Journal of Manufacturing Systems 1998: Vol 17 Index

15 Pages·1998·5.2 MB·English

Journal of Manufacturing Systems
Vol. 17/No. 6
1998 ABSTRACT INDEX
Volume 17/Number 1, 1998 monitoring and control. The paper concludes with a sum-
Machine Layout with a Linear Single-Row Flow Path in mary of fault mechanisms on SLS parts, implementation
an Automated Manufacturing System, Ying-Chin Ho, issues for improving part quality, and insights for applying
Colin L. Moodie, v17, nl, 1998, pp1-22 the approach to other manufacturing processes.
This paper investigates the machine layout problem with Keywords: Surface Quality, Part Quality, Manufacturing
a linear single-row flow path within an automated manufac- Surfaces, Fault Patterns, Fault Detection, Fault Diagnosis,
turing system. Traditional machine layout approaches can Selective Laser Sintering
produce inappropriate layout designs because they often do
not consider flow path characteristics, such as flow path Scheduling a Single Batch Processing Machine with
configuration and feasible flow path direction. This paper Secondary Resource Constraints, Karl G. Kempf, Reha
investigates the effects of such flow path characteristics on Uzsoy, Cheng-Shuo Wang, v17, nl, 1998, pp37-51
machine layouts. A two-phase layout procedure that com- This paper studies the problems of minimizing total com-
bines flow line analysis with simulated annealing is pro- pletion time ({C;) and makespan (Cmax) on a single batch
posed. The procedure can be employed using a variety of processing machine with job families and secondary
evaluation criteria (minimize total flow distance, maximize resource constraints. The motivation for this problem is the
number of in-sequence movements, and so on). Different burn-in operation in the final testing stage of semiconductor
layout procedures can be obtained by varying the flow line manufacturing, where both oven capacity and the number of
analysis method and temperature reduction strategy boards available may constrain scheduling decisions.
employed for simulated annealing. Experiments are per- Because both problems are NP-hard, integer programming
formed to test the performance of different layout proce- formulations are developed for special cases and are then
dures for different combinations of flow path characteristics used to develop heuristics. Extensive computational experi-
and quantities of machines. The experimental results pro- ments show that the heuristics are capable of consistently
vide vital information on selecting appropriate flow line obtaining good solutions in modest CPU times.
analysis methods and temperature reduction strategies for Keywords: Scheduling, Semiconductor Manufacturing,
different layout problems. Furthermore, the results will help Batch Processing Machines, Heuristics
designers determine appropriate evaluation criteria for dif-
ferent layout problems. A Neural Network Process Model for Abrasive Flow
Keywords: Machine Layout, Flow Line Analysis, Machining Operations, Kimberly L. Petri, Richard E.
Simulated Annealing, Automated Manufacturing System Billo, Bopaya Bidanda, v17, nl, 1998, pp52-64
This paper describes the development of a predictive
Characterization of Surface Fault Patterns with process modeling system for the abrasive flow machining
Application to a Layered Manufacturing Process, Irem Y. (AFM) process. This process is used for polishing and sur-
Tumer, David C. Thompson, Kristin L. Wood, Richard H. face removal of workpieces with an internal flow path. The
Crawford, v17, nl, 1998, pp23-36 core of the process modeling system is a set of neural net-
Detection of faults is a continuing need in all manufac- work models that predicts surface finish and dimensional
turing processes. This need is more pronounced in new man- change. These neural network models are then paired with a
ufacturing processes where continual product improvement heuristic search algorithm to select sets of machine setup
is desired. In this paper, a systematic approach is developed parameters for the AFM process. The heuristic search is
for addressing this need. Contemporary experimental and specifically designed to avoid allowing the neural networks
surface analysis techniques provide a basis for incremental- to extrapolate. The completed system was validated using
ly diagnosing the fault mechanisms leading to surface devi- several test pieces, and the results were very promising. The
ations. Based on this general approach, a maturing layered system is currently planned for implementation into the
manufacturing process is investigated, notably, Selective production process. The system has the potential to signifi-
Laser Sintering (SLS). First through experimental analysis it cantly reduce the development time for new applications of
is shown that layer thickness and part orientation affect sur- the process and can also be used to suggest alternative
face quality. Using these experimental results, random machine setup parameters when certain media types are
process analysis is carried out to determine the specific fault unavailable.
patterns. The quantification of these fault patterns leads to Keywords: Abrasive Flow Machining, Extrusion Honing,
the identification of fault sources, providing a foundation for Neural Networks, Process Modeling, Process Control
Journal of Manufacturing Systems
Vol. 17/No. 6
1998 ABSTRACT INDEX
Volume 17/Number 1, 1998 monitoring and control. The paper concludes with a sum-
Machine Layout with a Linear Single-Row Flow Path in mary of fault mechanisms on SLS parts, implementation
an Automated Manufacturing System, Ying-Chin Ho, issues for improving part quality, and insights for applying
Colin L. Moodie, v17, nl, 1998, pp1-22 the approach to other manufacturing processes.
