e-science e-manufacturing: fundamentals, applications and potentials professor kai cheng advanced...
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e-Science
e-Manufacturing: Fundamentals, Applications and Potentials
Professor Kai Cheng Advanced Manufacturing & Enterprise Engineering (AMEE) Group
School of Engineering & Design, Brunel UniversityUxbridge UB8 3PH, UK
Tel: 08195-267255 Fax: 08195-269703 email: [email protected]
Dr Richard BatemanCERAM Research LtdQueens Road, Penkull
Stoke-on-Trent, UK. ST4 7LQTel: (0) 1782 764349 email: [email protected]
• Background
- Why e-manufacturing?
- What is e-manufacturing?
• e-Manufacturing fundamentals
- Internet enabled technologies
- Advanced technologies for e-manufacturing
- Internet and manufacturing knowledge management
- Computing infrastructure for e-manufacturing
• e-Manufacturing applications and potentials
- Collaborative design and product development
- Mass customization and customer oriented e-manufacturing
- Remote control and condition monitoring
- Virtual manufacturing and systems
- e-Supply chain management
- e-Enterprise and global manufacturing
• Conclusions and the future ‘standing’
Outline of the presentatione-Science
The characteristics of e-manufacturing emphases the new philosophy through which manufacturing will be operated in integration with Internet technology. e-manufacturing philosophy results from that the way people work is being changed by the Internet, for instance:
• Digitisation• Globalisation• Mobility• Collaborative work• Immediacy
Why e-Manufacturing?e-Science
Manufacturing globalization - e-Manufacturing (1)
DesignManufacturing
Sale
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Distributed manufacturing - e-Manufacturing (2)e-Science
Development of manufacturing technology
Mass Production
Flexible Manufacturing
Computer IntegratedManufacturing
Lean Manufacturing
Just-In-Time
Concurrent Engineering
Agile Manufacturing
Production line& automation
Group technology& CNC, robotics
CAD/CAM, DNC& robotics
TQM &engineering tools
TQM, MRP II &engineering tools
CAX &engineering tools
e-ManufacturingDigital enterprise
ManufacturingTechnology
Towards 21st Century
• High precision• Automation
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Transformation by e-Manufacturing
• Mass production
• Long pipeline
• Sale from stock
• Sequential processes
• Cost of inventory
• Wait in line
• Mass customisation
• Shrinking supply chain
• Make to order
• Simultaneous processes
• Capital working
• First available slot
- Manufacturing 2020 Foresight Report
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UK e-Science research program(2001 onward)
What is meant by e-Science? In the future, e-Science will refer to the large scale science that will increasingly be carried out through distributed global collaboration enabled by the Internet. Typically, a feature of such collaborative scientific enterprises is that they will require access to very large data collections, very large scale computing resources and high performance visualisation back to the individual user scientists.
The Core Program has been structured around 6 key elements:
• A national e-Science centre linked to a network of regional grid centres
• Generic grid middleware and demonstrator projects
• Grid ‘IRC’ research projects
• Support for e-Science testbeds
• Participation in international grid projects and activities
• Establishment of a grid network team
- http://www.rcuk.ac.uk/escience/
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EU 6th Framework - IST program(2004 onward)
Applied IST research addressing major societal and economic challenges:
• Towards a global dependability and security framework
• Networked business and government
• e-Safety for road and air transport
• e-Health
• Technology-enhanced learning and access to cultural heritage
• Applications and services for the mobile user and worker
• Cross media content for leisure and entertainment
• Grid-based systems for solving complex problems
• Improving risk management
• e-Inclusion
• Products and services engineering 2010
- http://www.cordis.lu/ist/activities/activities.htm
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e-manufacturing covers a range of online manufacturing activities for products and services, including product design, production control and conditions monitoring, supply chain management, maintenance and sale services, etc., through the Internet/Intranet/Extranet and grid computing infrastructure.
