Advertisement

Module-based machinery design: a method to support the design of modular machine families for reconfigurable manufacturing systems

  • Leandro GaussEmail author
  • Daniel Pacheco Lacerda
  • Miguel Afonso Sellitto
ORIGINAL ARTICLE

Abstract

Increased demand for a greater variety of products has forced many companies to rethink their strategies to offer more product variants without sacrificing production efficiency. Consequently, to satisfy this demand for customized products in shorter lead time and lower costs, production systems must be highly reactive and reconfigurable. In this context, the concept of reconfigurable manufacturing systems (RMS) emerged in the late 1990s to overcome the limitations of traditional manufacturing in rapidly and cost-efficiently respond to changing market conditions. However, the traditional development process of special-purpose machines to meet the requirements of change turned into an expensive and time-consuming task, challenging practitioners and scholars for reducing the impact of variety on the manufacturing costs. In order to aid the transition towards the reconfigurability from an engineering design perspective, this article introduces the Module-Based Machinery Design, a method to support the conceptual and system-level design of modular machine families for RMS. The contributions of this research include (i) the organization of existing methods and techniques for designing module-based product families into a coherent framework intended for developing machine families for RMS. (ii) The proposition of a design method that accomplishes the majority of RMS characteristics through the use of modularity. (iii) The introduction of the Adherence Index, a measure to indicate the level of utilization of basic, auxiliary and adaptive modules within a module-based machine variant. (iv) Finally, the analytical evidence of an RMS implementation through the design process of a family of modular floor level palletizers.

Keywords

Reconfigurable manufacturing systems (RMS) Modularity Engineering design Product family design Platform-based product development 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