This paper investigates the machine layout problem with Keywords: Surface Quality, Part Quality, Manufacturing
a linear single-row flow path within an automated manufac- Surfaces, Fault Patterns, Fault Detection, Fault Diagnosis,
turing system. Traditional machine layout approaches can Selective Laser Sintering
produce inappropriate layout designs because they often do
not consider flow path characteristics, such as flow path Scheduling a Single Batch Processing Machine with
configuration and feasible flow path direction. This paper Secondary Resource Constraints, Karl G. Kempf, Reha
investigates the effects of such flow path characteristics on Uzsoy, Cheng-Shuo Wang, v17, nl, 1998, pp37-51
machine layouts. A two-phase layout procedure that com- This paper studies the problems of minimizing total com-
bines flow line analysis with simulated annealing is pro- pletion time ({C;) and makespan (Cmax) on a single batch
posed. The procedure can be employed using a variety of processing machine with job families and secondary
evaluation criteria (minimize total flow distance, maximize resource constraints. The motivation for this problem is the
number of in-sequence movements, and so on). Different burn-in operation in the final testing stage of semiconductor
layout procedures can be obtained by varying the flow line manufacturing, where both oven capacity and the number of
analysis method and temperature reduction strategy boards available may constrain scheduling decisions.
employed for simulated annealing. Experiments are per- Because both problems are NP-hard, integer programming
formed to test the performance of different layout proce- formulations are developed for special cases and are then
dures for different combinations of flow path characteristics used to develop heuristics. Extensive computational experi-
and quantities of machines. The experimental results pro- ments show that the heuristics are capable of consistently
vide vital information on selecting appropriate flow line obtaining good solutions in modest CPU times.
analysis methods and temperature reduction strategies for Keywords: Scheduling, Semiconductor Manufacturing,
different layout problems. Furthermore, the results will help Batch Processing Machines, Heuristics
designers determine appropriate evaluation criteria for dif-
ferent layout problems. A Neural Network Process Model for Abrasive Flow
Keywords: Machine Layout, Flow Line Analysis, Machining Operations, Kimberly L. Petri, Richard E.
Simulated Annealing, Automated Manufacturing System Billo, Bopaya Bidanda, v17, nl, 1998, pp52-64
This paper describes the development of a predictive
Characterization of Surface Fault Patterns with process modeling system for the abrasive flow machining
Application to a Layered Manufacturing Process, Irem Y. (AFM) process. This process is used for polishing and sur-
Tumer, David C. Thompson, Kristin L. Wood, Richard H. face removal of workpieces with an internal flow path. The
Crawford, v17, nl, 1998, pp23-36 core of the process modeling system is a set of neural net-
Detection of faults is a continuing need in all manufac- work models that predicts surface finish and dimensional
turing processes. This need is more pronounced in new man- change. These neural network models are then paired with a
ufacturing processes where continual product improvement heuristic search algorithm to select sets of machine setup
is desired. In this paper, a systematic approach is developed parameters for the AFM process. The heuristic search is
for addressing this need. Contemporary experimental and specifically designed to avoid allowing the neural networks
surface analysis techniques provide a basis for incremental- to extrapolate. The completed system was validated using
ly diagnosing the fault mechanisms leading to surface devi- several test pieces, and the results were very promising. The
ations. Based on this general approach, a maturing layered system is currently planned for implementation into the
manufacturing process is investigated, notably, Selective production process. The system has the potential to signifi-
Laser Sintering (SLS). First through experimental analysis it cantly reduce the development time for new applications of
is shown that layer thickness and part orientation affect sur- the process and can also be used to suggest alternative
face quality. Using these experimental results, random machine setup parameters when certain media types are
process analysis is carried out to determine the specific fault unavailable.
patterns. The quantification of these fault patterns leads to Keywords: Abrasive Flow Machining, Extrusion Honing,
the identification of fault sources, providing a foundation for Neural Networks, Process Modeling, Process Control
Journal of Manufacturing Systems
Vol. 17/No. 6
1998 abstract index
Estimating Capacity Loadings from Workcenter Arrival The Minimax Cylinder Estimation Problem, Sanjay
and Departure Events, Manuel D. Rossetti, Gordon M. Radhakrishnan, Jose A. Ventura, Sanjay E. Ramaswamy,
Clark, v17, nl, 1998, pp65-76 v17, n2, 1998, pp97-106
Manufacturing firms rely on automatic data collection In this study, the optimal characterization of the minimax
systems to replace labor-intensive data collection methods. cylinder estimation problem is presented. The complexity of
Most systems concentrate on locating and counting parts the optimal solution procedure is shown to be O(n*), where
without regard to transaction times; however, by capturing n is the number of sampled boundary points. Hence, an iter-
and processing event times, additional system characteris- ative cyclic coordinate procedure is also developed to pro-
tics can be inferred. Using product arrival and departure vide near-optimal solutions. The cyclic coordinate algorithm
event transactions based on bar code technology, this has been tested and the results of several test problems are
research develops a methodology for estimating the amount provided.
