The objective of this book is to support readers facing the urgency, challenges, analysis, and methodologies to reconfiguration. It presents a comprehensive framework for reconfiguring manufacturing enterprises and provides a set of valuable conceptual frameworks and methodologies for analyzing, evaluating, and assessing reconfiguration indices.
This book offers practical guidance for implementing the Fourth Industrial Revolution (Industry 4.0). It presents open-ended problems pertaining to the concepts covered in the book and provides a new approach for reconfiguring industrial systems.
Not only is this book for industrialists and academics, it will also appeal to undergraduate and graduate students studying industrial, mechanical, and manufacturing engineering. Scholars and practitioners in operations management will also find this book of interest.
Author(s): Ibrahim H. Garbie, Hamid Parsaei
Series: Manufacturing and Production Engineering
Publisher: CRC Press
Year: 2021
Language: English
Pages: 204
City: Boca Raton
Cover
Half Title
Series Page
Title Page
Copyright Page
Table of Contents
Preface
Authors
PART I: Introduction to Reconfiguration for Industry 4.0
Chapter 1 Introduction
1.1 Background
1.2 Manufacturing Systems
1.3 Industrial Revolutions
1.4 Reconfiguration of Manufacturing Systems
1.5 Concluding Remarks and Book Outline
References
PART II: Urgency to Reconfiguration
Chapter 2 Forecasting Demand and Mass Customization
2.1 Forecasting and Predictive Demand
2.2 Mass Customization
2.3 Reconfigurable Assessment for Forecasting Demand and Mass Customization
2.4 Concluding Remarks
References
Chapter 3 Innovation and Business Models
3.1 Innovation and Product Design
3.1.1 General Concepts of Innovation and Product Design
3.1.2 Reconfigurable Assessment for PDD
3.2 Business Models
3.2.1 Understanding Urgency of Business Models
3.2.2 Reconfigurable Assessment for BMs
3.3 Concluding Remarks
References
Chapter 4 Why Industry 4.0?
4.1 Introduction and Background
4.2 Why Industry 4.0 Is Important?
4.3 Definition of Industry 4.0
4.4 Principles and Technologies of Industry 4.0
4.4.1 Principles of Designing Industry 4.0
4.4.2 Technological Requirements for Industry 4.0
4.5 Smart Factories/Plants
4.6 Reconfigurable Assessment of Design Principles for Industry 4.0
4.7 Concluding Remarks
References
PART III: Challenges of Reconfiguration
Chapter 5 Manufacturing Complexity
5.1 Introduction and Background
5.1.1 Introduction
5.1.2 Complexity Measures
5.1.3 Structural (Static) Complexity Assessment
5.1.4 Dynamic (Operational) Complexity Assessment
5.2 Determining the Reconfigurable Level of Manufacturing Complexity
5.2.1 Manufacturing Enterprises’ Vision Complexity
5.2.2 Manufacturing Enterprises’ Design Complexity
5.2.3 Manufacturing Enterprises’ Operating Complexity
5.2.4 Manufacturing Enterprises’ Evaluating Complexity
5.3 Concluding Remarks
References
Chapter 6 Reconfigurable Machines
6.1 Introduction
6.2 Types of Reconfiguration
6.3 Characteristics of Reconfiguration
6.3.1 Hardware Characteristics
6.3.2 Software Characteristics
6.3.3 Requirements and Challenges of RMTs
6.4 Reconfigurable Index for RMTs
6.5 Concluding Remarks
References
Chapter 7 Lean-Agile 4.0
7.1 Lean Manufacturing
7.1.1 Types of Wastes
7.1.2 LM Techniques
7.1.3 Linking between Lean Manufacturing 4.0 and Industry 4.0
7.2 Agile Manufacturing 4.0
7.2.1 Manufacturing Agility
7.2.2 Manufacturing Agility 4.0
7.3 Reconfigurable Level of Manufacturing Philosophies
7.3.1 Assessing Manufacturing Leanness
7.3.2 Assessing Manufacturing Agility
7.3.3 Methodology for Measuring Leanness, Agility, and Le-Agility
7.4 Concluding Remarks
References
