 117, 184–187, 203, 218, 222, 227, 229, 243, 323, 364, 365, 378 Field-bus Systems 71 Flexibility 13, 14, 47–55, 57, 60–63, 101, 111, 113, 269, 355 Focused Flexibility Manufacturing Systems (FFMSs) 47, 49 Framework 8, 36, 50, 51, 54, 95, 182, 197– 199, 201, 210, 213, 215, 216, 219, 220, 228, 244, 267–271, 273, 274, 277–280, 321, 323, 328–330, 333, 334, 338, 349 Functionality 52, 53, 57, 60, 63 Fuzzy Logic 183, 338–342, 345, 346, 348, 349, 357 G Granularity 18 Group 29, 32, 36, 85, 274 Group Technology 275 H Hard- and Software Interface 71 Hierarchy 26, 27, 43, 305, 345 I Industrial Robot 147, 149 Integrability 16, 17, 214 Intelligent Automation 355 Intelligent Manufacturing System 337, 340, 350 L Laser 72, 73, 87, 99, 114, 362 Logistic 6, 13, 26, 197, 230, 285, 390 M Machining Center 101, 295 Maintainability 321, 330, 333 Maintenance 81, 102, 122, 321, 323–326, 330–334, 337–341, 344–350, 361, 384, 386 Maintenance Strategies 337 Manual Assembly 189 Manufacturing Planning 213 Manufacturing System Design 47, 279 Manufacturing System 4, 6, 13, 14, 16, 17, 25–27, 30–35, 37, 38, 40, 42–44, 48–51, 63, 71, 72, 74, 95, 109, 112, 192, 213, 214, 216, 218, 228, 230, 231, 267–270, 274, 276, 279, 285, 291, 303–305, 318, 319, 337, 338, 356–358, 361, 368, 385, 391 Mathematical Programming 40, 179 Mechatronic Components 71, 94 Metal Cutting, Assembly 179 Metrics 22, 25, 53, 315, 323 Migration 373, 375–378, 380, 382–386 Mobility 17, 18, 53 Modular Design 71, 80, 267, 273, 275 Modularity 9, 16, 17, 22, 29, 30, 32, 75, 116, 214, 273–275, 280, 325–327, 376 Multi-criteria Decision Making 303Index 405 N Neutrality 19 Niche Products 31 Niche Vehicles 373 O Object Oriented MPC System 213 Ontology 47, 51, 54, 55, 60, 62 Ontology on Flexibility 47, 51, 54, 55, 60, 62 P Platform 30, 31, 83–86, 88, 89, 99, 102, 116, 158, 270, 274, 279, 292, 375–377, 385 Portfolio 12, 13, 15, 31, 391 (PPC) Production Planning and Control 197–199, 229 Precedence 36, 37, 39–42, 182, 184–186, 189, 190 Process Planning 11, 18, 32, 33, 37, 38, 40–42, 179, 183, 184, 186, 190, 193, 216, 275, 285, 364 Process Plans 11, 18, 25–27, 30, 34, 37–44, 179–181, 183, 186, 192, 193, 275, 285, 304, 327, 331, 364, 367 Product Evolution 26, 34, 179 Product Families 26, 27, 30, 32, 34, 43, 181 Production Planning 11, 19, 52, 57, 60, 63, 197, 199, 216, 219 Q Quality 19, 321–323, 325, 326, 328, 331–334 R Real Options 63, 373 Reconfigurability 13–15, 26, 49, 51, 72, 75, 109, 268, 272, 273, 275, 276, 279, 305 Reconfigurable Machine Tool 80, 111, 191, 273 Reconfigurable Manufacturing Systems 49, 63, 111, 115, 181, 214, 304, 321, 334, 356, 385 Reconfigurable Modules 147 Reconfigurable Robots and Machine Tools 71 Reconfiguration 40, 96, 97, 101, 186, 191, 285–287, 289, 303, 307, 312, 314, 315 Reconfiguration Management 285, 289 Reconfiguring Process Plans 25, 26, 40, 41, 43, 179 Reliability 308, 321 Responsiveness 240, 303, 310, 315, 316 Robot 147 S Scalability 9, 16, 22, 48, 102, 214, 216, 218, 221, 229–231, 233, 234, 237, 238, 241, 243, 244, 272, 274, 280, 305, 325, 327, 349, 376, 382 Self Adapting Control System 71 Self-adaptable 91, 93 Species 33, 34, 64, 278, 279 Supply Chain 12, 32, 37, 180, 183, 199, 230, 270, 279, 384 Sustainability 390, 398 Synergetic Factory Planning 398 Synthesis 267, 268 T Transformability 13, 15, 19, 21, 272, 398–400 Transformable Factory 273, 391, 399, 400 Turbulence 50, 58, 197, 391 U Uncertainty 227, 228 Universality 17 V Variability 36, 62, 234, 237, 327, 333 Variant 39, 181, 187–190, 367, 375, 386 Variation 4, 25–27, 29–33, 37–39, 41, 43, 44, 214, 230, 237, 240, 303
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