of workload in a workcenter with a parallel server structure Keywords: Dimensioning and Tolerancing, Cylindricity,
commonly found in practice. This paper presents an evalua- Minimum Zone Error, Optimization Model
tion of the accuracy and precision of the resulting workload
estimators under conditions of varying product mix. It was A Simulation Study on Lot Release Control, Mask
found that the relative proportion of products in the produc- Scheduling, and Batch Scheduling in Semiconductor
tion mix can have a significant effect on estimator perfor- Wafer Fabrication Facilities, Yeong-Dae Kim, Dong-Ho
mance. For production mixes that change infrequently, the Lee, Jung-Ug Kim, Hwan-Kyun Roh, v17, n2, 1998, pp107-
estimator was within 5% of the true workcenter load in 98% 117
of the experiments. The estimator is simple and can be con- This paper focuses on production scheduling in semicon-
tinually updated as new data are collected. This research ductor wafer fabrication. Included in this study are decision
illustrates the value-added benefits to be gained in utilizing problems of lot release control (to determine the time and
bar code timing information for developing estimates of quantity of wafers to release into the wafer fab), mask
workcenter load especially within computer automated shop scheduling (to determine the time to change masks in pho-
floor control systems. tolithographic expose workstations), and batch scheduling
Keywords: Computer-Integrated Manufacturing, Shop (to determine the number of lots to be produced simultane-
Floor Control, Automatic Identification, Capacity Planning, ously in a batch and the processing sequence of batches in
Simulation, Regression Analysis front of batch processing workstations such as cleaning and
oxidation workstations). Unlike previous research, in which
these three problems are dealt with separately, the three
Volume 17/Number 2, 1998 problems are considered simultaneously using simulation,
Manufacturing Cost Modeling in Printed Wiring Board and new rules for the three problems are suggested in this
Assembly, Sheng-Hsien Gary Teng, Soma S. Garimella, study. Moreover, the setup time (mask change time) and the
v17, n2, 1998, pp87-96 processing time were considered separately in the photolith-
This paper discusses cost modeling of electronics assem- ographic expose workstations. Simulation results show that
bly operations. Station-by-station assembly cost equations the new rules give better performance than existing rules
are presented for the estimation of total assembly cost of a with respect to throughput rate, flow time, and work-in-
seven-station printed wiring board (PWB) assembly. The process inventory.
equations for the average production time of the acceptable Keywords: Loading and Scheduling, Production
assemblies at these stations are also demonstrated. The total Control, Scheduling and Sequencing Techniques, Heuristic
manufacturing cost equation includes three main elements, Methods, Simulation
which are inventory cost, assembly cost, and test and rework
associated cost. A case study is done to present the applica- Object-Oriented Design of FMS Control Software
tion of the developed cost model. The cost model developed Based on Object Modeling Technique Diagrams and Petri
in this paper can be used by the design team to evaluate the Nets, Kurapati Venkatesh, MengChu Zhou, v17, n2, 1998,
associated manufacturing cost for design alternatives in con- pp118-136
current engineering processes. Control software is very important to realizing the full
Keywords: Printed Wiring Board Assembly, Electronics benefits of flexible manufacturing systems. This paper high-
Assembly, Cost Modeling, Surface-Mount Technology lights the difficulties in developing such software and
Journal of Manufacturing Systems
Vol. 17/No. 6
1998 abstract index
proposes an object-oriented design (OOD) method using centerline offset. Three-dimensional heat conduction, phase
object modeling technique (OMT) diagrams and Petri nets change, and reflected beam energy are considered for a
(PNs). OOD is used to design reusable and easily maintain- piecewise planar cutting front. By using analytical models,
able software. OMT diagrams are used to represent explicit- real-time accurate estimates of the cutting front geometry
ly different kinds of static relations, such as generalization, can be developed with minimal computational burden.
aggregation, and association, among the objects in an FMS. Sequential optimization and constraint relaxation schemes
PNs are used to model the dynamic behavior of the objects are presented for determining laser power, cutting velocity,
and the entire FMS and to conduct performance analysis. and laser path compensation. Case studies of combined
The use of PNs also leads to a method to identify the data straight and curved-feature laser cutting of polymethyl-
structures and operations of software objects. The proposed methacrylate (PMMA) and aluminum oxide (Al,O3) are
method is illustrated through an FMS example. Its capabili- presented to show the effects of predictive planning on beam
ty to support reusability, extendibility, and modifiability of path and operating parameters.
the resulting control software design is also demonstrated Keywords: Process Planning, Laser Cutting, Process
when the FMS specifications change. Optimization, Laser Material Processing
Keywords: Control Software, Flexible Manufacturing
Systems, Object Modeling Technique Diagrams, Object-
Oriented Design, Petri Nets Volume 17/Number 3, 1998
Machine Vision Based Inspection of Oil Seals, Bernard C.
Development of Dispatching Rules for Automated Guided Jiang, S.J. Jiang, v17, n3, 1998, pp159-166
Vehicle Systems, Hark Hwang, Sang Hwi Kim, v17, n2, In this research, the dimensions (inner and outer diame-
1998, pp137-143 ters) and surface defects of oil seals are measured or inspect-
This paper proposes a new automated guided vehicle ed by a machine vision system. There are four steps of the
(AGV) dispatching algorithm based on a bidding concept. measurement: (1) obtain the threshold value of an image, (2)
The suggested algorithm utilizes the information of work in use that value and a boundary-tracking method to ascertain
process in incoming and outgoing buffers of a machine cen- the positions of boundary points, (3) use the Gaussian tech-
ter, and travel time of an AGV through mathematical func- nique to smooth the boundary points, and (4) use the mini-
tions that are called "bidding functions" in this paper. mum errors area method to calculate inner and outer diame-
Because the bidding functions have parameters, a sensitivi- ters. Before inspecting for surface defects, the center posi-
ty test is performed to find their appropriate values. The per- tion must be calculated. With that position determined, the
formance of the algorithm is compared with those of well- gray levels of the circumferential pixels in the inspected
known existing rules in terms of system throughput through regions can be obtained. To check the gray levels, an
simulation on a hypothetical job shop type manufacturing improved moving-range chart and an individual observation
system. control chart are employed, thus completing the inspection.
