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1

Conceptualization of Industry 4.0 technology for the production of tailor-made furniture – a case study

Łukaszewicz Krzysztof, Urban Wiesław, Krawczyk-Dembicka Elżbieta

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2023

|

Vol. 71, nr 1

art. no. e144587

EN

Production is becoming more customer-focused as it departs from delivering standardized mass products to market segments, and the emerging Industry 4.0 technologies render this much easier than before. These technologies enable two-way information exchange with customers throughout all the steps of product development, particularly in terms of tailor-made products. This study aims at presenting proposals of implementing Industry 4.0 technologies into the process of tailored products, where the product is customized for the customer from the start and where adjustments are also made at the manufacturing stage. The study also aims to build a concept of intensification of customer contact and to improve the process flow by applying Industry 4.0 technologies. The study’s subject is tailor-made furniture production, with individually designed products that are manufactured and installed at a customer’s facilities. The company in the study operates on a small scale. The study employs a case study methodology that shows how the process can be improved in terms of real-time effective customer contact and process flow. The huge potential of 3D visualization as well as augmented and virtual reality technologies are also demonstrated. The study concludes with several directions for further development of existing technology solutions.

2

Rozwój konstrukcji murowych w Polsce

Drobiec Łukasz, Jasiński Radosław

Materiały Budowlane

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2022

|

nr 4

12--14

PL

Konstrukcje murowe w Polsce przez ostatnie dwadzieścia pięć lat mocno się rozwinęły. Wprowadzono nowe elementy murowe i zaprawy, dzięki czemu mury wznosi się obecnie szybciej i dokładniej. Zwiększono wymagania dotyczące parametrów mechanicznych, cieplnych i akustycznych ścian murowanych. Opracowano zaprawy do cienkich spoin oraz kleje do łączenia elementów murowych. W artykule przedstawiono stan obecny i perspektywy rozwoju konstrukcji murowych.

EN

Masonry structures in Poland have developed significantly over the last twenty-five years. New masonry elements and mortars were introduced, thanks to which the walls are now erected faster and more accurately. The mechanical, thermal, and acoustic parameters of masonry walls were increased. Mortars for thin joints and adhesives for joining masonry elements have been developed. The article presents state and development prospects of masonry structures.

3

The Effect of the Return Material Implementation into the Production of Silumin Casts on Technological and Economic Indicators of Production Process

Gaspar S., Majernik J., Trytek A., Podaril M., Benova Z.

Archives of Foundry Engineering

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2022

|

Vol. 22, iss. 1

69--76

EN

The production of high pressure die casts also brings difficulties regarding the processing of the waste material. It is mainly formed by runners, overflows and other foundry supplements used and, in the case of machines using the cold chamber, also the remainder from this chamber. As this material is often returned to the production process, we refer to it as return material. In the production process, it is therefore essential to deal with the proportion issue of return material against primary material that can be added to the melt to maintain the required cast properties. The submitted article monitors the quality properties of the alloy, selected mechanical properties of casts and porosity depending on the proportion of the return material in the melt. At the same time, the material savings are evaluated with regards to the amount of waste and the economic burden of the foundries. To monitor the above-mentioned factors, series of casts were produced from the seven melting process variants with a variable ratio of return to the primary material. The proportion ratio of return material in the primary alloy was adjusted from 100% of the primary alloy to 100% of the return material in the melting process. It has been proven that with the increasing proportion of the return material, the chemical composition of the melt changes, the mechanical properties of the alloy decrease and the porosity of the casts increases. Based on the results of the tests and analyzes, the optimal ratio of return and primary material in the melting process has been determined. Considering the prescribed quality of the alloy and mechanical properties, concerning the economic indicator of the savings, the ratio is set at 70:30 [%] in favor of the primary material.

4

Cast Structures Improving Thermalm Conductivity for Energy Storage

Raźny Natalia M.

