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Comparison of the Classic and Hybrid Production Methods with the Use of SLM Taking into Account the Aspects of Sustainable Production Development

Terelak-Tymczyna Agnieszka, Bachtiak-Radka Emilia, Grzesiak Dariusz, Jardzioch Andrzej

Advances in Science and Technology. Research Journal

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2023

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Vol. 17, no 1

94--107

EN

Problems on the world market, related to delays in supply chains, have forced enterprises to adopt a more flexible approach in the production processes of the offered products. In order to meet customer needs, companies can often look for alternative supply chains, as well as take over the production of key components necessary to maintain business continuity. Therefore, companies have to make important decisions in the context of management. A simulation model may be a tool helpful in making decisions related to production planning, which, based on the actual data collected from the process, allows for the verification of decisions before entering them into the real system. The motivation to conduct the research was the search for answers: How entrepreneurs, while maintaining profitability, can ensure the continuity of production processes by searching for alternative production methods. The article considers a comparison of two production processes for the production of a shield type product: classic production - on a lathe and hybrid production using the SLM method and machining only technologically significant surfaces on a lathe. The main goal of the research is to compare two production processes: classic and hybrid in terms of efficiency, energy efficiency and production costs. The research takes into account the use of different laser powers and the possibility of incremental production of several products at the same time. In order to achieve the assumed goal, a simulation model was used to carry out the research, which was developed on the basis of preliminary experimental studies. A series of simulations were performed, taking into account the variability criteria, and then the efficiency, energy efficiency and profitability of using alternative production methods were analysed.

2

Zastosowanie logiki rozmytej do szeregowania zleceń produkcyjnych

Jardzioch Andrzej, Witkowska Weronika

Zarządzanie Przedsiębiorstwem

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2022

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Vol. 25, nr 3-4

15--20

EN

The article presents an algorithm that allows using fuzzy logic to determine the effective arrangement of production orders in the production system. The main criterion used to rate was the total cost related to delayed implementation of production orders. In addition, the sum of delays of all orders and the total time of order execution were assessed. The elaborated algorithm uses fuzzy inference and allows us to estimate dynamically the effectiveness of selecting the next order from orders awaiting execution. As a result, the computational complexity of the proposed algorithm is linear. The research was conducted to assess the usefulness of the proposed algorithm. To illustrate the possibilities of the proposed algorithm, the obtained rankings were compared with those obtained using typical heuristic rules (FIFO, EDD, Johnson’s algorithm, and min changeover time). The obtained results confirmed the benefits of the proposed algorithm for scheduling production orders. The developed algorithm was implemented in Matlab and research was carried out for different series of production orders.

3

Application of simulation research to analyse the production process in terms of sustainable development

Zachciał Agnieszka, Jardzioch Andrzej

Applied Computer Science

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2022

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Vol. 18, no 3

54--62

EN

Sustainable development is an very important idea nowadays and it influences on many factors. It is very important to focus on the goals of sustainable development and implement them both in industry and in everyday life. The aim of the article is to analyse the impact of implementing an automatic conveyor belt transport system between the stands of an exemplary assembly line on sustainable development in economic and environmental terms. The analyzed production process consists of one production line with six assembly stations. The efficiency of individual design solutions and electricity consumption were adopted as the evaluation criteria. To compare the two processes, a simulation analysis was performed in the Plant Simulation program. First chapter is the introduction to the article. The second chapter describes the current applications of simulation tests. The third chapter describes the production system that is improved by adding conveyors. The next chapter compares the processes with and without the use of conveyors and presents how much energy must be used additionally by imple-menting conveyor belts, but also what energy savings can be obtained by installing additional stop sensors. The fifth chapter presents the conclusions: the conducted research allowed concluding that the implementation of conveyor belts affects a higher number of finished products at the same time as the transport of components is manual. However, the best solution is to use conveyors with stop sensors, and the power consumption is then low and more profitable for the enterprise.

4

Comparative Analysis of the Production Process of a Flange-Type Product by the Hybrid and Traditional Method with the Use of Simulation Methods

Terelak-Tymczyna Agnieszka, Bachtiak-Radka Emilia, Jardzioch Andrzej

Advances in Science and Technology. Research Journal

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2022

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Vol. 16, no 1

231--242

EN

In the era of Industry 4.0, the digitization of production processes is one of the important elements contributing to the reduction of uncertainty related to the implementation of new production methods. The worldwide epidemic situation and its constraints have resulted in supply chain continuity problems. These problems make enterprises look for the possibility of producing products that they need at the moment and which they cannot obtain from the market. In special cases, this may also apply to spare parts necessary to maintain the continuity of production. The main reason for research on comparing production processes is meeting the challenges related to the pandemic situation and problems in maintaining timeliness, flexibility, and continuity of the supply chain. The first stage of the research was to visualize the course of the process and determine the lead times for both production methods. For further analysis, a digital process model was used to compare the hybrid and the classical method to check the viability of the interchangeability of methods for the production process of the flange part. The interchangeability of production methods was dictated by problems related to the supply of components for the execution of orders. The article simulates the model for unit and small-lot production in batches of 10 and 100 pieces, considering such aspects as: order completion time, energy consumption of the process, production costs, taking into account the classic and hybrid methods. The conducted research was aimed at determining the profitability of the production of flange-type products by means of classical processing and hybrid and checking the interchangeability of production methods in accordance with quality requirements as well as reducing uncertainty with the implementation of new production systems in changing market conditions. The simulations show that the use of hybrid production is recommended for unit production. In the case of small-lot production, already with 10 items, production in the traditional process is 21% cheaper, and for the production of 100 items, the cost of traditional production is reduced by 33% compared to hybrid production.

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Application of a fuzzy controller in the process of automated polyethylene film thickness control

Jardzioch Andrzej, Marczak Wioletta

Applied Computer Science

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2021

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Vol. 17, no 3

31--46

EN

The present article aims to describe the design of a fuzzy controller used for automated control of the thickness of the extruded polyethylene film effected by the adjustment of the actuator in the cooling ring. In order to determine whether the designed controller operates properly, a model extruder was created and a simulation study was carried out. The Simulink programming environment integrated with Matlab was used for the development of the fuzzy controller and the simulation. The conducted simulation study demonstrated that the implementation of the designed controller would enable the adjustment of thickness on the perimeter of the film tube and quick reaction to possible departure in the assumed film thickness in mass production.

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The application of artificial intelligence methods in polyethylene film production process control

Jardzioch Andrzej, Marczak Wioletta

Zarządzanie Przedsiębiorstwem

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2020

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Vol. 23, nr 1

16--22

EN

The paper presents the design of a fuzzy controller whose task is intelligent, linguistic rule based control of thickness of the extruded polyethylene film. The structure of the fuzzy controller was developed; then, its model was built in MATLAB SIMULINK program and simulations were run to verify its performance under laboratory conditions. Based on the investigation, it can be concluded that the developed controller enables precise adjustment of polyethylene film thickness, taking into account disturbances caused by internal and external factors.

7

Heuristic based production planning in automated manufacturing system.

Jardzioch Andrzej

Advances in Manufacturing Science and Technology

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2000

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Vol. 24, nr 4

113-123

EN

This paper proposes a computer aided control system, which manages both efficiency and flexibility in the manufacturing system. It has been considered that application of Fuzzy-Logic methods is necessary for the multicriterial control of production systems. The proces of production scheduling involves applies an algorithm of lingustic rules generation on the basis of numerical data. The quality of rules obtained automatically was assessed by comparison of generated results with the assessment of importance of orders made by an expert.

PL

W pracy zapropnowano komputerowo wspomagany system sterowania pozwalający na wydajne i elastyczne wytwarzanie. Wielokryterialne sterowanie systemem produkcyjnym wymaga zastosowania metod Fuzzy - Logic. Przedstawiono koncepcję tworzenia i wykorzystania lingwistycznej bazy wiedzy koniecznej do sterowania systemami produkcyjnymi. Do budowy bazy reguł zastosowano alegorytm generowania reguł lingwistycznych na podstawie danych numerycznych. Dokonano oceny baz reguł lingwistycznych opracowanych w sposób konwencjonalny na podstawie doświadczenia eksperta oraz wygenerowanych w sposób automatyczny na podstawie danych numerycznych.