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"Manufacturing processes Case studies."
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Product and furniture design
With some 430 specially commissioned photographs and technical illustrations, this book describes more than 30 manufacturing processes, from the traditional and established to cutting-edge technologies.
Book
Regulation, Market Prices, And Process Innovation
Through the study of innovation in processes for the production of synthetic ammonia, the authors examine the effects of environmental and workplace regulations on business innovation in general. They present a history of ammonia production in the U.S., a survey of government regulation in the industry, and a model of process innovation that combines the economist's production function with the technical and practical concepts of the engineer.
Contrary to the widely held view that regulation has an unfortunate impact on business, the authors demonstrate that-at least in one industry-the economic factors of production have a measurable impact on innovation, while regulation does not.
eBook
Human-centred design in industry 4.0: case study review and opportunities for future research
The transition to industry 4.0 has impacted factories, but it also affects the entire value chain. In this sense, human-centred factors play a core role in transitioning to sustainable manufacturing processes and consumption. The awareness of human roles in Industry 4.0 is increasing, as evidenced by active work in developing methods, exploring influencing factors, and proving the effectiveness of design oriented to humans. However, numerous studies have been brought into existence but then disconnected from other studies. As a consequence, these studies in industry and research alike are not regularly adopted, and the network of studies is seemingly broad and expands without forming a coherent structure. This study is a unique attempt to bridge the gap through the literature characteristics and lessons learnt derived from a collection of case studies regarding human-centred design (HCD) in the context of Industry 4.0. This objective is achieved by a well-rounded systematic literature review whose special unit of analysis is given to the case studies, delivering contributions in three ways: (1) providing an insight into how the literature has evolved through the cross-disciplinary lens; (2) identifying what research themes associated with design methods are emerging in the field; (3) and setting the research agenda in the context of HCD in Industry 4.0, taking into account the lessons learnt, as uncovered by the in-depth review of case studies.
Journal Article
Machine learning integrated design for additive manufacturing
For improving manufacturing efficiency and minimizing costs, design for additive manufacturing (AM) has been accordingly proposed. The existing design for AM methods are mainly surrogate model based. Due to the increasingly available data nowadays, machine learning (ML) has been applied to medical diagnosis, image processing, prediction, classification, learning association, etc. A variety of studies have also been carried out to use machine learning for optimizing the process parameters of AM with corresponding objectives. In this paper, a ML integrated design for AM framework is proposed, which takes advantage of ML that can learn the complex relationships between the design and performance spaces. Furthermore, the primary advantage of ML over other surrogate modelling methods is the capability to model input–output relationships in both directions. That is, a deep neural network can model property–structure relationships, given structure–property input–output data. A case study was carried out to demonstrate the effectiveness of using ML to design a customized ankle brace that has a tunable mechanical performance with tailored stiffness.
Journal Article
Designing and developing smart production planning and control systems in the industry 4.0 era: a methodology and case study
In furtherance of emerging research within smart production planning and control (PPC), this paper prescribes a methodology for the design and development of a smart PPC system. A smart PPC system uses emerging technologies such as the internet of things, big-data analytics tools and machine learning running on the cloud or on edge devices to enhance performance of PPC processes. It achieves this by using a wider range of data sources from the production system, capturing and utilizing the experience of production planners, using analytics and machine learning to harness insights from the data and allowing dynamic and near real-time action to the continuously changing production system. The proposed methodology is illustrated with a case study in a sweets and snacks manufacturing company, to highlight the key considerations and challenges production managers might face during its application. The case further demonstrates considerations for scalability and flexibility via a loosely coupled, service-oriented architecture and the selection of fitting algorithms respectively to address a business requirement for a short-term, multi-criteria and event-driven production planning and control solution. Finally, the paper further discusses the challenges of PPC in smart manufacturing and the importance of fitting smart technologies to planning environment characteristics.
Journal Article
Shapley-based explainable AI for clustering applications in fault diagnosis and prognosis
Data-driven artificial intelligence models require explainability in intelligent manufacturing to streamline adoption and trust in modern industry. However, recently developed explainable artificial intelligence (XAI) techniques that estimate feature contributions on a model-agnostic level such as SHapley Additive exPlanations (SHAP) have not yet been evaluated for semi-supervised fault diagnosis and prognosis problems characterized by class imbalance and weakly labeled datasets. This paper explores the potential of utilizing Shapley values for a new clustering framework compatible with semi-supervised learning problems, loosening the strict supervision requirement of current XAI techniques. This broad methodology is validated on two case studies: a heatmap image dataset obtained from a semiconductor manufacturing process featuring class imbalance, and the benchmark N-CMAPSS dataset. Semi-supervised clustering based on Shapley values significantly improves upon clustering quality compared to the fully unsupervised case, deriving information-dense and meaningful clusters that relate to underlying fault diagnosis model predictions. These clusters can also be characterized by high-precision decision rules in terms of original feature values, as demonstrated in the second case study. The rules, limited to 2 terms utilizing original feature scales, describe 14 out of the 19 derived equipment failure clusters with average precision exceeding 0.85, showcasing the promising utility of the explainable clustering framework for intelligent manufacturing applications.