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 2

11--16

EN

Thermal energy encounters a huge demand in the world, part of which can be met by renewable energy sources, such as solar energy, and storage of thermal energy surplus from industrial processes. For this purpose, thermal energy storage (TES) units, in which heat is stored, are developed. The energy is accumulated by phase change materials (PCM) characterized by high phase transition enthalpy. PCMs have poor thermal conductivity; therefore, to take full advantage of their capabilities and to accelerate the charging and discharging cycle, metallic structures are used. These structures are manufactured using investment casting technology. Creating models with additive methods, such as 3D printing, allows obtaining complex shapes with high accuracy, such as thin-walled castings. At a large scale, the method may not be cost-effective. In this paper, the heat exchanger models were made from PLA and the castings - from AC44200 aluminum alloy. Investment casting requires the proper selection of parameters, such as the right material for the model, the selection of the firing temperature, the adjustment of the temperature of the molten metal, the temperature of the mold, and the pressure in it. Misaligning any of the parameters can lead to imperfections on the finished casting. Based on the model roughness study, it was found that minor roughness and higher accuracy are presented by the lower parts of the casting, while weaker performance is observed for the upper parts. Metal castings in a salt PCM environment may be subjected to corrosion. Therefore, the authors proposed to produce protective coatings on aluminum castings by the PEO method - plasma electrolytic oxidation. Porous ceramic thin films consisting mainly of alumina were obtained. The next tests will be aimed to confirm whether this layer will not negatively influence the thermal conductivity of the thermal energy storage.

5

Integration of Virtual Engineering and Additive Manufacturing for Rapid Prototyping of Precision Castings

Krutiš V., Šprta P., Kaňa V., Zadera A., Cileček J.

Archives of Foundry Engineering

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2021

|

Vol. 21, iss. 1

51--55

EN

The present paper is concerned with the practical interconnection between virtual engineering tools and additive model manufacturing technologies and the subsequent production of a ceramic shell by rapid prototyping with the use of Cyclone technology to produce the aluminium casting prototype. Prototypes were developed as part of the student formula project, where several parts originally produced by machining were replaced by castings. The techniques of topological optimization and the combination with the tools of the numerical simulation were used to optimise the virtual prototype before a real production of the first prototype. 3D printing of wax pattern ensured direct and fast assembly of the cluster without any additional operations and troubles during dewaxing. The shell was manufactured in 6 hours thanks to a system of quick-drying of individual layers of ceramic shell. It has been verified that the right combination of individual virtual tools with the rapid prototyping can shorten the development time and delivery of the first prototypes from a few months to a few weeks.

6

How to measure the supplier involvement?

Wieteska Grażyna

Gospodarka Materiałowa i Logistyka

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2019

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nr 8

29--39

EN

Increasing a degree of supply chain integration is a common strategy today. Therefore, more and more companies decide to implement joint projects with their first tier suppliers. One of the examples of such projects is the joint product development. The purpose of this paper is to present a comprehensive framework of the measurement of supplier involvement (SI) in product development based on the systematic literature review. SLR covered 126 papers published between 1989 and August 2018 in three databases of well-known journal publishers. The results of in-depth analysis of previous quantitative and qualitative research allowed to develop the proposition of supplier involvement measurement. It consists of three constructs, which are: 'degree of supplier involvement', 'partnership in product development process' and 'communication during product development'. They are all expressed with the twenty six different items. The developed SI measurement approach can be used for quantitative research on NPD or other projects implemented in cooperation with suppliers as well as different business partners. The paper is a result of the project "Flexibility in relationships with suppliers in terms of supplier-purchaser models of cooperation on product development in the B2B market", no. 2016/21/B/HS4/00665, that is financed by the National Science Centre (NCN) in Poland.

