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Research Papers: Design for Manufacture and the Life Cycle

Functional Synthesis of Manufacturing Systems Using Co-Platforming to Minimize Cost of Machines and System Changes

[+] Author and Article Information
Mohamed Abbas

Intelligent Manufacturing Systems (IMS) Center,
Industrial and Manufacturing
Systems Engineering,
University of Windsor,
401 Sunset Avenue,
Windsor, ON N9B 3P4, Canada
e-mail: abbasl@uwindsor.ca

Hoda ElMaraghy

Mem. ASME
Intelligent Manufacturing Systems (IMS) Center,
Industrial and Manufacturing
Systems Engineering,
University of Windsor,
401 Sunset Avenue,
Windsor, ON N9B 3P4, Canada
e-mail: hae@uwindsor.ca

1Corresponding author.

Contributed by the Design for Manufacturing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received September 2, 2016; final manuscript received September 11, 2017; published online November 10, 2017. Assoc. Editor: Gary Wang.

J. Mech. Des 140(2), 021701 (Nov 10, 2017) (15 pages) Paper No: MD-16-1616; doi: 10.1115/1.4038069 History: Received September 02, 2016; Revised September 11, 2017

Manufacturing systems need to be designed to cope with products’ variety and frequent changes in market requirements. Switching between product families in different production periods often requires reconfiguration of the manufacturing system with associated additional cost and interruption of production. A mixed integer linear programing (MILP) model is proposed to synthesize manufacturing systems based on the co-platforming methodology taking into consideration machine level changes including addition or removal of machine axes and changing setup as well as system level changes such as addition or removal of machines. The objective is to minimize the cost of change needed for transition between product families and production periods. An illustrative numerical example and an industrial case study from tier I automotive supplier are used for verification. Finally, the effect of maintaining a common core of machines in the manufacturing system on the total capital and change cost is investigated. It has been demonstrated that synthesizing manufacturing systems designed using the co-platforming strategy reduces the total investment cost including initial cost of machines and cost of reconfiguration.

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Figures

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Fig. 1

Illustration of co-platforming [3]

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Fig. 2

Illustration of machined features (adapted from Ref. [8])

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Fig. 3

Illustration of machine operation matrix

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Fig. 4

Illustration of the different decision variables in the mathematical model: (a) no change, (b) no change, (c) removal of axis form nonplatform m/c, (d) removal of axis form platform m/c, (e) addition of axis to nonplatform m/c, (f) addition of axis to platform m/c, (g) removal of m/c and axis, (h) addition of m/c and axis, (i) addition of m/c, and (j) removal of m/c

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Fig. 5

The different product variants for the numerical example and their features

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Fig. 6

Machine type in each production period for the numerical example

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Fig. 7

Standard parts (a) ANC-90 and (b) ANC-101 adapted from Ref. [18]

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Fig. 8

Product features for the I-4 and V-8 cylinder blocks

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Fig. 9

Illustration of Mathematical model results showing the different machine types in each production period as well as the added/removed machining axes

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Fig. 10

Effect of maintaining a common platform machines on the cost within system level and machine level

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Fig. 11

Results obtained by solving the case study presented in this paper using the mathematical model presented in Ref. [3]

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