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Structured Analysis of Reconfigurable Manufacturing Systems

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Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

Abstract

The realization of a short product-time-to-market is a key-challenge in the design of modern manufacturing equipment. Compression of lead-times for product design and manufacturing require a concurrent way of engineering. This implies that structural decisions about manufacturing-equipment need to be made when products are still under development. This introduces development risks; changes in the layout of production systems, due to late modifications in the product design, are inefficient for lead-time and cost. It is preferable that the production system can be designed in a ‘first-time-right’ fashion. Therefore, the architectural freeze of a manufacturing system is preferably pushed backwards in time to sustain modifications of the product design as long as possible. Reconfigurable Manufacturing Systems (RMS) have been developed for this purpose. With their modular structure, they can be integrated in a short period of time. Though this leaves more time for product development, it does not exclude the industrialization risks. Since configuration of equipment only works reliably if its process technology is well understood, it is needed that poorly functioning manufacturing processes are detected and addressed in an early stage. Only then, sufficient time is available for corrective actions to be taken. This paper presents a scientific framework to model the development of RMS. The method has the capability to uncover manufacturing risks during early development. In combination with RMS, the freeze of system architecture can indeed be pushed backwards in time. The method uses the ‘Structured Analysis Design Technique’ (SADT). The process risks, as outcome of the analysis process, are ranked using a Failure Mode Effect Analysis (FMEA) to determine the severity of their impact. It helps focussing on primary issues to be addressed. The method was applied to a true case; the development of a RMS for cell Phone lenses. The industrialization process may be considered successful. By application of this approach, engineers profit of a complete overview of what actions need to be taken and the effects if these actions are omitted. The method can also be used to inform higher management, to increase understanding of the cause and effect of management decisions related to manufacturing.

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Abbreviations

DfA:

Design for assembly

FMEA:

Failure mode effect analysis

FTR:

First time right

QMAP:

Qualitative modeling and analysis of processes

RMS:

Reconfigurable manufacturing systems

SADT:

Structured analysis design technique

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Acknowledgments

This research was funded by the company MA3 Solutions, TNO Science & Industry & the HU University of Applied Sciences in the Netherlands.

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Correspondence to Erik Puik .

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© 2013 Springer International Publishing Switzerland

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Puik, E., Telgen, D., van Moergestel, L., Ceglarek, D. (2013). Structured Analysis of Reconfigurable Manufacturing Systems. In: Azevedo, A. (eds) Advances in Sustainable and Competitive Manufacturing Systems. Lecture Notes in Mechanical Engineering. Springer, Heidelberg. https://doi.org/10.1007/978-3-319-00557-7_12

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  • DOI: https://doi.org/10.1007/978-3-319-00557-7_12

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  • Publisher Name: Springer, Heidelberg

  • Print ISBN: 978-3-319-00556-0

  • Online ISBN: 978-3-319-00557-7

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