Journal Article
An LSTM-autoencoder based online side channel monitoring approach for cyber-physical attack detection in additive manufacturing
Additive manufacturing (AM) has gained increasing popularity in a large variety of mission-critical fields, such as aerospace, medical, and transportation. The layer-by-layer fabrication scheme of the AM significantly enhances fabrication flexibility, resulting in the expanded vulnerability space of cyber-physical AM systems. This potentially leads to altered AM parts with compromised mechanical properties and functionalities. Furthermore, those internal alterations in the AM builds are very challenging to detect using the traditional geometric dimensioning and tolerancing (GD&T) features. Therefore, how to effectively monitor and accurately detect cyber-physical attacks becomes a critical barrier for the broader adoption of AM technology. To address this issue, this paper proposes a machine learning-driven online side channel monitoring approach for AM process authentication. A data-driven feature extraction approach based on the LSTM-autoencoder is developed to detect the unintended process/product alterations caused by cyber-physical attacks. Both supervised and unsupervised monitoring schemes are implemented based on the extracted features. To validate the effectiveness of the proposed method, real-world case studies were conducted using a fused filament fabrication (FFF) platform equipped with two accelerometers. In the case study, two different types of cyber-physical attacks are implemented to mimic the potential real-world process alterations. Experimental results demonstrate that the proposed method outperforms conventional process monitoring methods, and it can effectively detect part geometry and layer thickness alterations in a real-time manner.
Journal Article
Industry 4.0 Technologies in Flexible Manufacturing for Sustainable Organizational Value: Reflections from a Multiple Case Study of Italian Manufacturers
In this study, we analyse the value creation of Industry 4.0 (I40) technologies in flexible manufacturing (FM) under a sustainability perspective. I40 is a popular strategy that Western manufacturing organizations adopt to face competition from low-cost producers. Organizations adopting I40 use advanced digital technologies to make production processes more flexible and increasingly automated. Several pieces of evidence confirm how I40 leads to higher productivity and higher-quality products, improving the economic performance of organizations. However, increasing automation may also lead to the reduction of human labour in the production process, which may contribute to the disappearance of jobs, the reduction of expertise and the loss of know-how in manufacturing organizations. While the literature acknowledges the technical and economic advantages of I40, the sustainability of the value created through these technologies deserves further investigation. To address the gap, we complement the IT value theory with the concept of sustainability, including the three dimensions of economic, environmental and social sustainability. We perform a multiple case study analysis of four Italian manufacturing organizations that have successfully implemented I40 technologies in FM. The cases show that I40 technologies support sustainable organizational value when they are deployed with a worker-centric approach. In this condition, the organization leverages workforce activities to continuously fine-tune the technologies and to exploit the adaptive features of the technologies to continuously improve processes.
Journal Article
Smart Industrial Internet of Things Framework for Composites Manufacturing
Composite materials are increasingly important in making high-performance products. However, contemporary composites manufacturing processes still encounter significant challenges that range from inherent material stochasticity to manufacturing process variabilities. This paper proposes a novel smart Industrial Internet of Things framework, which is also referred to as an Artificial Intelligence of Things (AIoT) framework for composites manufacturing. This framework improves production performance through real-time process monitoring and AI-based forecasting. It comprises three main components: (i) an array of temperature, heat flux, dielectric, and flow sensors for data acquisition from production machines and products being made, (ii) an IoT-based platform for instantaneous sensor data integration and visualisation, and (iii) an AI-based model for production process forecasting. Via these components, the framework performs real-time production process monitoring, visualisation, and prediction of future process states. This paper also presents a proof-of-concept implementation of the framework and a real-world composites manufacturing case study that showcases its benefits.
Journal Article
Machine learning techniques applied to mechanical fault diagnosis and fault prognosis in the context of real industrial manufacturing use-cases: a systematic literature review
When put into practice in the real world, predictive maintenance presents a set of challenges for fault detection and prognosis that are often overlooked in studies validated with data from controlled experiments, or numeric simulations. For this reason, this study aims to review the recent advancements in mechanical fault diagnosis and fault prognosis in the manufacturing industry using machine learning methods. For this systematic review, we searched Web of Science, ACM Digital Library, Science Direct, Wiley Online Library, and IEEE Xplore between January 2015 and October 2021. Full-length studies that employed machine learning algorithms to perform mechanical fault detection or fault prognosis in manufacturing equipment and presented empirical results obtained from industrial case-studies were included, except for studies not written in English or published in sources other than peer-reviewed journals with JCR Impact Factor, conference proceedings and book chapters/sections. Of 4549 records, 44 primary studies were selected. In 37 of those studies, fault diagnosis and prognosis were performed using artificial neural networks (n = 12), decision tree methods (n = 11), hybrid models (n = 8), or latent variable models (n = 6), with one of the studies employing two different types of techniques independently. The remaining studies employed a variety of machine learning techniques, ranging from rule-based models to partition-based algorithms, and only two studies approached the problem using online learning methods. The main advantages of these algorithms include high performance, the ability to uncover complex nonlinear relationships and computational efficiency, while the most important limitation is the reduction in model performance in the presence of concept drift. This review shows that, although the number of studies performed in the manufacturing industry has been increasing in recent years, additional research is necessary to address the challenges presented by real-world scenarios.
Journal Article