References

  1. 1.
    Zhu B, Li Y, Feng G (2017) A fuzzy optimisation method for product variety selection under uncertainty constraints. Int J Comput Integr Manuf 30(6):606–615CrossRefGoogle Scholar
  2. 2.
    Simpson TW, Jiao JR (2014) Advances in product family and product platform design. Springer New York, New YorkCrossRefGoogle Scholar
  3. 3.
    Roland Berger Strategy Consultants, Mastering product complexity, 2012Google Scholar
  4. 4.
    Jiao J, Simpson TW, Siddique Z (2007) Product family design and platform-based product development: a state-of-the-art review. J Intell Manuf 18(1):5–29CrossRefGoogle Scholar
  5. 5.
    Antunes JAV, Alvarez R, Bortolotto P, Klippel M, de Pellegrini I (2008) Sistemas de produção: Conceitos e práticas para projetos e gestão da produção enxuta. Bookman, Porto AlegreGoogle Scholar
  6. 6.
    Kull H (2015) Mass Customization: Opportunities, methods, and challenges for manufacturers, vol. 1. ApressGoogle Scholar
  7. 7.
    Marseu E, Kolberg D, Birtel M, Zühlke D (2016) Interdisciplinary engineering methodology for changeable cyber-physical production systems. IFAC-PapersOnLine 49(31):85–90CrossRefGoogle Scholar
  8. 8.
    Rösiö C, Säfsten K (2013) Reconfigurable production system design—theoretical and practical challenges. J Manuf Technol Manag 24(7):998–1018CrossRefGoogle Scholar
  9. 9.
    Koren Y, Heisel U, Jovane F, Moriwaki T, Pritschow G, Ulsoy G, van Brussel H (1999) Reconfigurable manufacturing systems. CIRP Ann 48(2):527–540CrossRefGoogle Scholar
  10. 10.
    Koren Y (2006) General RMS characteristics. Comparison with dedicated and flexible systems. In: D AI (ed) Reconfigurable manufacturing systems and transformable factories. Springer, Berlin, pp 27–45CrossRefGoogle Scholar
  11. 11.
    Andersen A-L, Brunoe TD, Nielsen K (2015) Reconfigurable manufacturing on multiple levels: literature review and research directions. IFIP Adv Inf Commun Technol 459:266–273CrossRefGoogle Scholar
  12. 12.
    Andersen A-L, Brunoe TD, Nielsen K, Rösiö C (2017) Towards a generic design method for reconfigurable manufacturing systems: analysis and synthesis of current design methods and evaluation of supportive tools. J Manuf Syst 42:179–195CrossRefGoogle Scholar
  13. 13.
    Mehrabi MG, Ulsoy AG, Koren Y (2000) Reconfigurable manufacturing systems: key to future manufacturing. J Intell Manuf 11:403–419CrossRefGoogle Scholar
  14. 14.
    Schuh G, Lenders M, Nussbaum C, Kupke D (2009) Design for Changeability. In: Changeable and Reconfigurable Manufacturing Systems, 1st edn. Springer-Verlag London Limited, London, pp 251–266Google Scholar
  15. 15.
    Lameche K, Najid NM, Castagna P, Kouiss K (2017) Modularity in the design of reconfigurable manufacturing systems. IFAC-PapersOnLine 50(1):3511–3516CrossRefGoogle Scholar
  16. 16.
    Mpofu K, Kumile CM, Tlale NS (2008) Design of reconfigurable machine systems: knowledge based approach. J Konbin 8(1):135–144CrossRefGoogle Scholar
  17. 17.
    Bi ZM, Lang SYT, Shen W, Wang L (2008) Reconfigurable manufacturing systems: the state of the art. Int J Prod Res 46(4):967–992CrossRefzbMATHGoogle Scholar
  18. 18.
    El Maraghy HA (2006) Flexible and reconfigurable manufacturing systems paradigms. Flex Serv Manuf J 17(4):261–276Google Scholar
  19. 19.
    Malhotra V, Raj T, Arora A (2010) Excellent techniques of manufacturing systems: RMS and FMS. Int J Eng Sci Technol 2(3):137–142Google Scholar
  20. 20.
    Zhang G, Liu R, Gong L, Huang Q (2006) An analytical comparison on cost and performance among DMS, AMS, FMS and RMS. In: D AI (ed) Reconfigurable manufacturing systems and transformable factories. Springer, Berlin, pp 659–673CrossRefGoogle Scholar
  21. 21.
    Mehrabi MG, Ulsoy AG, Koren Y, Heytker P (2002) Trends and perspectives in flexible and reconfigurable manufacturing systems. J Intell Manuf 13:135–146CrossRefGoogle Scholar
  22. 22.
    Abdi MR, Labib AW (2004) Feasibility study of the tactical design justification for reconfigurable manufacturing systems using the fuzzy analytical hierarchical process. Int J Prod Res 42(15):3055–3076CrossRefzbMATHGoogle Scholar
  23. 23.
    Benkamoun N, Kouiss K, Huyet A-L (2015) An Intelligent Design Environment for Changeability Management - Application To, in ICED, pp 1–10Google Scholar
  24. 24.
    Marion TJ, Thevenot HJ, Simpson TW (2007) A cost-based methodology for evaluating product platform commonality sourcing decisions with two examples. Int J Prod Res 45(22):5285–5308CrossRefzbMATHGoogle Scholar
  25. 25.
    Park J, Simpson TW (2008) Toward an activity-based costing system for product families and product platforms in the early stages of development. Int J Prod Res 46(1):99–130CrossRefzbMATHGoogle Scholar
  26. 26.
    Meyer MH, Lehnerd AP (1997) The power of product platforms. Free PressGoogle Scholar
  27. 27.
    Erens F, Verhulst K (1997) Architectures for product families. Comput Ind 33(2–3):165–178CrossRefGoogle Scholar
  28. 28.
    T. W. Simpson, Z. Siddique, and J. (Roger) Jiao (2006) Product platform and product family design: methods and applications, 1st ed. Springer USGoogle Scholar
  29. 29.
    Kong FB, Ming XG, Wang L, Wang XH, Wang PP (2009) On Modular Products Development. CERA 17(4):291–300Google Scholar
  30. 30.
    Otto K, Hölttä-Otto K, Simpson TW, Krause D, Ripperda S, Ki Moon S (2016) Global views on modular design research: linking alternative methods to support modular product family concept development. J Mech Des 138(7):071101CrossRefGoogle Scholar
  31. 31.
    Du X, Jiao J, Tseng MM (2001) Architecture of product family: Fundamentals and methodology. CERA 9(4):309–325Google Scholar
  32. 32.