What is e-Manufacturing? - (1)e-Science
e-manufacturing is the complete electronic (computer systems and networks) integration of all factory components. Users range from operators to technicians to engineers to managers.
- UK Industrial White Paper (2002)
What is e-Manufacturing? - (2)e-Science
• Internet Enabled Technologies- HTML- Java programming- XML- Client/server architecture- Java database connectivity
• Advanced Technologies for e-Manufacturing- Agent technology- Multi-agent systems- Data mining and knowledge discovery- Grid computing
• Internet and Manufacturing Knowledge Management- Internet characteristics - Design agility and the Internet - Manufacturing responsiveness and the Internet - CBR and web-based computational intelligence
• Computing Infrastructure for e-manufacturing- Software tools- Hardware- Networking- Implementation
e-Manufacturing fundamentalse-
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e-manufacturing applications
Application (1) - case studies- Web-based bearing design support systems
- Web-based manufacturing assembly simulation
- Web-based intelligent (CBR) selection of cutting tool inserts
- Modelling and simulation of the extended enterprise operations based on dynamic Petri nets
- Remote condition monitoring and control of manufacturing systems
- Creative design search engine
- RFID application for diamond cutting tools’ tooling service
Application (2) - devolved manufacturing
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Web-based Intelligent (CBR) Selection System for Cutting Tool Inserts
A proposed system architecture…
Language selection
Main CBR loop
Standard e-Catalogue search
CBR validation loop
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Modelling and Simulation of the Extended Enterprise Operations Based on Dynamic Petri Nets
EVENTS
ORGANISATION MODELS
PROCESS MODELS
RESOURCES PRODUCTS
DATABASE
INTRANET/ INTERNET
JAVA SIMULATION
REAL-TIME VISUALISATOIN
MANUFACTURING ENTERPRISE
EVENTS
INTERNET
CO-ORDINATOR
DESIGN
MANAGEMENT
INTRANET/ INTERNET
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Internet
Client on the Internet
RT100Robot Arm
Web Camera
Send a live image to the clients
Commands
Response
Remote Condition Monitoring and Control of Manufacturing Systems
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Creative Design Search Engine …
Creative Design & Innovative Manufacturing
- 3D models
- ……
- ……
- ……
- ……
- ……
- ……
- ……
- ……
- ……
- ……
-……
A search engine for innovative/creative …
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RFID Application for Diamond Cutting Tools’ Tooling Service
TaggedCutting Tools
T1…TN
ReaderHost System
with Tool Database
Look up Geometric images SpecificationUser informationRe-sharpening records ……
Update
Read
Identify
Reader
TaggedTools
Host system with Tool Database
Reading Successfully
Antenna
Diamond tools tracking and servicing support sys
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Selected ‘Milestone’ Publications (in e-manufacturing) from the AMEE Group
Books:(1) K. Cheng, D. Webb and R. Marsh, Advances in e-Engineering and Digital Enterprise Technology I (Editors),
Professional Engineering Publishing, London, September 2004.(2) K. Cheng, e-Manufacturing, Fundamentals and Applications, WIT Press, London, February 2005.
Journal Papers:(1) K. Cheng, P.Y. Pan and D.K. Harrison, Internet as a tool with application to agile manufacturing: a web-based
engineering approach and its implementation issues, International Journal of Production Research, Vol.38 No.12, 2000, pp.2743-2759.
(2) K. Cheng, P.Y. Pan and D.K. Harrison, Web-based design and manufacturing support systems: implementation perspectives, International Journal of Computer Integrated Manufacturing, Vol.14 No.1, 2001, pp.14-27.
(3) K. Cheng, M.L. Yang, G.E. Taylor and A. Dow, Petri net as a tool with application in modelling an Internet based virtual manufacturing enterprise, International Journal of Agile Manufacturing, Vol.4 No.2, 2002, pp.100-109.
(4) J. Toussaint and K. Cheng, Implementation of design agility and manufacturing responsiveness on the web: two case studies, Integrated Manufacturing Systems, Vol.13 No.5, 2002, pp.328-339.
