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Technical Paper

Integrating the Production Information System with Manufacturing Cell Design - A Lean, Linked Cell Production System Design Implementation

1999-05-10
1999-01-1634
The linked cell system gives both reduced cost and volume flexibility. The characteristics of the linked cell system are a consequence of decoupling the operators from the machines, using standard work in process between the cells and by integrating the information system with the cell and system design. By decoupling the operators from the machines the capacity can be increased/decreased in small increments by using more or fewer operators in the cell. The information system is integrated with the linked cell design by the use of a Heijunka box. The Heijunka is used to level production and to initiate the pace of production as a result of pulling withdrawal kanban at a standard time interval. This standard time interval is called the pitch of production. The kanban cards give information about what to produce, when to produce, when to make changeovers but they also give information to control the material replenishment.
Technical Paper

The Importance of Takt Time in Manufacturing System Design

1999-05-10
1999-01-1635
Lean production has greatly influenced the way manufacturing systems should be designed. One important aspect of lean production is takt time. Takt time relates customer demand to available production time and is used to pace the production. This paper applies the manufacturing system design and deployment framework to describe the impact of takt time on both the design and the operation of a manufacturing system. The goal of this paper is to illustrate the relevant relationships of takt time to overall system design.
Technical Paper

Application of a Lean Cellular Design Decomposition to Automotive Component Manufacturing System Design

1999-05-10
1999-01-1620
A design framework based on the principles of lean manufacturing and axiomatic design was used as a guideline for designing an automotive component manufacturing system. A brief overview of this design decomposition is given to review its structure and usefulness. Examples are examined to demonstrate how this design framework was applied to the design of a gear manufacturing system. These examples demonstrate the impact that low-level design decisions can have on high-level system objectives and the need for a systems-thinking approach in manufacturing system design. Results are presented to show the estimated performance improvements resulting from the new system design.
Technical Paper

Design of Manufacturing Systems to Support Volume Flexibility

1999-05-10
1999-01-1621
This paper presents an Axiomatic Design framework for manufacturing system design and illustrates how lean cellular manufacturing can achieve volume flexibility. Axiomatic Design creates a design framework by mapping the functional requirements of a system to specific design parameters. Volume flexibility is often neglected as a requirement of manufacturing systems. Very few industries are fortunate enough to experience stable or predictable product demand. In reality, demand is often volatile and uncertain. It is important that manufacturing system designers are aware of manufacturing system types which can accommodate volume flexibility and follow a structured design methodology that assures that all requirements are met by the system.
Technical Paper

The Production System Design and Deployment Framework

1999-05-11
1999-01-1644
This session keynote paper presents a framework for designing and deploying production systems. The framework enables the communication and determination of objectives and design solutions from the highest level to the lowest level of a manufacturing enterprise. The design methodology ensures that the physical implementation, called Design Parameters (DPs), meets the objectives or Functional Requirements (FRs) of the production system design. This paper presents a revolutionary approach to determine the objectives and the implementation of a “lean” production system design for a manufacturing business as guided by the design axiom of independence.
Technical Paper

Introduction of Functional Periodicity to Prevent Long-Term Failure Mechanism

2006-04-03
2006-01-1203
One of the goals of designing engineering systems is to maximize the system's reliability. A reliable system must satisfy its functional requirements without failure throughout its intended lifecycle. The typical means to achieve a desirable level of reliability is through preventive maintenance of a system; however, this involves cost. A more fundamental approach to the problem is to maximize the system's reliability by preventing failures from occurring. A key question is to find mechanisms (and the means to implement them into a system) that will prevent its system range from going out of the design range. Functional periodicity is a means to achieve this goal. Three examples are discussed to illustrate the concept. In the new electrical connector design, it is the geometric functional periodicity provided by the woven wire structure. In the case of integrated manufacturing systems, it is the periodicity in scheduling of the robot motion.
Technical Paper

Optical Flow Sensor Using Geometric Moiré Interferometry

2004-07-19
2004-01-2267
We report on a feasibility study of an optical micro-electro-mechanical systems (MEMS) flow sensor to measure flow rate using Moiré fringe displacement of a floating element. Due to constraints on weight, power, and size for space environmental systems, the development of sensor components that minimize the equivalent systems mass (ESM) while maintaining or exceeding required specifications is highly desirable. A feature of the optical detection method is a physical separation of electrical components from the flow stream. The geometric Moiré fringe shift optically amplifies small displacements by the ratio of the fringe pitch to the movable grating pitch that is detected using an external CCD imager, providing an electrically isolated, robust, direct scheme for detecting flow from shear stress induced displacement.
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