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EN
Today's dynamic market places new demands on manufacturers, with regard to the continuous and rapid response to market changes and more frequent replacing older products with new ones. Producers looking for new solutions that meet the requirements related to the possibility of further production, without incurring even more manufacturing costs. The change in strategy business method gives the possibility to use the so-called Virtual Manufacturing Network (VMN), which may be the answer to these problems, production in the shortest possible time and at limited cost. This paper proposes a method to help the process of planning the production flow in Virtual Manufacturing Networks to assist solving problems related to the process of alternative routes selection in the network.
EN
An effective optimization process carried out in industrial conditions requires multiple actions in many different areas and the dynamic nature of the manufacturing system and its environment enforce its constant repetition. The paper presents selected techniques for increasing production flow efficiency that can be regarded as a first step of production flow optimization. The considered model was built on the basis of a real production system of mechanical industry, located in Silesia, Poland. A number of improvement actions was proposes, among which the most significant are: elimination of unused and slightly loaded resources, changing transportation lots between workstations, strengthening bottlenecks and optimization of a schedule. In the study the KBRS scheduling system [10] as a tool for solve complex scheduling problems and supporting particular simulations was used. In the result of carried out activities the significant improvements of the production schedule was achieved, in comparison to initial schedule.
EN
This paper describes case study of application of OPC technology in the Laboratory of Integrated Manufacturing Systems, equipped with various industrial controllers, in order to acquire data for exemplary client application using this data. Communication between the automated equipment of the production system allows efficient and immediate acquisition of data on the state of adjoining equipment and production orders, which are the main postulate of Industry 4.0 methodology. Because of the variety of hardware and software in production systems, it seems necessary to use a standard method of communication, such as OPC, allowing client applications to acquire data in a standardized form. Article presents description of configuration of different laboratory stations controlled by PLCs, development of PLC applications, configuration of OPC server (KEPServerEX) with hardware drivers, testing of communication, and finally, example of usage of acquired data in OPC client application - HMI/SCADA iFIX.
EN
In spite of constant development of rapid manufacturing methods and apparatus, rapid manufactured parts still offer limited quality, both dimensional, and surface. Taking into account above there is still a need for additional product finishing. Currently used finishing methods include the two basic types; it is with or without material loss. In this paper a short review of both types of finishing methods is given.
PL
Zmieniające się gusta klientów i ich oczekiwania, postęp technologiczny, nowe technologie oraz zachowania konkurentów są wyznacznikami działań dla przedsiębiorstw, które muszą dynamicznie reagować na to, co dzieje się na rynku. Wprowadzenie nowego produktu bądź ulepszenie już istniejącego wiąże się z wieloma zmianami nie tylko na płaszczyznach zasobów ludzkich czy kapitału, ale i na płaszczyźnie związanej z organizacyjnym przygotowaniem samego procesu wytwarzania. Nowoczesne przedsiębiorstwo musi być na tyle elastyczne, aby mogło skutecznie podejmować działania dostosowujące swoje systemy produkcyjne do wytwarzania wielu wariantów produktów w zmiennych partiach produkcyjnych. Wymagane jest zatem wprowadzanie innowacyjnych i inteligentnych technologii oraz zmian w strukturze organizacyjnej, w celu zwiększenia elastyczności w dostosowywaniu posiadanego parku maszynowego do spływających zleceń produkcyjnych. Odpowiedni dobór zasobów produkcyjnych dla wymaganych operacji produkcyjnych wraz z analizą możliwych do realizacji marszrut alternatywnych, zapewnić może z jednej strony zrównoważone wykorzystanie dostępnych zasobów, z drugiej zaś wygenerowanie jak najlepszego wyniku finansowego. Problemy te związane są ściśle z możliwością realizacji koncepcji przedsiębiorstw wirtualnych (Virtual Enterprise – VE), dla których dostępne zasoby produkcyjne są rozproszone w wielu organizacjach. Osiągnięcie zakładanych wskaźników produkcyjnych (poziom wykorzystania zasobów, koszty produkcji, terminy reali-zacji zleceń itd.) zależą zatem od poziomu sprawnej synchronizacji działań dla różnych dostępnych zasobów, przydzielanych już na etapie planowania. Podobne podejście wykorzystywane jest w najnowszych koncepcjach dynamicznych sieci produkcyjnych (Dynamic Manufacturing Network – DMN) [11], których celem jest wzajemna współpraca w udostępnianiu łańcucha wartości do prowadzenia wspólnej produkcji, poprzez stałą lub czasową kooperację obejmującą systemy produkcyjne geograficznie rozproszonych małych i średnich przedsiębiorstw.