Keywords: Automated Guided Vehicle System, Keywords: Machine Vision, Inspection, Control Chart,
Dispatching, Bidding Function, Simulation Flaw Detection
Predictive Process Planning for Laser Cutting, P. Sheng, Machining Algebra for Mapping Volumes to Machining
L. Cai, v17, n2, 1998, pp144-158 Operations for Developing Extensible Generative CAPP,
Industrial lasers exhibit high potential for material, geo- Arvind Shirur, Jami J. Shah, Kartheek Hirode, v17, n3,
metric, process, and volume flexibility; however, in practice, 1998, pp167-182
laser processing is still limited to repetitive high-rate opera- This paper presents geometric models for representing
tions due to the trial-and-error calibrations involved in machining operations. The characteristic shapes produced
obtaining an acceptable operating condition when changes by machining operations are represented in a uniform
in workpiece thickness, material, geometry, dimensional (canonical) form. The canonical representation is an alge-
accuracy, and surface/bulk quality are imposed. As an alter- braic expression that encodes the geometric shapes that can
native to manual calibration, a predictive planning scheme is be produced by a process as a set of volumes resulting from
presented for straight and curved-path kerf geometry based two types of tool-workpiece interactions. Each interaction is
on an analytical energy-balance solution, given constraints characterized by a type of sweep operator. The directors of
for material removal rate, taper angles, kerf width, and kerf these sweep operations are derived from cutting and feed
Journal of Manufacturing Systems
Vol. 17/No. 6
1998 abstract index
motion directions. The profiles used in the sweeps are computer-aided manufacturing (CAM) has advanced to the
defined in terms of geometric entities and constraints based stage where NC (numerically controlled) codes can be auto-
on tool geometry and tool-workpiece interaction. Most con- matically generated for components created using a CAD
ventional machining processes can be represented using the model; however, there still remains a gap between the
proposed model (process-to-volume mapping). Inverse CAD/CAM environment and the physical machining
operators are also defined for mapping volumes to process- processes. A critical aspect of this gap is setup planning,
es; the inverse operators can be used in selecting potential which requires extensive experience and is typically per-
machining processes for removing given volumes. Thus, formed manually. To improve the performance of
representation of machining knowledge is process-based not CAD/CAM systems, the task of setup planning needs to be
feature-based, which overcomes the problem of dealing with automated. This paper presents an automatic approach to
new feature shapes that are not predefined in the process setup planning for components machined on a lathe. The
selector. The formulation allows users to add new processes problem of setup planning is formulated as a mathematical
to the system without any changes to the code. problem. Issues taken into consideration include geometry
Keywords: CAPP, CAD, Generative Process Planning, analysis, precedence constraint analysis, kinematic analysis,
Feature Mapping, Machining force analysis, and tolerance analysis. An algorithm is then
presented to solve the setup planning problem. An example
A Design-to-Manufacture Case Study: Automatic Design is also given to show the effectiveness of the algorithm. The
of Post-Fabrication Mechanisms for Tubular Components, mathematical formulation of the setup planning problem is
Karim Abdel-Malek, Nicholas Maropis, v17, n3, 1998, theoretically sound, and the algorithm can deal with a vari-
pp 183-195 ety of turned components with promising results.
An automated design-to-manufacture system and its Keywords: Setup Planning, Positioning, Workholding,
implementation are outlined. The system is described in the Mathematical Model, Algorithm
context of the design of a mechanism for post-fabrication of
miniature metal tubular components. Post-fabrication oper- Criteria for the Design of Manipulator Arms for a High
ations considered include dimpling, bending, slotting, lanc- Stiffness-to-Weight Ratio, Karim Abdel-Malek, Burton
ing, punching, corseting, and notching. The system has been Paul, v17, n3, 1998, pp209-220
demonstrated to reduce design-to-manufacturing cycle time Design aspects of a six degree-of-freedom high-accuracy
by many orders of magnitude. The method outlined encom- manipulator are presented. The manipulator arm (called the
passes the integration of rule-based expertise with theoreti- UTI-arm) comprises four revolute and two prismatic joints.
cal considerations underlying the manufacturing process. The mechanical design of the manipulator is aimed at
Using an artificial intelligence language, this module is then obtaining high accuracy and a high stiffness-to-weight ratio
linked to a computer-aided design system to automatically of the links. Prestressing of mechanical elements is per-
generate detailed drawings of the mechanism. The system formed to transform strength to stiffness. Design of links
emphasizes the automatic design of the assembly and gen- under tension load is carried out to enhance bending stiff-
eration of blueprints and NC code for appropriate mechani- ness. In the past, researchers have reported inefficiency of
cal parts. To determine whether a component can be made prismatic joints due to their high compliance. Compared to
using current company technology, an advise-on-manufac- a uniform thin-walled tube, prismatic joints used in this
turability module was developed. Analytical considerations design provide an isotropic, higher bending stiffness with a
pertaining to springback effects in bending of thin-walled relatively low loss in torsional stiffness. Experiments were
tubular components are addressed as a case study. This conducted to verify the theory presented for calculating tor-
paper describes the methodology used in developing this sional stiffness of such joints. A finite element model was
system as well as the difficulties encountered during the also used to validate the model. The mechanical design of
development. the arm is presented in detail in view of the proposed pris-
Keywords: Rapid Prototyping, Design-to-Manufacturing, matic joint cross section and the prestressing effects.