    Ulrich K (1995) The role of product architecture in the manufacturing firm. Res Policy 24(3):419–440CrossRefGoogle Scholar
  33. 33.
    Jiao J, Tseng MM (2000) Fundamentals of product family architecture. Integr Manuf Syst 11(7):469–483CrossRefGoogle Scholar
  34. 34.
    Jiao J, Tseng MM (1999) A methodology of developing product family architecture for mass customization. J Intell Manuf 10(1):3–20CrossRefGoogle Scholar
  35. 35.
    Piran FAS, Lacerda DP, Antunes JAV, Viero CF, Dresch A (2016) Modularization strategy: analysis of published articles on production and operations management (1999 to 2013). Int J Adv Manuf Technol 86(1–4):507–519CrossRefGoogle Scholar
  36. 36.
    Martin MV, Ishii K (2002) Design for variety: developing standardized and modularized product platform architectures. Res Eng Des 13(4):213–235Google Scholar
  37. 37.
    Meng X, Jiang Z, Huang GQ (2007) On the module identification for product family development. Int J Adv Manuf Technol 35(1–2):26–40CrossRefGoogle Scholar
  38. 38.
    Liu Z, Wong YS, Lee KS (2010) Modularity analysis and commonality design: a framework for the top-down platform and product family design. Int J Prod Res 48(12):3657–3680CrossRefzbMATHGoogle Scholar
  39. 39.
    Emmatty FJ, Sarmah SP (2012) Modular product development through platform-based design and DFMA. J Eng Des 23(9):696–714CrossRefGoogle Scholar
  40. 40.
    Hanafy M, Elmaraghy H (2015) A modular product multi-platform configuration model. Int J Comput Integr Manuf 28(9):999–1014CrossRefGoogle Scholar
  41. 41.
    Goswami M, Daultani Y, Tiwari MK (2017) An integrated framework for product line design for modular products: product attribute and functionality-driven perspective. Int J Prod Res 55(13):3862–3885CrossRefGoogle Scholar
  42. 42.
    Fettermann D d C, Echeveste MES (2014) New product development for mass customization: a systematic review. Prod Manuf Res 2(1):266–290Google Scholar
  43. 43.
    Ulrich KT, Eppinger SD (2012) Product design and development: Fifth EditionGoogle Scholar
  44. 44.
    Pahl G, Beitz W, Feldhusen J, Grote K-H (2007) Engineering design: a systematic approach, Springer, no. 2, p. 617Google Scholar
  45. 45.
    Rozenfeld H et al. (2006) Gestão de Desenvolvimento de Produtos: Uma referência para a melhoria do processo, 1st ed. Editora SaraivaGoogle Scholar
  46. 46.
    Mascle C, Zhao HP (2008) Integrating environmental consciousness in product/process development based on life-cycle thinking. Int J Prod Econ 112(1):5–17CrossRefGoogle Scholar
  47. 47.
    Charter M, Tischner U (2017) Sustainable solutions: developing products and services for the future. RoutledgeGoogle Scholar
  48. 48.
    Xiao W, Du G, Zhang Y, Liu X (2018) Coordinated optimization of low-carbon product family and its manufacturing process design by a bilevel game-theoretic model. J Clean Prod 184:754–773CrossRefGoogle Scholar
  49. 49.
    Cox JF, Schleier JG (2010) Theory of constraints handbook. McGraw-Hill, New YorkGoogle Scholar
  50. 50.
    Hilier F, Lieberman G (2015) Introduction to operational research, 10th edn. McGraw-Hill, New YorkGoogle Scholar
  51. 51.
    Montgomery DC, Runger GC (2011) Applied statistics and probability for engineers, Fifth Edition, 5th ed. John Wiley & Sons, LtdGoogle Scholar
  52. 52.
    Stone RB, Wood KL (2000) Development of a functional basis for design. J Mech Des 122(4):359–370CrossRefGoogle Scholar
  53. 53.
    Stone R, Wood K (2000) A heuristic method for identifying modules for product architectures. Des Stud 21:1–47CrossRefGoogle Scholar
  54. 54.
    Yoshimura M, Takeuchi A (1994) Concurrent optimization of product design and manufacturing based on information of users’ needs. CERA 2(1):33–44Google Scholar
  55. 55.
    Dempster AP, Laird NM, Rubin DB (1977) Maximum likelihood from incomplete data via the EM algorithm. J R Stat Soc Ser B Methodol 39(1):1–38MathSciNetzbMATHGoogle Scholar
  56. 56.
    Abbas OA (2008) Comparisons between data clustering algorithms. Int Arab J Inf Technol 5(3):320–325Google Scholar
  57. 57.
    Suh NP (1998) Engineering design axiomatic design theory for systems. Res Eng Des 10:189–209CrossRefGoogle Scholar
  58. 58.
    Suh NP (2001) Axiomatic design: advances and applications. Oxford University Press, New York, p 528Google Scholar
  59. 59.
    Kusiak A, Chow WS (1987) Efficient solving of the group technology problem. J Manuf Syst 6(2):117–124CrossRefGoogle Scholar
  60. 60.
    Jung S, Simpson TW (2017) New modularity indices for modularity assessment and clustering of product architecture. J Eng Des 28(1):1–22CrossRefGoogle Scholar
  61. 61.
    Jiao J, Tseng MM (1999) A pragmatic approach to product costing based on standard time estimation. Int J Oper Prod Manag 19(7):738–755CrossRefGoogle Scholar
  62. 62.
    Kohlhase N, Birkhofer H (1996) Development of modular structures: the prerequisite for successful modular products. J Eng Des 7(3):279–291CrossRefGoogle Scholar
  63. 63.
    Popple RA (2009) The science of palletizing: how to choose the right system. Columbia Machine, Inc., VancouverGoogle Scholar
  64. 64.
    DAN‐Palletizer. [Online]. Available: https://www.wrh-global.com.au/en/3677/DAN-Palletizer.htm. Accessed 28 Sep 2018
  65. 65.
    Frank E, Hall MA, Witten IH (2016) The WEKA Workbench. Online Appendix for Data Mining: Practical Machine Learning Tools and TechniquesGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Leandro Gauss
    • 1
    Email author
  • Daniel Pacheco Lacerda
    • 1
  • Miguel Afonso Sellitto
    • 1
  1. 1.Production and Systems Engineering Graduate ProgramUniversidade do Vale do Rio dos SinosSão LeopoldoBrazil

Personalised recommendations