PL

Firmy ukierunkowują dziś swoje działania na zwiększanie stopnia integracji w łańcuchu dostaw. W związku z tym, coraz więcej przedsiębiorstw decyduje się na realizowanie wspólnych projektów razem ze swoimi bezpośrednimi partnerami gospodarczymi. Jednym z przykładów takich projektów jest rozwój produktów z dostawcami (ang. Supplier Involvement, SI). Celem artykułu jest zaprezentowanie ram kompleksowego pomiaru włączania dostawców w rozwój produktów w oparciu o systematyczny przegląd literatury. Badanie objęło 126 artykułów opublikowanych pomiędzy 1989 a 2018 rokiem w trzech znanych międzynarodowych bazach czasopism. Rezultaty pogłębionej analizy poprzednich, zarówno ilościowych jak i jakościowych, badań pozwoliły na opracowanie kompleksowego podejścia do pomiaru SI. Składa się on z trzech konstruktów, którymi są: „stopień włączenia dostawcy w rozwój produktu”, „partnerstwo w procesie rozwoju produktu” oraz „komunikacja podczas rozwoju produktu”. Wszystkie trzy konstrukty wyrażone zostały dwudziestoma sześcioma zmiennymi. Zaproponowany pomiar może być wykorzystywany w przyszłych badaniach ilościowych, których przedmiotem są nie tylko projekty o tematyce rozwijania produktów w relacjach z dostawcami, ale także projekty o innej tematyce prowadzone z pozostałym interesariuszami. Artykuł napisany został w ramach realizowanego projektu o numerze 2016/21/B/HS4/00665, pt. „Elastyczność w relacjach z dostawcami a rodzaje współpracy dostawca-nabywca w zakresie rozwijania produktów na rynku B2B”, który uzyskał finansowanie z Narodowego Centrum Nauki.

7

The Influence of Abrasive Paste on the Effects of Vibratory Machining of Brass

Bańkowski D., Spadło S.

Archives of Foundry Engineering

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2019

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iss. 4

5--10

EN

The article presents the results of research on the finishing of M63 Z4 brass by vibratory machining. Brass alloy was used for the research due to the common use of ammunition elements, cartridge case and good cold forming properties on the construction. Until now, the authors have not met with the results of research to determine the impact of abrasive pastes in container processing. It was found that the additive for container abrasive treatment of abrasive paste causes larger mass losses and faster surface smoothing effects. The treatment was carried out in two stages: in the first stage, the workpieces were deburred and then polished. Considerations were given to the impact of mass of workpieces, machining time and its type on mass loss and changes in the geometric structure of the surface. The surface roughness of machining samples was measured with the Talysurf CCI Lite optical profiler. The suggestions for future research may be to carry out tests using abrasive pastes with a larger granulation of abrasive grains, and to carry out tests for longer processing times and to determine the time after which the parameters of SGP change is unnoticeable.

8

Optimisation of a Production System in the Process of Remelting of Post-Reduction Slag by Applying New Physical and Chemical Conditions

Bydałek A. W., Wołczyński W., Wędrychowicz M., Holtzer M., Basiura B., Palimąka P.

Archives of Foundry Engineering

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2018

|

Vol. 18, iss. 4

5--8

EN

Production processes at KGHM are complex and require from customers products of constantly higher quality at relatively lowest prices. Such situation results in an increase of the importance of optimisation of processes. As products and technologies change rapidly, technologists at the plant in Głogów have less time to achieve optimisation basing on own experiences. Analysing a particular process, we can e.g. detect occurring disturbances, find factors having an influence on quality problems, select optimal settings or compare various production procedures. Analysis of the course of production process is the basis of process optimisation. One optimisation in case of the process of decopperisation of flash slag can be a change of a technological additive to a less energy-consuming one, and its final result can be an improvement of the productivity index, a change of the relation between final effects and born expenditures, as well as optimisation of production costs.

9

Monitoring of Manufacture Stability of Large Turbine Blades Using Infrared Thermography (IRT) in Investment Casting Technology

Herman A., Vrátný O., Kubelková I.

Archives of Foundry Engineering

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2018

|

Vol. 18, iss. 4

9--14

EN

With increasing technology development, an increasing emphasis is placed on the precision of products, but cannot be guaranteed without a stable production process. To ensure the stability of the production process, it is necessary to monitor it in detail, find its critical locations and eliminate or at least control it. With such a precise manufacturing method as investment casting, such a process is a must. This paper therefore deals with monitoring the production process of wax models of large turbine blades using infrared thermography. The aim was to evaluate the critical locations of this production and to propose recommendations for their elimination or, at the very least, significant mitigation of their impact on the final quality of the large turbine blade casting.

10

Increasing the Capability of the Process of Placing Inserts in Foundry Moulds

Jaworski J., Kluz R., Trzepieciński T.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 2

187--190

EN

This article discusses the issue of the preparation of the foundry moulds with the use of an industrial robot. The methodology is presented for the determination of the process capacity index for placing inserts with flat and cylindrical faces. On the basis of the relationships developed, the process capability indices were determined at various points in the workspace, which are characterised by different values of the repeatability positioning error. It was shown that the value of the process capacity index can be increased by the selection of a suitable location for the process of placing the inserts in the workspace. It should also be noted that the value of the process's capability index depends on the selection of the place in the robot workspace where the process is carried out. Implementation of the joining process at an analysed point in the robot workspace leads to an increase of the process capability index MCp for inserts with flat faces up to 1.1 (+4.5%) and for inserts with cylindrical faces up to 1.3. This results in an increase of 13% to a level corresponding to the global standard for process reliability (MCp = 1.33).

11

Challenges in Producing Reliable Tensile Properties by SIMA 7075

Erzi E., Gursoy O., Yüksel Ç.O.K., Kirtay S., Dispinar D.

Archives of Foundry Engineering

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2018

|

Vol. 18, iss. 3

71--75

EN

Aluminium alloys are one of the preferred materials especially for land and air transportation because of their high strength and low-density properties. Although production using casting method is economical yet it has some disadvantages. Shrinkage which is occurred due to the density difference between the solid and liquid metal is prevented by feeders which need to be calculated. Liquid metal should be transferred to the mould without any turbulence. As a result, sprues are needed to be designed precisely. On the other hand, aluminium alloys can also be shaped by forging at semi-solid temperatures. There are some advantages compared to the traditional forging methods of improving die life due to the lower tonnage values. In this study, semi-solid produced 7075 aluminium alloy die filling capabilities were investigated. To achieve semisolid structure strain induced melt activated method (SIMA) was used. The desired structure was achieved at 635°C and 30 minutes of duration of heat treatment. After determining the optimum parameters, metallographic analysis, density calculations, porosity distribution and tensile tests were carried out. It was found that the reproducibility of SIMA produced 7075 alloy was quite low. A proper tensile test result was achieved only 7 of the total 15 tests and the mean value was 386 MPa. The main reason for this scattered in mechanical properties could be the chemical composition of the alloy and the rapid solidification of the liquid eutectic phases. It is important to define the best fitting process parameters and controlling them precisely will be the most important factors for future studies.

12

Zagadnienie ryzyka w rozwoju produktu

Siuta-Stolarska B.

Zarządzanie Przedsiębiorstwem

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2016

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Vol. 19, nr 1

29--36

EN

The paper shows specifics of product development process, its unique character and changing conditions influencing its realisation. It also points most important risks, that might significantly influence efficiency of product development process. In the paper, author suggested three strategies (Postponement, Mass Customization and Collective Customer Commitment) that allow to reduce risks in the product development process and consequently may increase products’ success chance and efficiency of product development process itself. The paper emphasises also the meaning of appropriate risk management in reducing consequences and chances of occurring risks during product development process. Special attention was given to engaging the client into the process of creating products’ value, so that both his and producers’ expectations can be met much more effectively.

13

Nowoczesne zarządzanie rozwojem produktu w kontekście integracji systemów informatycznych

Dudziak A., Zając G.

Logistyka

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2015

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nr 5

115--119, CD1

PL

W pracy zaprezentowano problematykę zintegrowanych systemów informatycznych w kontekście rozwoju nowych produktów. Są to istotne zagadnienia dla przedsiębiorstwa, które umożliwiają przepływ strumienia wartości od momentu powstania do zakończenia pracy nad produktem. Jakość poszczególnych procesów uzależniona jest od jego fazy. Jednym z nowszych systemów wczesnego definiowania procesów wytwarzania jest model „Shift left”, który pozwala na „przesunięcie w lewo” czyli przeniesienie procesu wytwarzania do początku, koncentrując się tym samym na zapewnieniu najwyższej jakości od pierwszego dnia projektu. Zjawisko to umożliwia zmniejszenie kosztów i wysiłku związanego z ustaleniem wad w późniejszych etapach procesu, wtedy kiedy czas jest najważniejszy.

