Skip to main content

Change in Manufacturing – Research and Industrial Challenges

  • Conference paper
  • First Online:
Enabling Manufacturing Competitiveness and Economic Sustainability

Abstract

Change, in products and systems, has become a constant in manufacturing. This sector continues to witness major market shifts, introduction of new materials and processing technologies as well as great changes in consumer preferences and productsvariety. This presents significant challenges to industrialists, researchers and educators alike. Changes can most often be anticipated but some go beyond the design range. This requires providing innovative change enablers and adaptation mechanisms to mitigate the effects of, and capitalize on, changes in manufacturing. Experiential research and learning is essential to enhance responsiveness and prepare production leaders of the future. The training and experimentation could be significantly enhanced if manufacturing systems could be brought into the laboratories of academic and research institutions. This paper describes the latest state-of-the art fully reconfigurable “plug & play” changeable and flexible “Factory-in-the-Lab” infrastructure and supporting design innovation and advanced research environment. It discusses the use of the iFactory and iDesign system to address these challenges and develop many key technologies and strategies for success. It presents severa novel approaches and methods for achieving the desired balance in the wide spectrum of variation in markets, products, processes, systems and manufacturing enterprises.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 169.00
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 219.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info
Hardcover Book
USD 219.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. Hummel, V. and Westkamper, E. (2007): Learning factory for advanced industrial engineering - integrated approach of the digital learning environment and the physical model factory. Production Engineering, University Publishing House: Krakow, Poland. pp. 215-27.

    Google Scholar 

  2. Ssemakula, M., Liao, G., Ellis, D., Kim, K- Y. and Sawilowsky, S. (2009): Introducing a flexible adaptation framework for implementing 'Learning Factory' - Based manufacturing education. in 2009 ASEE Annual Conference and Exposition, 14-17 June. Austin, TX, United states: American Society for Engineering Education.

    Google Scholar 

  3. amancusa, J.S., Jorgensen, J.E., and Zayas-Castro, J.L., (1997): Learning Factory - a new approach to integrating design and manufacturing into the engineering curriculum. Journal of Engineering Education. Vol. 86, No., pp. 103-112.

    Google Scholar 

  4. Abele, E., Tenberg, R., Wennemer, J., Cachay, J. (2010): Production Skills Development in Learning Factories. ZWF Zeitschrift fur Wirtschaftlichen Fabrikbetrieb. Vol. 105, No., pp. 909-13.

    Google Scholar 

  5. Westkämper, E., et al., (2005): Smart Factory - Bridging the gap between digital planning and reality. in 38th International Seminar on Manufacturing Systems 2005, May. Florianopolis, Brazil.

    Google Scholar 

  6. Westkämper, E. and Hummel, V., (2005): The Stuttgart Enterprise Model - Integrated Engineering of Strategic & Operational Functions. in 38th International Seminar on Manufacturing Systems 2005, May. Florianopolis, Brazil.

    Google Scholar 

  7. ElMaraghy, H., Changing and Evolving Products and Systems - Models and Enablers, in Changeable and Reconfigurable Manufacturing Systems, ed. H.A. ElMaraghy, Springer-Verlag: London. p. 25-45.

    Google Scholar 

  8. Azab, A. and ElMaraghy, H., (2007): Mathematical Modeling for Reconfigurable Process Planning. CIRP Annals - Manufacturing Technology. Vol. 56, No. 1, pp. 467-472.

    Article  Google Scholar 

  9. Ismail, M. and ElMaraghy, H., (2009): Progressive Modeling – An Enabler of Dynamic Changes in Production Planning. CIRP Annals. Vol. 58, No. 1, pp. 407-412.

    Article  Google Scholar 

  10. Wiendahl, H.-P., ElMaraghy, H., Nyhuis, P., Zäh, M.F., Wiendahl, H.-H., Duffie, N. and Brieke, M. (2007): Changeable Manufacturing: Classification, Design, Operation. Keynote Paper, CIRP Annals. Vol. 56, No. 2, pp. 783-809.

    Article  Google Scholar 

  11. ElMaraghy, H., Reconfigurable Process Plans for Responsive Manufacturing Systems, in Digital Enterprise Technology: Perspectives & Future Challenges, F. Cunha and G. Maropoulos, Editors. 2007, Springer Science. p. 35-44.

    Google Scholar 

  12. ElMaraghy, H., AlGeddawy, T., and Azab, A., (2008): Modelling evolution in manufacturing: A biological analogy. CIRP Annals - Manufacturing Technology. Vol. 57, No. 1, pp. 467-472.

    Article  Google Scholar 

  13. AlGeddawy, T. and ElMaraghy, H., (2010): Co-evolution hypotheses and model for manufacturing planning. CIRP Annals - Manufacturing Technology. Vol. 59, .No. 1, pp. 445- 448.