Metalworking, Machine Design, Metal Fabrication Keywords: Manipulator Design, Structural Stiffness,
Robot Design, Robotics
Automated Setup Planning for Lathe Machining, Samuel
H. Huang, v17, n3, 1998, pp196-208 Trends and Perspectives: Review of QFD and Related
The development of computer-aided design (CAD) and Deployment Techniques, Biren Prasad, v17, n3, 1998, pp22 1-234
Journal of Manufacturing Systems
Vol. 17/No. 6
1998 abstract index
The paper reviews some historical developments in the quickly conduct cost estimation and performance evaluation
quality function deployment (QFD) and extended house of on any given flowpath layout.
quality (EHOQ) concepts that are popular for conveniently Keywords: AGVS, Petri Nets, Flowpath Model, Control
organizing product, process, and production planning infor- Model, Wiring Layout
mation and for processing customer requirements. Since the
inception of QFD in Japan in the early 1970s, it has met with A Classification Algorithm and Optimal Feature Selection
varying degrees of success. This paper first reviews the lit- Methodology for Automated Solder Joint Defect
erature and describes the EHOQ, which is a mature arrange- Inspection, Olagunju Oyeleye, E. Amine Lehtihet, v17, n4,
ment of QFD. Other related deployment techniques are 1998, pp251-262
examined, and a new concept called concurrent function A classification algorithm and optimal feature selection
deployment (CFD) is described. CFD is based on parallel methodology are developed for implementation on an auto-
deployment of several lifecycle "value plans" in addition to mated solder defect inspection system. Computer-generated
the "quality plan" used in QFD. CFD thus gives rise to inte- three-dimensional geometric models of solder joint defects
grated templates, called house of values (HOV), which are are used to train the system and simulate defect classifica-
compared to EHOQ templates. The differences and similar- tion. System performance is assessed through simulation
ities between QFD and CFD are discussed. and is shown to be successful at classification of dominant
Keywords: Quality Function Deployment (QFD), House solder defects, including simultaneously occurring defects
of Quality, Process Planning, Production Planning, and overlapping defect classes.
Deployment Techniques, Concurrent Function Deployment Keywords: Surface Mount Technology, Solder Joint
(CFD) Inspection, Solder Joint Classification, Inspection
Simulation
Volume 17/Number 4, 1998 Adaptive Control of WEDM Process Using the Fuzzy
Developing AGVS Petri-Net Control Models from Control Strategy, M.T. Yan, Y.S. Liao, v17, n4, 1998, pp263-274
Flowpath Nets, Suhua Hsieh, Ming-Yuan Kang, v17, n4, The proportion of abnormal sparks (abnormal ratio) and
1998, pp237-250 the sparking frequency are employed to monitor and evalu-
The paper presents a control-based Petri net (PN) model- ate the gap condition of the wire electrical discharge
ing method that translates a high-level automated guided machining (WEDM) process on-line. The relationships are
vehicle system (AGVS) flowpath net model into a low-level investigated between these two sensing parameters and wire
on/off control model systematically. The relation between a breaking phenomenon, metal removal rate (MRR), and sur-
high-level AGVS flowpath net model and the equivalent face roughness of the machined part under various machin-
low-level control net model is uniquely defined by introduc- ing conditions. Based on the results, an adaptive control
ing certain I/O control functions and station control macros optimization (ACO) system is developed. Fuzzy rules based
into the net model. To ensure the uniqueness of the transla- on operator experience and expert knowledge are construct-
tion, the AGVS flowpath layout is first decomposed into ed, and a multivariable and three-region fuzzy controller is
constituent basic PN flowpath modules. By employing a designed and implemented. By regulating the servo feed and
modular concept, the wiring layout of each basic flowpath the pulse off-time in real time, the abnormal ratio is con-
module is established. Proper I/O control functions and sta- trolled at a predetermined value for optimum and stable
tion control macros are introduced and incorporated into machining, while at the same time the sparking frequency is
basic flowpath net modules to generate basic control net kept under a critical value for wire rupture prevention.
modules. The union of constituent basic control net modules Experimental results demonstrate that the developed control
systematically leads to a complete AGVS control PN model. system results in very satisfactory performance.
A laboratory AGVS is used to verify the effectiveness of the Keywords: WEDM, Wire Breaking, Adaptive Control,
proposed modeling method. The results indicate that the Fuzzy Controller
proposed method is capable of generating a control model
directly from a given flowpath layout. Many by-products are COMPASS: Computer Oriented Materials, Processes, and
generated by the method: wiring layout, minimum size and Apparatus Selection System, Kevin Chan, Calvin King (for-
specification of the controller, scanning time of the control merly A.R. Thangaraj), Paul Wright, v17, n4, 1998, pp275-286
program, and so on. These features allow a designer to Today's competitive manufacturing environment requires
Journal of Manufacturing Systems
Vol. 17/No. 6
1998 abstract index
a shortened product development time. Although great Keywords: Discrete Die, Reconfigurable Tooling, Rapid
emphasis has been placed on concurrent engineering, it is Tooling, Sheet Metal Forming, Composites Molding
still a challenge for engineers to bridge the gap between
design and manufacturing. This paper proposes a new Trends and Perspectives: A Survey of Factory Control
approach to an emerging concept, Meta Planning, which Algorithms That Can Be Implemented in a Multi-Agent
brings manufacturing issues upstream by generating timely Heterarchy: Dispatching, Scheduling, and Pull, Albert D.