EN
Modern companies must be flexible enough so that they can effectively act in order to adapt their production systems to manufacture many variants of products in variable production batches. Therefore, the introduction of innovative technologies and implementation of changes in the organizational structure – flexibility in adapting of owned resources to incoming production orders with the analysis of feasible alternative routes is required. These problems are closely connected with the ability of realization of Virtual Enterprises (VE) concept, for which the available production resources are scattered through many organizations. A similar approach is found in the latest concepts of Dynamic Manufacturing Networks (DMN), where the goal is a mutual cooperation in the process of value chain sharing in order to conduct joint production through a permanent or temporary cooperation involving geographically dispersed production systems of small and medium-sized enterprises. In the paper the concept of implementation of methods and models form game theory to solve problems connected with production planning is presented. Considered problems, commonly met in the area of production planning and control are related to the selection of the route for the implementation in the system from the available set of alternative routes – the allocation of adequate resources to meet specific production orders from the production plan. The production system and order model and the decision-making model with the associated mathematical apparatus according to the formalism borrowed from game theory is also being formulated. Particular processes are treated as objects of players, which shall decide according to the strategies implemented by them – one of the possible routes for the implementation from a set of possible alternative routes shall be selected in order to reach the goal. The purpose of this is to perform the task within the time limit at the lowest costs related to the use of productive resources represented on the route. The possibilities of using advanced simulation systems, which, together with prepared models can be an effective and efficient tool for determining the value of payments for all players have been shown on the example. The subject of further research work in the presented area will be the determination of the values of the payoff matrix and the search for equilibrium strategies for both pure and mixed strategies, together with an analysis of the applicability of one of the strategies to solve specific classes of the problems and comparison of the obtained results with the other presently used methods of the decision-making process support.
6
Content available The automated process of creating simulation models
EN
In the paper the method of data transformation to a scripting language code creating the simulation model objects used in the implementation of the methodology of production planning and control with discrete simulation systems integration has been presented. For this purpose the so-called transformation templates containing the code of the templates, without a specified value, but together with the placement of the input data have been used. The examples of transformation template notation and the result code generated by the XSLT processor have been shown.
EN
In the paper concepts and Lean Manufacturing methods on the example of manufacturing company have been described. Some presented Lean Manufacturing methods have been implemented to shorten the production cycle and reorganized existing production department. To that end, plans and feasible indicators have been used to improve the entire production and show how to use simulation modeling and computer visualization to help achieve those goals.
EN
In the paper RapidSim software for supporting production planning and control (PPC) and discrete event simulation (DES) systems integration has been presented. RapidSim system is a computer implementation of a methodology based on the automatic generation of production systems simulation models methods, data mapping and transformation methods and data-to-program code transformation and is designed for multi-assortment production systems. Application of shown software together with developed data structures and data transformation definitions provides complete and fully flexible solution that could be used with any commercial PPC and DES systems.
EN
In the paper production planning and simulation systems integration has been presented. The integration process is executed using the method of data-driven modelling. The process of automatic generation of simulation models is realized in two stages – data mapping to indirect data model and data transformation from this data model to the code of the simulation system internal programming language. In the process of data-driven modelling XML, XML and XSLT Transformation languages are used. The result of transformation is the input file for simulation systems, containing information about the model of production system, together with control procedures.