    Article  Google Scholar 

  14. AlGeddawy, T. and ElMaraghy, H., (2011): Design of Single Assembly line for the delayed differentiation of Product Variants. Flexible Services and Manufacturing Journal. Vol. 22, No. 3, pp. 163-182.

    Article  Google Scholar 

  15. ElMaraghy, H., Azab, A., Schuh, G. and Pulz, C. (2009): Managing variations in products, processes and manufacturing systems. CIRP Annals - Manufacturing Technology. Vol. 58, No. 1, pp. 441-446.

    Article  Google Scholar 

  16. Tolio, T., Ceglarek, D., Elmaraghy, H., Fischer, A., Hu, S.J., Laperrière, L., Newman, S.T. and Váncza, J., (2010): SPECIES-Co-evolution of products, processes and production systems. CIRP Annals - Manufacturing Technology. Vol. 59, No. 1, pp. 672-693.

    Article  Google Scholar 

  17. Deif, A. and ElMaraghy, H., (2007): Assessing Capacity Scalability Policies in RMS Using System Dynamics. International Journal of Flexible Manufacturing System. Vol. 19, No., pp. 128-150.

    Article  MATH  Google Scholar 

  18. Arafa, A. and ElMaraghy, W., (2011): Manufacturing strategy and enterprise dynamic capability. CIRP Annals - Manufacturing Technology. Vol. 60, No. 1, pp. 507-510.

    Article  Google Scholar 

  19. Lu, S.C.Y., Elaraghy, W., Schuh, G. and Wilhelm, R. (2007): A scientific foundation of collaborative engineering. CIRP Annals - Manufacturing Technology. Vol. 56, No. 2, pp. 605- 634.

    Article  Google Scholar 

  20. ElMaraghy, W. (2009): Knowledge Management in Collaborative Engineering. International Journal Collaborative Engineering. Vol. 1, No. 1/2, pp. 114-124.

    Article  Google Scholar 

  21. Ziout, A., Ramadan, K., and ElMaraghy, W. (2009): Inventive Conceptual Designs In Active Disassembly Using Theory Of Inventive Problem Solving (TRIZ). in Proceeding of the 16th CIRP Conference On Life Cycle Engineering. 4-6 May 2009, Cairo, Egypt.

    Google Scholar 

  22. Azab, A., ElMaraghy, H., and Samy, S.N., Reconfiguring Process Plans: A New Approach to Minimize Change, in Changeable and Reconfigurable Manufacturing Systems, H. ElMaraghy, Editor 2009, Springer London. p. 179-194.

    Google Scholar 

  23. Samy, S.N. and ElMaraghy, H. (2010): A model for measuring products assembly complexity. International Journal Computer Integrated Manufacturing. Vol. 23, No. 11, pp. 1015-1027.

    Article  Google Scholar 

  24. Shokri, S. and ElMaraghy, W. (2008): Modeling of Manufacturing Assembly Complexity. in 2nd International CIRP Conference on Assembly Technologies and Systems. 21-23 Septemper 2008, Toronto, Canada.

    Google Scholar 

  25. Tomiyama, T., D'Amelio, V., Urbanic, J. and Eimaraghy, W. (2007): Complexity of Multi-Disciplinary Design. CIRP Annals - Manufacturing Technology. Vol. 56, No. 1, pp. 185-188.

    Article  Google Scholar 

  26. ElMaraghy, H. (1993): Evolution and future perspecives of CAPP. CIRP Annals. Vol. 1, No. 42(2), pp. 739-751.

    Article  Google Scholar 

  27. Azab, A. and ElMaraghy, H. (2007): Sequential process planning: A hybrid optimal macro-level approach. Journal of Manufacturing Systems. Vol. 26, No. 3-4, pp. 147-160.

    Article  Google Scholar 

  28. Garey, M.R. and Johnson, D.S., (1979): Computers and intractability: a Guide to the Theory of NP-Completeness. 1979: San Francisco: W.H. Freeman.

    MATH  Google Scholar 

  29. Ssemakula, M.E. and Cloyd, W.J., (1994): Functional specification of a dynamic process planning system. Computers & Industrial Engineering, Vol. 27, pp 99-102.

    Article  Google Scholar 

  30. Zhang, Y., Feng, S.C. Wang, X., Tian, W. and Wu, R. (1999): Object oriented manufacturing resource modelling for adaptive process planning. International Journal of Production Research. Vol. 37, No. 18, pp. 4179-95.

    Article  MATH  Google Scholar 

  31. Hetem, V., (2003): Variant process planning, a basis for reconfigurable manufacturing systems. in CIRP 2nd international conference on reconfigurable manufacturing, Ann Arbor, MI, U.S.A. 2003.