and appropriate feedback to design engineers. While a prod- Baker, v17, n4, 1998, pp297-320
uct or feature is being designed, all feasible downstream This paper describes various multi-agent architectures,
manufacturing processes can be compared. A meta planner including the heterarchical architecture. It reviews the
can be integrated into existing CAD/CAPP/CAM systems to claimed advantages for multi-agent heterarchies and
automate high-level process planning such that heteroge- describes the types of factories that could use this architec-
neous processes can be organized into a coherent plan. ture. It surveys the three common types of factory control
COMPASS (Computer Oriented Materials, Processes, and algorithms: dispatching algorithms, scheduling algorithms,
Apparatus Selection System), developed as a meta planner, and pull algorithms. It then asks the question: which of these
has the basic framework to provide essential information algorithms can be implemented in a multi-agent heterarchy?
regarding production cost, cycle time, and product quality This paper describes how all common factory control algo-
for all of the candidate processes. It is a tool that helps rithms used in industry can be implemented in an multi-
design engineers identify potential manufacturing problems agent heterarchy. It discusses how many of the algorithms
in the earlier stages of product development. Three different that are popular in current research can be implemented in a
hole-making process models are implemented in COM- multi-agent heterarchy, while others will require further
PASS to illustrate the mechanism that analyzes and com- research.
pares different manufacturing processes. Close interaction Keywords: Systems and Architectures, Heterarchy,
between design parameters and manufacturing performance
Scheduling and Control, ERP, Discrete Optimization,
for selected processes is demonstrated through a detailed Heuristics, Distributed Artificial Intelligence, Agent
case study involving a single feature. Technology, Multi-Agent Systems
Keywords: Process Selection, Manufacturing Planning,
CAPP, Concurrent Engineering
Volume 17/Number 5, 1998
Development of a Reconfigurable Tool for Forming Vacuum Forming of Compound Curved Surfaces with a
Aircraft Body Panels, Daniel F. Walczyk, Jayant Variable Geometry Mold, H.S. Kleespies III, R.H.
Lakshmikanthan, Daniel R. Kirk, v17, n4, 1998, pp287-296 Crawford, v17, n5, 1998, pp325-337
To significantly cut the time and cost of tooling develop- Most rapid prototyping technologies focus on small
ment, a reconfigurable discrete die (that is, matrix of indi- three-dimensional parts and are generally not applicable to
vidually actuated pins) is being developed for aircraft fuse- fabrication of large, thin, curved surfaces. This initial study
lage parts made by forming sheet metal or molding of com- demonstrates a method for producing prototypes of com-
posite materials. Each pin in the die is a simple hydraulic pound curved surfaces with a variable configuration vacuum
actuator outfitted with an in-line N/C solenoid valve to con- forming mold composed of a number of discrete pins and a
trol its vertical position. Pin positions can either be set in a rubber interpolation sheet. A multi-parameter design study,
closed or open-loop fashion. Once the pins are "set," then using theoretical, numerical, and experimental results,
the entire matrix is clamped into a rigid tool. A single pin explored the feasibility of building prototype surface parts
was constructed to resolve several design issues, including with a variable molding process. The analyses provide fun-
the removal of trapped air in the hydraulic circuit, preven- damental design relationships for a variable geometry ther-
tion of hydraulic leakage, motion control, and quantifying moforming mold as a function of the surface quality and the
the dynamic frictional forces. Because the performance of minimum achievable radii of compound curvature.
the single pin was deemed acceptable, a 4 x 4 test die of sim- Prototype parts of ABS and styrene thermoplastics were
ilar design has been constructed to establish the frictional vacuum formed with the variable geometry mold. It was
interactions between adjacent pins, the workability of the demonstrated that a variable configuration mold can be
pin matrix clamping scheme, and the feasibility of closed automated so that shapes are assumed quickly and directly
and open-loop control. from computer surface models. Rapid prototyping of curved
Journal of Manufacturing Systems
Vol. 17/No. 6
1998 abstract index
surfaces with a variable geometry vacuum forming mold is decode time: lighting conditions, reading distance, orienta-
shown to be a feasible process, but with limitations of sur- tion angles of the reader, and use of the readers in a typical
face smoothness and achievable curvatures. freehand application. Results show the tests to be a valid
Keywords: Rapid Prototyping, Molding, Vacuum means for comparing performance of differing hand-held
Forming, Process Modeling reader technologies typically used for two-dimensional
symbologies.
Automated Process Planning for Sheet Metal Bending Keywords: Bar Codes, Two-Dimensional Bar Codes,
Operations, S.K. Gupta, D.A. Bourne, K.H. Kim, S.S. PDF417, Bar Code Readers, Automated Data Collection,
Krishnan, v17, n5, 1998, pp338-360 Performance Standards
This paper describes a generative process planning sys-
tem for robotic sheet metal bending press brakes. This Optimal Cutter Selection and Machining Plane
process planning system employs a distributed planning Determination for Process Planning and NC Machining
architecture. Currently, the system consists of a central oper- of Complex Surfaces, Yen-Hung Chen, Yuan-Shin Lee,
ation planner and three specialized domain-specific plan- Shu-Cherng Fang, v17, n5, 1998, pp371-388
ners: tooling, grasping, and moving. The central operation
This paper deals with the optimal cutter selection and
planner proposes various alternative partial sequences, and
machining plane determination problems for NC machining
each specialized planner evaluates these sequences based on
and process planning. Two optimization methods, an integer
its objective function. The central operation planner uses
programming (IP) method and a dynamic programming
state-space search techniques to optimize the operation
(DP) method, are presented. While the IP method provides
sequence. Once a CAD design is given for a new part, the
an upper bound for such a problem, the DP method provides
system automatically determines: the operation sequence,
an optimal solution at the cost of longer computational time.
the tools and robot grippers needed, the tool layout, the
Both methods can be used to automate the traditional, expe-
grasp positions, the gage, and the robot motion plans for
rience-based cutter selection tasks and to reduce the total
making the part. The distributed architecture allows the
machining time in NC machining operations. Numerical
development of an open-architecture environment for doing
examples are included to illustrate both methods.
generative process planning and encapsulating the special-
Keywords: Cutter Selection, Process Planning,
ized knowledge in specialized planners.