EN
In the paper the problem of production orders sequencing in a mixed-model production system is considered. The authors present the design of the system and production orders, manufactured in the system. Model of the system consists of an input buffer and an assembly line with a given number of stations. The system is presented in a simplified manner, which provides the ability to compare it (under certain assumptions) with a real system. A virtual model of the mixed-model production system has been created. The main objective is to verify the correct operation of the prepared simulation model and the possibility of generating of input data and acquisition of output data in a mixed-model production system. The question is whether such model can be used to simulate the operation of a mixed-model production system in a manner that represents the outcome of a real system.
PL
W artykule przedstawiono komputerową implementację metody automatycznego generowania modeli symulacyjnych dla potrzeb symulacji komputerowej. Zastosowanie tej metody w praktyce umożliwia komputerową integrację systemów planowania produkcji z systemami symulacyjnymi. W procesie integracji wykorzystano język XML oraz techniki mapowania i transformacji danych, które zaimplementowano z wykorzystaniem języka XSLT Transformation. Przedstawiony przykład automatycznego generowania modeli wraz z procedurami sterującymi został zrealizowany z wykorzystaniem systemu weryfikacji zleceń produkcyjnych (SWZ) oraz komercyjnego systemu symulacyjnego Enterprise Dynamics.
EN
In this paper a computer implementation of method for automatically generating simulation models for computer simulation was presented. Application of this method in practice allow computer integration of production planning systems with simulation ones. The integration uses XML, data mapping and transformation techniques, which are implemented using XSLT Transformation. An example of automatic generation of simulation models, together with control procedures, was carried out to verify the integration of production orders verification system (SWZ) and commercial Enterprise Dynamics simulation system.
PL
W artykule przedstawiono metodę integracji systemów planowania produkcji z systemami symulacyjnymi. W procesie integracji wykorzystano język XML, XML Schema oraz XSLT Transformation. Opracowano definicję struktury dokumentu XML, zawierającego dane na temat modelowanego systemu produkcyjnego oraz zlecenia produkcyjnego. Pokazano proces generowania pliku wejściowego do systemu symulacyjnego, realizowany poprzez transformację dokumentu XML z wykorzystaniem rozszerzalnego języka arkusza stylów XSLT. Wynikiem transformacji jest plik wejściowy dla systemów symulacyjnych, zawierający informacje o modelu systemu produkcyjnego wraz z procedurami sterującymi - dane o zasobach produkcyjnych i procesach wykonywanych na tych zasobach oraz o sposobie sterowania przepływem produkcji w systemie, zapisany w postaci skryptów w języku 4DScript.
EN
In the paper the method of integration of production planning and simulation systems was presented. In the integration process XML, XML schema and XSLT transformation languages were used. The definition of the structure of the XML document containing data on the production system and the production order was elaborated. The process of generating the input file into a simulation system implemented by transforming an XML document using extensible stylesheet language XSLT was shown. The result of transformation is the input file for simulation systems, containing information about the production system model, together with control procedures - information about resources and production processes performed on these resources and their control written in the 4DScript scripting language.
EN
In this paper the method of production planning and control systems (PROEDIMS and SWZ) integration is presented. Both systems are parts of a distributed system which is thought as a replacement of large MRP / ERP systems for SMEs. This idea derived from the needs of several small and medium enterprises. In these kind of enterprises the larger stress is applied rather on technical preparation of production than tackling business problems. Integration is achieved by methods of data transformation and data mapping. The proposed data transformation interface uses neutral data formats like XML, XML schema, Extensible Stylesheet Language Transformations XSLT and XML Path Language. The functional scheme of the module for data exchange which is necessary for the interaction between the production planning module of PROEDIMS system and production orders verification system for a multiassortment, concurrent production (SWZ) has been proposed and various stages of data transformation have been discussed.