(5) R. Bateman and K. Cheng, Devolved manufacturing, Concurrent Engineering: Research and Applications, Vol.10 No.4, December 2002, pp.291-297.
(6) K. Cheng and Y. Popov, Internet enabled modelling of extended manufacturing enterprises using the process based techniques, International Journal of Advanced Manufacturing Technology, Vol.23 No.1, 2004, pp. 148-153.
(7) J. Toussaint and K. Cheng, Web-based CBR (case-based reasoning) as a tool with the application to tooling selection, International Journal of Advanced Manufacturing Technology, Vol. 26, 2006.
(8) R. Bateman and K. Cheng, Extending the product portfolio with ‘devolved manufacturing’: methodology and case studies, International Journal of Production Research, Vol.45, 2006.
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Devolved Manufacturing – (1)
Current developments in e-manufacture are generally ‘factory-centric’
Transport/logistics problems increasing (‘gridlock Europe’)
New technologies are available or emerging
New possibilities … Need to ‘Think outside
the box’…
Internet / WWW
MassCustomisation
RapidManufacture
Key areas for integration
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Agile Manufacturing
Manufacturing Processes Capability
Technology etc.
IT Internet WWW
CAD/CAM etc.
Mass Customisation Mass customisation
Make-to-order Personalisation
etc. …
People/HRM Organisation
Team Working Training
Recruitment Communications
Succession etc.
Organisation Virtual Orgs
Network Orgs Distribution
Logistics Supply chains
Finance etc.
Integrated Approach
Technology
Devolved Manufacturing
Devolved Manufacturing – (2)e-
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Mass Customisation
MASS PRODUCTION
MASS CUSTOMISATION
MASS ‘INDIVIDUALISATION’
Outcome of industrial revolution Driven by production and cost needs
Concept developed in 1980’s
Increases product range by allowing customers to choose from range of options
Needs to be set up with care to avoid extra overheads associated with increased product variety
Ultimate goal of MC ?
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Rapid Manufacturing (RM)
1. The CAD model is sliced into layers
2. RM machine ‘creates’ model
3. Finished Object
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End-user & Practitioner Surveys
Breakdown of Systems by Type
Global RP/RM Installations
Rise in Annual Sales of RP/RM machines (000’s)
Number of Patents Issued for RP/RM Technology
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Case One – CAL system
Typical Race Clutch Construction
Central Splines in Friction Plate Hub
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System Menu
Search Existing Products
Input Spline Dimensions
View 3D Model
Send files for manufacture
Test Mfg at Brunel
Case One – CAL systeme-
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Case Two – wydiwyg.co.uk
Home page
Details
Download mini-CAD program
Use mini-CAD program
View model in 3D
Stage ONE Stage TWO
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Home Page
Register
Find outlet
Outlet details
Upload CAD file
Make payment
Confirmation
Test part
Stage THREE
Case Two – wydiwyg.co.uke-
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Case Three – Creatorium Portal
Customers
Manufacturing outlets
Design companies
The
CREATORIUM web portal
Discussion forums
Designers (individual)
Legislative bodies
RM machine manufacturers
Trade associations
Professional bodies
Academic institutions
Stakeholders in the CREATORIUM Portal
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Customers
Manufacturing outlets
Design companies
The
CREATORIUM web portal
Discussion forums
Designers (individual)
Legislative bodies RM machine
manufacturers
Trade associations
Professional bodies
Academic institutions
Information based stakeholders
Case Study One Case Study Two
CREATORIUM relationship with Cases One and Two
Case Three – Creatorium Portale-
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Discussions
Implementation key issues Start points and direction Organisational issues Technology adoption Strategies for DM Design, legal and ethical issues Control and management of a DM venture
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Acknowledgements
• EPSRC• Royal Society• DTI TCS / Faraday Schemes• NATO Scientific Program• HEFCE• SHEFC
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Thank You!
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