Computer-Aided Manufacturing, NC Machining, Dynamic
Keywords: Process Planning, Sheet Metal Bending,
Programming, Integer Programming
Automated Manufacturing, State-Space Search, Distributed
Systems
Technical Note: A Progress Report on the Manufacturing
Analysis Service, an Internet-Based Reference Tool,
Test Protocol for Comparing Two-Dimensional Bar Code
Simon M. Brown, Paul K. Wright, v17, n5, 1998, pp389-398
Hand-Held Reader Technologies, Martin Adickes, Richard
E. Billo, v17, n5, 1998, pp361-370 The Manufacturing Analysis Service (MAS) is an
Current advances in reader technology offer users of two- Internet-based engineering reference tool. Based on various
dimensional bar codes many choices in selecting a hand- input parameters provided by the remote designer, the MAS
held reader for their particular application. Specifications determines which manufacturing processes are most rele-
exist that describe required functionality for various scan- vant to the inputted part. The goal is to provide the designer
ning technologies, but little work has been done in the pub- with knowledge of the future production requirements of the
lished literature with respect to assessing the relative perfor- part. The service provides advice that, first, indicates which
mances of these technologies when actually incorporated manufacturing process is the most suited to the emerging
design and, second, how the design could best be modified
into a hand-held unit. In this paper, a suite of standard tests
is presented to measure the decode time of hand-held read- to satisfy the constraints of that particular process. The MAS
can also be used as a "library" of manufacturing techniques
ers. These tests were applied to a PDF417 two-dimensional
bar code symbol and used to compare the performance of since it contains detailed web sites for 13 manufacturing
five newly developed hand-held readers over four different processes.
reader technologies. The technologies included laser scan- Keywords: Manufacturing Process Selection, World Wide
ning, linear CCD, area CCD, and CMOS technology. The Web, Java, Internet
tests focused on the following factors that typically affect
Journal of Manufacturing Systems
Vol. 17/No. 6
1998 abstract index
Volume 17/Number 6, 1998 with and without aggregation. A theoretical approximation
Organizing Principles for the Design of Classification and of the error incurred as a result of aggregations is derived.
Coding Software, Richard E. Billo, v17, n6, 1998, pp405-417 The results show that time savings of up to 400% can be
This paper describes several organizing principles useful achieved at the expense of only a few percentage points loss
in designing classification and coding (C&C) software in a in accuracy of the average flowtime performance measure.
relational database management system (DBMS) environ- The developed concepts have been integrated in an algo-
ment. Specifically, these software design principles include rithm to serve as a front end for discrete-event simulation to
the usage of Operational Constructors, Meta Models, adapt simulation models to real-time decision-making
Dynamic Binding, and Associative Naming to aid the design requirements. The application of this algorithm is illustrated
of full-purpose classification and coding software that can with an example.
take as input a classification model of part families. These Keywords: Flexible Manufacturing Systems, Discrete-
principles aid the software development effort in the follow- Event Simulation, Real-Time Decision Support, CPU Time,
ing ways. Operational Constructors are universal program- Aggregation Algorithms
ming concepts that allow the programmer to take advantage
of the graphical user interface (GUI) features of the DBMS, Design and Analysis of Reconfigurable Discrete Dies for
such as list boxes, scroll boxes, subforms, and the like. Meta Sheet Metal Forming, Daniel F. Walczyk, David E. Hardt,
models represent the structure of the classification model. v17, n6, 1998, pp436-454
By implementing any classification model as a meta model, Discrete dies have been investigated for sheet metal
it can easily be instantiated into the software without the forming since the early part of the 20th century. The recon-
need for custom development. Dynamic Binding provides a figurable nature of these dies lends itself well to flexible
general mechanism to query the database for part informa- manufacturing systems; unfortunately, the state of knowl-
tion by dynamically stitching user selections to a general edge on how to design and analyze discrete dies consisting
structured query language (SQL) query. Finally, Associative of close-packed pins is very limited, thereby hindering
Naming allows the user to retrieve data in a general manner industry's acceptance of this type of tooling. This paper
through an innovative table-naming scheme and traversal addresses the design and analysis issues involved with die
process. A case study is presented showing application of pin details, with methods for turning the pin matrix into a
these principles in support of a C&C system for a purchas- rigid tool, and with the pin containment frame. A general-
ing application used for procurement of raw materials, elec- ized procedure for designing a discrete dies is developed and
tronic components, and consumable supplies. then applied to the design and fabrication of a pair of high-
Keywords: Classification and Coding, Group Technology, resolution dies. These dies are configured and used to stamp
Software Engineering, Object-Oriented Modeling a benchmark part out of steel sheet.