PL
W artykule przedstawiono metodę automatyzacji procesu tworzenia modeli systemów produkcyjnych na potrzeby symulacji i wizualizacji z wykorzystaniem standardów języka XML, XML schema oraz XSLT. Opracowano definicję struktury dokumentu XML, zawierającego dane na temat modelowanego systemu produkcyjnego. Pokazano proces generowania pliku wejściowego do systemu symulacyjnego, realizowany poprzez przekształcanie dokumentu XML z wykorzystaniem rozszerzalnego języka arkusza stylów XSLT. Do praktycznej weryfikacji przedstawionej metody zostało użyte autorskie oprogramowanie weryfikacji zleceń produkcyjnych SWZ v 4.0 oraz komercyjny systemem symulacyjny Enterprise Dynamics. Wynikiem transformacji danych zawartych w dokumentach XML jest kod wyjściowy zawierający dane o zasobach produkcyjnych i procesach wykonywanych na tych zasobach oraz o sposobie sterowania przepływem produkcji w systemie, zapisany w postaci skryptów w języku 4DScript odczytywanych przez system symulacyjny Enterprise Dynamics. Przedstawiono obecne możliwości opracowanej metody oraz podano kierunki dalszych badań w tym zakresie.
EN
In that paper automation of model generating process for computer simulation and visualization using XML standards, XML schema and XSL Transformation has been presented. XML Schema describing the structure of an XML document containing data on the production system and XSLT document have been formulated. The simulation model code is generated using Extensible Stylesheet Language Transformations for the transformation an input XML document into a model code. The Order Verification System SWZ 4.0 and Enterprise Dynamics Simulation Software are used to illustrate and test the utility of the simulation code generating method. Generated simulation code contains data about the production resources, manufacturing processes and their control. The output code is written in 4DScript computer language and is used by Enterprise Dynamics simulation system to design and implement simulation objects, define functions, the user-interface and user action. The capabilities of developed method and directions for further research have been presented.
16
Content available remote Production flow synchronisation versus buffer capacities in assembly systems
EN
Purpose: The goal of the considerations carried-out in that paper is the determination of the system synchronisation conditions. Those conditions concern capacities of system buffers. The fulfilment of the developed conditions should guarantee the production flow synchronisation into the expected steady state determined by the system bottleneck. In analysed assembly system rhythmic concurrent production with wide assortment is realised. Design/methodology/approach: The considerations presented in that paper are rooted in the authority method called Requirements and Possibilities Balance Method (RPBM). The experiments in the computer simulations programmes have been carried-out within the confines of the researches. The computer simulation models of the assembly systems using Taylor II for Windows and Enterprise Dynamics have been built. Findings: There are two kinds of system buffers: the entrance buffers and the inter-resources buffers in the assembly systems. The interdependences informing about the required number of elements allocated into the system buffers in order to the production realisation during the first cycle of the system steady state has been formulated. Moreover, the minimal buffer capacities have been determined. Research limitations/implications: The developed interdependences constitute the first step towards formulation of the automatic method designed for the automatic construction of rules controlling the system work during system transition state. That method should enable the automation of the system buffers filling-up. Practical implications: The presented system synchronisation conditions can become an integrated part of existing authority computer system. It aids the decision-making process connected with production planning and control. Originality/value: To develop the interdependences is the main achievement of the given paper. The presented approach permits to solve the problem concerning the production flow synchronisation into the expected steady state determined by the system bottleneck.