EN

The paper presents problems of integrated information systems in the context of the development of new products. These are important issues for the company, which allow a flow of value stream from the moment of formation to completion of work on the product. The quality of the various processes depends on the phase. One of the newer systems for early defining the manufacturing processes is the model "shift left", which allows to "shift to the left" that is moving to the beginning of the manufacturing process, thus focusing on providing the highest quality from the first day of the project. This situation enables to reduce the cost and effort associated with the determining the flaws in the later stages of the process, then when time is the most important.

14

Modele biznesowe dla start-upów

Cech I.E.

Recykling

|

2014

|

nr 12

17--19

PL

Wizjonerskie podejście do tworzenia produktu i poszukiwanie dróg jego zbycia pozwalają na dokładniejsze zaplanowanie wstępnego etapu działalności gospodarczej. Przy tworzeniu wizji przedsiębiorstwa pomocny jest model wypracowany przez Alexandra Osterwaldera, amerykańskiego teoretyka biznesu, oraz Yvesa Pigneura, współautora modelu biznesowego Canvas, skierowanego raczej do dużego biznesu, a nie do nowo powstałych podmiotów. Model ten został zmodyfikowany przez Asha Mauraya, który dojrzał możliwości wykorzystania go w przypadku start-upów i tworzonych właśnie produktów. Oba modele pomagają w początkowej fazie, w której nie skupiamy się jeszcze na dokładniejszym wyliczaniu rachunku kosztów czy korzyści finansowych dla przedsiębiorstwa.

15

Rozwój i wdrożenie nowych produktów – koncepcje umożliwiające wprowadzenie nowych wyrobów na rynek

Jankowski Ł.

Logistyka

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2014

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nr 4

4354--4358, CD6

PL

Klient oczekuje, aby wyroby trafiały na rynek jak najbardziej efektywnie. Wymusza to na organizacjach stosowanie metod, które umożliwiają jednoczesną pracę projektową i wdrożeniową nowych wyrobów, angażując w taki proces rozwoju pracowników wiele działów przedsiębiorstwa. W takich działaniach znajdują zastosowanie takie metody, jak projektowanie współbieżne, DMADV (define, measure, analyze, design, verify), oraz DFMA (Design for Manufacture and Assembly). W artykule przedstawiono te trzy koncepcje oraz na podstawie obserwacji wskazano warunki, w których proces rozwoju i wdrożenia nowego produktu może przebiegać najefektywniej.

EN

Clients expect that companies will introduce new product into market in short period of time. To perform this action in effective way companies use methods like concurrence engineering, DMADV or Design for Manufacture and Assembly(DFMA). This methods allow not only develop new product in shorter time but also achieve satisfactory level of quality for first manufactured batch of new product. This paper present this tree methods and show conditions necessary to successful introduction of new product.

16

Well-founded decisions based on product-specific Knowledge Balances prior to the product development process

Hinsen S., Gust P., Ruschitzka M.

Zeszyty Naukowe Instytutu Pojazdów / Politechnika Warszawska

|

2012

|

z. 5/91

43--48

EN

Optimal products and services as well as optimal product development processes are in demand to deal with the continuously growing product complexity and the increasingly competitive markets. Regardless of the development discipline or company location, expert knowledge has to be pooled and condensed to generate valuation methods and key figures for new product-specific Knowledge Balances. This approach will take account of methodologies according to different research fields. Using and combining technological and economical key figures as well as specific information about the company and its products, this new approach of a product-specific Knowledge Balance is able to dynamically suggest an optimal choice of product development groups and processes. Considering all data, it will be possible to generate a solid basis for decision making prior to the product development process and derive detailed product specifications and project plans as the result of the Knowledge Balance.

17

Prezentacja wieloaspektowej oceny cyklu życia obiektu technicznego z uwzględnieniem współzależności pomiędzy aspektami

Koper K.

Problemy Eksploatacji

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2012

|

nr 1

201-206

PL

Zarządzanie cyklem życia integruje kategorie oddziaływań środowiskowych, ekonomicznych i społecznych, występujące na różnych etapach cyklu życia obiektów technicznych, umożliwiając określenie dominujących wpływów. Jest to możliwe do ukazania w formie tabelarycznej, uwzględniającej współprzenikanie się kategorii oddziaływań z poszczególnymi fazami cyklu życia. Decyzje dotyczące zmniejszania wielkości oddziaływań są podejmowane na podstawie wyników pochodzących z przeprowadzonych analiz ilościowych, takich jak LCA (Life Cycle Assessment - środowiskowa ocena cyklu życia), LCC (Life Cycle Costing - ocena kosztów cyklu życia) lub S-LCA (Social Life Cycle Assessment - społeczna ocena cyklu życia). W niniejszym artykule przedstawiono nowe podejście do ewaluacji rezultatów wieloaspektowej oceny cyklu życia obiektów technicznych. Zasygnalizowano również, dlaczego nie jest możliwa jednoczesna redukcja wszystkich kategorii negatywnych oddziaływań. Zostało to ukazane w postaci przykładów pozytywnych i negatywnych współzależności pomiędzy aspektami.

EN

Life Cycle Management integrates categories of impact an object has on environmental, economical and social levels with phases of its life cycle in which certain categories of those impacts are dominant. This can be presented in a form of matrix of interlacing subcategories. After thorough analysis of an object through its life cycle, using complex tools like LCA (Life Cycle Assessment), LCC (Life Cycle Costing) and S-LCA (Social Life Cycle Assessment), decisions can be made concerning its development aimed at reducing impacts in these subcategories. The paper presents a new approach in measurement and evaluation of results in life cycle assessment of products. It also gives an insight for understanding why is it, or is not possible for an object to show improvements in all the categories and spheres simultaneously. Examples of positive and negative correlation are given to illustrate the problem of continuous development of a technical object in means of LCM philosophy.

18

The comparison of selected methods of cast iron spheroidization in industrial conditions

Válek T., Šimon P., Střílková L.

Archives of Foundry Engineering

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2012

|

Vol. 12, iss. 2

89-92

EN

Production of spheroidal graphite cast iron is today quite mastered technology. There are many methods achieving the nodular graphite morphology. Each of these methods have specific characteristics and requirements to technical support, properties and the type of applied modifier. Selection of the spheroidization method is dependent on foundry disposition, production character, economic balance, quality requirements, etc. In case of centrifugally casting the core, which fills body and neck of the roll, is created by ductile iron. Considering the sophisticated production of centrifugally cast rolls for hot rolling mills it is necessary to ensure a high reproducibility and reliability of ductile cast iron production quality in the bulk range of 9-18 t per tapping. These conditions are in the Roll Foundry in Vítkovicke Slevarny, spol. s r.o. provided and verified mastered overpour method and the newly injection of cored wire in the melt.

19

Dilatometric characterization of foundry sands

Břuska M., Beňo J., Cagala M., Jasinková V.

Archives of Foundry Engineering

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2012

|

Vol. 12, iss. 2

9-14

EN

The goal of this contribution is summary of physical - chemistry properties of usually used foundry silica and no - silica sands in Czech foundries. With the help of dilatometry analysis theoretical assumptions of influence of grain shape and size on dilatation value of sands were confirmed. Determined was the possibility of dilatometry analysis employment for preparing special (hybrid) sands with lower and/or more linear character of dilatation.

20

Continuous modification of cast iron by the FLOTRET method

Hanus A., Hanusová P.

Archives of Foundry Engineering

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2012

|

Vol. 12, iss. 3

43-48

EN

Increasing demands on the utility properties of materials used for castings have led to the production of cast iron with a modified shape of graphite, where the required properties are achieved by a change in graphite shape, its size and layout, and a change in the basic structure of the metal. This paper is focused on the continuous method of producing spheroidal graphite FLOTRET. In the introductory section is summarized the theoretical foundations of the secondary treatment of cast irons, especially the FLOTRET flow method, describes the advantages and disadvantages of the method. The practical part is divided into laboratory and operational tests. Laboratory experiments were conducted on a laboratory-type modifier FLOTRET chamber, which was designed and hydraulically optimized. Experiments were focused on the effects of pressure altitude and amount of modifier on the residual values of magnesium, as conditions for a successful modification. The method was tested in two foundries under operating conditions and in one of them was observed a long-term modification process.