Keywords: Discrete Die, Rapid Tooling, Sheet Metal
An Analytical Approach for Using Simulation in Real- Forming, Die Design
Time Decision Making in FMSs, N.S. Merchawi, H.A.
ElMaraghy, v17, n6, 1998, pp418-435 Classification and Methodologies for Orientation and
This paper presents an analytical approach to determine Stacking of Parts Based on Internal Features, Anil
the suitability of and adapt discrete-event simulation for Mankame, Philip Datseris, Musa Jouaneh, v17, n6, 1998,
real- time decision making in flexible manufacturing sys- pp455-475
tems (FMSs). First, a formula is developed to predict the Methods for orientation and stacking of parts have been
simulation CPU run time for a given manufacturing system, mostly based on the parts' external features. There are a
a planning horizon, and a computer system. It is shown that number of parts that need to be oriented and stacked based
there are only three main factors that affect simulation run on internal features, either because internal features are of
time: the planning horizon, the overall system average inter- primary importance or because of a lack of appropriate
arrival time, and the average number of workstations per external features. Issues concerning the orientation and
part routing. In light of this, an approach to reduce simula- stacking of parts based on their internal features are investi-
tion run time is presented. It is based on aggregating work- gated, and two-dimensional (flat) parts are classified into
stations to reduce the average number of workstations per groups based on both internal and external features.
part routing. The validity of the approach is justified by Fundamental methodologies are developed for orienting and
comparing the performance measures of example systems stacking of parts based on internal features, and experimental
Journal of Manufacturing Systems
Vol. 17/No. 6
1998 abstract index
verification is performed for many cases. Results indicate ly accepted rule that orientational position of parts should be
that parts can be oriented efficiently and at high speeds. The preserved does not necessarily hold.
key variables that play an important role in the process are Keywords: Part Orientation, Part Stacking, Internal
identified and investigated further. In addition, it can be con- Features, High-Speed Automation
cluded from these experiments that in many cases, the wide-
1998 AUTHOR INDEX
Abdel-Malek, Karim, v17, n3, p183; v17, n3, p209 Krishnan, S.S., v17, n5, p338
Adickes, Martin, v17, n5, p361
Lakshmikanthan, Jayant, v17, n4, p287
Baker, Albert D., v17, n4, p297 Lee, Dong-Ho, v17, n2, p107
Bidanda, Bopaya, v17, nl, p52 Lee, Yuan-Shin, v17, n5, p371
Billo, Richard E., v17, nl, p52; v17, n5, p361; v17, n6, p405 Lehtihet, E. Amine, v17, n4, p251
Bourne, D.A., v17, n5, p338 Liao, Y.S., v17, n4, p263
Brown, Simon M., v17, n5, p389
Mankame, Anil, v17, n6, p455
Cai, L., v17, n2, pl44 Maropis, Nicholas, v17, n3, p183
Chan, Kevin, v17, n4, p275 Merchawi, N.S., v17, n6, p418
Chen, Yen-Hung, v17, n5, p371 Moodie, Colin L., v17, nl, p]
Clark, Gordon M., v17, nl, p65
Crawford, Richard H., v17, nl, p23; v17, n5, p325 Oyeleye, Olagunju, v17, n4, p251
Datseris, Philip, v17, n6, p455 Paul, Burton, v17, n3, p209
Petri, Kimberly L., v17, nl, p52
E!Maraghy, H.A., v17, n6, p418 Prasad, Biren, v17, n3, p22]
Fang, Shu-Cherng, v17, n5, p371 Radhakrishnan, Sanjay, v17, n2, p97
Ramaswamy, Sanjay E., v17, n2, p97
Garimella, Soma S., v17, n2, p87
Roh, Hwan-Kyun, v17, n2, p107
Gupta, S.K., v17, n5, p338
Rossetti, Manuel D., v17, nl, p65
Hardt, David E., v17, n6, p436
Shah, Jami J., v17, n3, p167
Hirode, Kartheek, v17, n3, p167
Sheng, P., v17, n2, p144
Ho, Ying-Chin, v17, nl, pl
Shirur, Arvind, v17, n3, p167
Hsieh, Suhua, v17, n4, p237
Huang, Samuel H., v17, n3, p196 Teng, Sheng-Hsien Gary, v17, n2, p87
Hwang, Hark, v17, n2, pi37 Thompson, David C., v17, nl, p23
Tumer, Irem Y., v17, nl, p23
Jiang, Bernard C., v17, n3, p159
Jiang, $.J., v17, n3, p159 Uzsoy, Reha, v17, nl, p37
Jouaneh, Musa, v17, n6, p455
Walczyk, Daniel F., v17, n4, p287; v17, n6, p436
Kang, Ming- Yuan, v17, n4, p237 Wang, Cheng-Shuo, v17, nl, p37
Kempf, Karl G., v17, nl, p37 Wood, Kristin L., v17, nl, p23
Kim, Jung-Ug, v17, n2, p107 Wright, Paul K., v17, n4, p275; v17, n5, p389
Kim, K.H., v17, n5, p338
Kim, Sang Hwi, v17, n2, p137 Venkatesh, Kurapati, v17, n2, p118
Kim, Yeong-Dae, v17, n2, p107 Ventura, Jose A., v17, n2, p97
King, Calvin (formerly A.R. Thangaraj), v17, n4, p275
Yan, M.T., v17, n4, p263
Kirk, Daniel R., vi7, n4, p287
Kleespies III, H.S., v17, n5, p325 Zhou, MengChu, v17, n2, p118