17
Content available remote Required buffer capacities in assembly systems
EN
Purpose: The aim of the realised analysis is the determination of the set of conditions. The fulfilment of those conditions enables the synchronisation of the assembly system work into the steady state. It is necessary to specify the rules controlling the assembly system work. Rhythmic concurrent production with wide assortment in the considered assembly system is realised. Design/methodology/approach: The theoretical roots of the considerations presented in that paper include theory of constraints. The presented approach is consistent with the authority method called Requirements and Possibilities Balance Method (RPBM). Findings: Two kinds of system buffers: the entrance buffers and the inter-resources buffers are considered in that paper. The number of buffers elements needed for production during first steady state of the given system has been determined. Mathematical formulas specifying the minimal capacity of the buffers allocated in the assembly system have been outworked. Research limitations/implications: The formulas specifying the minimal buffer capacity constitute the first step towards formulation of the automatic method. That method is designed for the automatic construction of rules controlling the system work during transient phases between two different steady states. The process enables automation of the introduction filling of the system buffers. Practical implications: The presented formulas can become an integrated part of existing authority software. The developed computer system aids the decision-making process connected with production planning and ensures effective utilisation of production resources. Moreover, the formulas correctness during computer simulations has been verified. Originality/value: To develop the formulas specifying the minimal capacity of the system buffers is the main achievement of the given paper. The presented approach permits to solve the problem concerning the synchronisation of the assembly system work into the steady state.
PL
W artykule przedstawiono problem szacowania czasu fazy rozruchu oraz wygaszania w systemie, w którym dostęp do zasobów regulują lokalne reguły rozstrzygania konfliktów zasobowych. Przedstawiono metodę i procedurę tworzenia harmonogramu dla faz przejściowych. Przedstawione podejście zilustrowano przykładami z wykorzystaniem systemów SWZ i KbRS.
EN
The problem of time estimation of the starting and cease phases in the system which is controlled by the local dispatching rules is dealt in the paper. The method and the procedure of the scheduling is presented. Proposed approach is illustrated by the example where SWZ and KbRS systems are applied.
19
Content available remote The selection of the production route in the assembly system
EN
Purpose: The aim of the conducted research is the outworking of the methodology enabling the selection of the fastest production route from the set of the alternative production routes. The presented approach is applied to the assembly system described by the following matrices: the assembly process matrices specified for each assembly process, the processes links matrix specified for the entire system and the alternative routes matrix specified for the entire system. In the considered assembly system rhythmic concurrent production with wide assortment is realised. Design/methodology/approach: The considerations presented in that paper have the theoretical roots in theory of constraints as well as critical path scheduling techniques. Findings: The result of carried out works is the three-step methodology enabling the determination which production route from the set of the alternative production routes enables the fastest customer order realisation. The proposed methodology enables production planning in the way ensuring the satisfaction of the customer needs as soon as possible. Research limitations/implications: The future research will concern the assembly system behaviour in a starting-up phase and a cease phase as well as transient phases. That work boils down to meta-rules determination for the considered class of the system. Practical implications: The proposed three-step methodology can become the integrated part of existing authority software. The outworked computer system aids the decision-making process connected with production planning and ensures effective utilisation of production resources. Originality/value: The main achievement of the given paper is to outwork the three-step methodology permitting to solve the decision problem concerning the selection of the fastest production route from the set of the alternative production routes, which are possible for the realisation in the assembly system.
PL
W artykule zaprezentowano trzy oryginalne metody podejmowania decyzji możliwe do zastosowania w różnych zakresach i na różnych etapach planowania i sterowania produkcji. Przedstawiono metodę zarządzania łańcuchem dostaw, w szczególności metodę bieżącej konfiguracji zaopatrzeniowo-dystrybucyjnego systemu logistycznego z wykorzystaniem logiki rozmytej. Ponadto omówiono problem weryfikacji zleceń produkcyjnych i zastosowania propagacji ograniczeń do podejmowania decyzji o możliwości ich terminowej realizacji w warunkach deterministycznych ograniczeniach zasobowych. Przedstawiono również przykład zastosowania systemu eksperckiego wspomagającego podejmowanie decyzji w zakresie harmonogramowania i reharmonogramowania produkcji.
EN
Three original methods taking of decision possible to apply in different ranges and on different stages of planning and production process control were presented. There were displayed Supply Chain & Delivery Management solutions, especially current supply and distribution logistic system using fuzzy logic. Moreover, there was discussed problem of verification production orders and propagation of restric-tion applying in taking of decision concerning possibilities of prompt implementation in conditions of deterministic restriction of reserves. It was also shown example of using expert system for schedule production procedure.
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