    Google Scholar 

  32. Xu, H., Tang, R.-Z., and Cheng, Y.-D., (2004): Study Of Process Planning Techniques For Reconfigurable Machine Tool Design. Journal of Zhejiang University. Vol. 38, No., pp. 1496-1501.

    Google Scholar 

  33. Bley, H. and Zenner, C., (2005): Feature-based planning of reconfigurable manufacturing systems by a variant management approach. in 2005 CIRP 3rd International Conference on Reconfigurable Manufacturing. 2005.

    Google Scholar 

  34. Shabaka, A.I. and ElMaraghy, H. (2007): Generation of machine configurations based on product features. International Journal of Computer Integrated Manufacturing. Vol. 20, No. 4, pp. 355-369.

    Article  Google Scholar 

  35. Song, S., Li, A., and Xu, L., (2007): Study of CAPP system suited for reconfigurable manufacturing system. in 2007 International Conference on Wireless Communications, Networking and Mobile Computing, WiCOM 2007. 2007. Shanghai, China: IEEE.

    Google Scholar 

  36. Song, S.G., Hu, X.X., and Liu, J., (2011): Research of process planning based on similarity theory under reconfigurable manufacturing system. in 2011 International Conference on Advanced Material Research, ICAMR 2011, January 21, 2011 - January 23, 2011. 2011. Chongqing, China: Trans Tech Publications.

    Google Scholar 

  37. Pine, J., (1993): Mass Customization: The New Frontier in Business Competition. 1993, Boston: Harvard Business School Press.

    Google Scholar 

  38. ElMaraghy, H. (2005): Flexible and reconfigurable manufacturing systems paradigms. International Journal of Flexible Manufacturing Systems. Vol. 17, No. 4, pp. 261-276.

    Article  Google Scholar 

  39. Pandremenos, J., Paralikas, J., Salonitis, K. and Chryssolouris, G. (2009): Modularity concepts for the automotive industry: A critical review. CIRP Journal of Manufacturing Science and Technology. Vol. 1, No., pp. 148-152.

    Article  Google Scholar 

  40. Ulrich, K. and Tung, K., (1991): Fundamentals of Product Modularity. Issues in Design Manufacturing / Integration, ASME. Vol. 39, No. 1, pp. 73-79.

    Google Scholar 

  41. Jose, A. and Tollenaere, M., (2005): Modular and platform methods for product family design: literature analysis. Journal of International Manufacturing. Vol. 16, No., pp. 371-390.

    Article  Google Scholar 

  42. Boothroyd, G.D.P., (1989): Product design for assembly. [3rd Ed], Wakefield, RI: Boothroyd Dewhurst. 134 p..

    Google Scholar 

  43. AlGeddawy, T. and ElMaraghy, H. (2009): Sustainability and Modularity Analysis of Varying Products and Families Using Cladistics. in 3rd International Conference on Changeable, Agile, Reconfigurable and Virtual Production (CARV 2009). 5-7 October 2009, Munich, Germany.

    Google Scholar 

  44. Lee, L. and Tang, C. (1997): Modelling the Costs and Benefits of Delayed Product Differentiation. Management Science. Vol. 43, No. 1, pp. 40-53.

    Article  MATH  Google Scholar 

  45. Ko, J. and Jack Hu, S. (2008): Balancing of manufacturing systems with complex configurations for delayed product differentiation. International Journal of Production Research. Vol. 46, No. 15, pp. 4285 - 4308.

    Article  MATH  Google Scholar 

  46. Hu, S.J., Ko, J., Weyand, L., ElMaraghy, H., Lien, T.K., Koren, Y., Bley, H., Chryssolouris, G., Nasr, N. and Shpitalni, M. (2011): Assembly system design and operations for product variety. CIRP Annals - Manufacturing Technology. Vol. 60, No. 2.

    Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Editor information

Editors and Affiliations

Rights and permissions

Reprints and permissions

Copyright information

© 2012 Springer-Verlag Berlin Heidelberg

About this paper

Cite this paper

ElMaraghy, H., AlGeddawy, T., Azab, A., ElMaraghy, W. (2012). Change in Manufacturing – Research and Industrial Challenges. In: ElMaraghy, H. (eds) Enabling Manufacturing Competitiveness and Economic Sustainability. Springer, Berlin, Heidelberg. https://doi.org/10.1007/978-3-642-23860-4_1

Download citation

  • DOI: https://doi.org/10.1007/978-3-642-23860-4_1

  • Published:

  • Publisher Name: Springer, Berlin, Heidelberg

  • Print ISBN: 978-3-642-23859-8

  • Online ISBN: 978-3-642-23860-4

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics