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Seru Production System: A Review and Projections for Future Research

Shih Yung Chin

Management and Production Engineering Review

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2021

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Vol. 14, No. 4

53--70

EN

In mid-1992, Japanese consultant Yamada Hitoshi was tasked with modifying the production systems of Japanese companies as the existing configurations at manufacturing plants no longer satisfied unstable demands. He made improvements to the overall production system by dividing the long assembly lines into several short ones called cells or seru. Although of the advantages, it is still unclear about how to manage this new production system, and what variables really promoted the desired benefits. We identify in total 39 articles from 2004– 2020 about the progress of the seru production system, and we observe some possibilities to improve the effectiveness of this type of the production system. The first is the possibility of manufacturing the product in flexible sequence, in which the operations are independent among them. We show through the developed example that the makespan may be different. We noted when converting the in-line production system to one pure seru, the makespan tend to increase. Nevertheless, when analyzing the effectiveness of serus working concomitantly considering splitting the same lot, makespan and the cost may be reduced. And finally, when converting to one of pure serus, the performance may be similar to that obtained when serus working concomitantly.

2

Scalability analysis of selected structures of a reconfigurable manufacturing system taking into account a reduction in machine tools reliability

Gola Arkadiusz, Pastuszak Zbigniew, Relich Marcin, Sobaszek Łukasz, Szwarc Eryk

Eksploatacja i Niezawodność

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2021

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Vol. 23, no. 2

242--252

EN

Scalability is a key feature of reconfigurable manufacturing systems (RMS). It enables fast and cost-effective adaptation of their structure to sudden changes in product demand. In principle, it allows to adjust a system's production capacity to match the existing orders. However, scalability can also act as a "safety buffer" to ensure a required minimum level of productivity, even when there is a decline in the reliability of the machines that are part of the machine tool subsystem of a manufacturing system. In this article, we analysed selected functional structures of an RMS under design to see whether they could be expanded should the reliability of machine tools decrease making it impossible to achieve a defined level of productivity. We also investigated the impact of the expansion of the system on its reliability. To identify bottlenecks in the manufacturing process, we ran computer simulations in which the course of the manufacturing process was modelled and simulated for 2-, 3-, 4- and 5-stage RMS structures using Tecnomatix Plant Simulation software.

3

Reconfigurable manufacturing system – a new class of manufacturing system

Prasad Durga, Jayswal S. C.

Management and Production Engineering Review

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2019

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Vol. 10, No. 4

37--47

EN

Today’s manufacturing environment is highly uncertain, and it is continuously changing. It is characterized by shorter life cycles of products and technologies, shorter delivery times, an increased level of customization at the price of a standard product, increased product variety, quality as well as demand variability and intense global competition. Academicians, as well as practitioners, agree that uncertainty will continue to grow in the twenty-ﬁrst century. To deal with the uncertainties in demand variation and production capacity a manufacturing system is required which can be easily reconﬁgured when there is a need at low cost. A reconﬁgurable manufacturing system is such a type of system. In the present work, the concept of the reconﬁgurable manufacturing system has been discussed and reviewed. It has been compared with dedicated systems and ﬂexible manufacturing systems. Part family formation and barriers of reconﬁguration also have been discussed. This work is an attempt to contribute to the conceptual systematization of the reconﬁgurable manufacturing system and reconﬁgurability by synthesizing the vast literature available after a systematic review.

4

Reliability analysis of reconfigurable manufacturing system structures using computer simulation methods

Gola Arkadiusz

Eksploatacja i Niezawodność

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2019

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Vol. 21, no. 1

90--102

EN

Choosing the right production structure (configuration) is one of the most important steps in the process of designing a reconfigurable manufacturing system (RMS). Whether or not a production process to be executed is capable of achieving the assumed performance parameters depends, among others, on the reliability of the machines and technological devices that make up the system under design. Because the individual components of a manufacturing system have different levels of reliability, the reliability of the system as a whole depends to a large extent on the way in which they are configured. This article discusses the process of selecting the structure of a manufacturing system with changing machine reliability, which allows to accommodate these changes to maintain the stability of the production process. The focus of the study was a manufacturing system under design dedicated to the machining of body parts. The experiments were carried out using analytical methods and computer simulation methods. Simulations were performed using Enterprise Dynamics software.

PL

Wybór odpowiedniej struktury produkcyjnej (konfiguracji) stanowi jeden z ważniejszych kroków w procesie projektowania rekonfigurowalnego systemu produkcyjnego (RMS). Możliwość osiągnięcia zakładanych parametrów wydajnościowych planowanego do realizacji procesu produkcyjnego jest uzależniona m.in. od stopnia niezawodności maszyn i urządzeń technologicznych wchodzących w skład projektowanego systemu. Zróżnicowany poziom niezawodności poszczególnych elementów systemu produkcyjnego powoduje, iż niezawodność systemu jako całości w dużej mierze zależy od sposobu ich konfiguracji. W niniejszym artykule przedstawiono proces wyboru struktury systemu produkcyjnego pod kątem możliwości zachowania stabilności procesu produkcyjnego wraz ze zmianą stopnia niezawodności maszyn technologicznych wchodzących w skład systemu. Jako obiekt badań przyjęto projektowany system produkcyjny dedykowany do obróbki części klasy korpus. Badania przeprowadzono z wykorzystaniem metod analitycznych oraz metod symulacji komputerowej. Jako narzędzie symulacji wykorzystany został system Enterprise Dynamics.

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Pewne podejście do integracji informacyjnej przygotowania i realizacji produkcji

Zając J., Kmiecik A.

Pomiary Automatyka Robotyka

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2014

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R. 18, nr 4

63--67

PL

W pracy podjęto tematykę integracji informacyjnej procesów przygotowania i realizacji produkcji. Wykorzystując standard XML, zaproponowano hierarchiczny opis wielowariantowych procesów wytwarzania. Przyjęty sposób budowy opracowanego formatu zapisu wielowariantowego procesu wytwórczego sprawia, iż zapis ten jest rozwiązaniem otwartym i skalowalnym. Dzięki temu nadaje się do bezpośredniego wykorzystania w rozproszonych, wieloagentowych systemach sterowania produkcją, które umożliwiają budowę rekonfigurowalnych systemów wytwarzania. Systemy takie odpowiadają współczesnym wyzwaniom ukierunkowanym na indywidualizację wytwarzanych produktów.

EN

The article relates to process of information integration for preparation and execution of production. A hierarchical description of alternative manufacturing processes using XML is proposed. This concept presents open and scalable solution resulting from construction of applied data format. This makes it suitable for direct use in distributed, multi-agent manufacturing control systems that allow the construction of reconfigurable manufacturing systems. These systems meet today’s challenges focused on the individualization of manufactured products.

6

RMS – system of the future or new trend in science?

Gola A., Konczal W

Advances in Science and Technology. Research Journal

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2013

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Vol. 7, nr 20

35--41

EN

Manufacturing companies in the 21st century will face unpredictable, high-frequency market changes, driven by global competition. The article presents a new concept of manufacturing systems – which address these challenges - known as Reconfigurable Manufacturing Systems (RMS). The concept began in 1999 at University of Michigan and is widely developed in many scientific publications. The paper first analyses main features of RSP. The next sections are devoted to analyze basic assumptions of RMS design and technical measures of RMS. Finally, the answer for the question if the RMS has the perspective of wide industrial implementations is discussed.