Chapter 8 Advanced Manufacturing Technologies
8.1 Industrial Internet of Things (IIoT) and Cyber-Physical Production System (CPPS)
8.2 Big Data Analytics
8.3 Digitalization
8.4 Cloud Computing
8.5 Cybersecurity
8.6 Virtual Reality and Augmented Reality
8.7 Additive Manufacturing
8.8 Reconfigurable Assessment of Advanced Manufacturing Technologies
8.9 Concluding Remarks
References
Chapter 9 Designing Manufacturing Systems
9.1 Introduction
9.2 Design Issues
9.2.1 Manufacturing or Processing (Operation) Time
9.2.2 Machine Capacity (Reliability)
9.2.3 Machine Capability (Flexibility)
9.2.4 Demand (Volume) Variability
9.2.5 Introducing a New Product
9.3 Designing Methodology
9.3.1 Phase 1: Collecting the Existing Data from Job Shop Manufacturing Systems
9.3.2 Phase 2: Grouping Parts to Part Families
9.3.3 Phase 3: Assigning Machines to Machine Cells
9.3.4 Phase 4: Formation of Manufacturing Cells
9.3.5 Phase 5: Performance Evaluation
9.3.5.1 Productivity Measures
9.3.5.2 Flexibility Measures
9.4 Case Study and Implementation
9.4.1 Analysis of Machines Information
9.4.2 Products (Parts) Information Analysis
9.4.3 Analysis of Machines-Parts Information
9.4.4 Application of Reconfiguration Methodology
9.5 Reconfigurable Level of Manufacturing System for Industry 4.0
9.6 Concluding Remarks
References
Chapter 10 Implementation of Industry 4.0
10.1 Introduction and Background
10.2 General Concept of Implementation
10.2.1 Horizontal Integration
10.2.2 Vertical Integration
10.2.3 End-to-End Integration
10.3 Technical Challenges of Implementation
10.4 Risks, Critical Success Factors, and Opportunities
10.4.1 Risks
10.4.2 Critical Success Factors
10.4.3 Opportunities
10.5 Enablers of Implementation
10.6 Reconfigurable Assessment for Implementing Industry 4.0
10.7 Concluding Remarks
References
PART IV: Analysis for Reconfiguration
Chapter 11 A Roadmap for Reconfiguration
11.1 Introduction
11.2 A Framework of Roadmap
11.2.1 Conceptual Model of Roadmap
11.2.2 Mathematical Model to Assess the Roadmap
11.3 Analysis and Implementation of the Roadmap
11.3.1 Product Design and Development
11.3.2 Designing a Hybrid Manufacturing System
11.3.3 Estimating the Level of Advanced Manufacturing Technologies for Industry 4.0
11.3.4 Estimating the Manufacturing Complexity Levels
11.3.5 Manufacturing Strategies and Philosophies
11.3.6 Management for Change
11.3.7 Performance Evaluation and Appraisal
11.4 Concluding Remarks
References
Chapter 12 Reconfiguration Level
12.1 Introduction and Background
12.2 Issues for Reconfiguration
12.3 Analysis of Reconfiguration Processes
12.4 Concluding Remarks
References
PART V: Reconfiguration Methodology
Chapter 13 Reconfiguration Process
13.1 Introduction and Background
13.2 A Methodology for the Reconfiguration Process
13.2.1 Phase I: Estimation of the Needed Reconfigurable Level (Configurability Index)
13.2.2 Phase II: Hybrid Manufacturing System
13.2.3 Phase III: Plant Layout System (PLS)
13.2.4 Phase IV: Material Handling Systems (MHS)
13.3 Concluding Remarks
References
Chapter 14 Performance Measurement
14.1 Introduction
14.2 A New Performance Measure
14.2.1 Product Cost (C)
14.2.2 Manufacturing Response (R)
14.2.3 System Productivity (SP)
14.2.4 People Behavior (PB)
14.2.5 Work-in-Progress (WIP)
14.2.6 Product Quality (PQ)
14.3 An Illustrative Numerical Example
14.3.1 Case 1: Effect of Changing Forecasting Demand Only
14.3.2 Case 2: Effect of Changing Forecasting Demand and Product Design
14.3.3 Effect of Changing Market Demand Only (Case 1)
14.3.3.1 Cost (C)
14.3.3.2 Response (R)
14.3.3.3 System Productivity (SP)
14.3.3.4 People Behavior (PB)
14.3.3.5 Work-in-Progress (WIP)
14.3.3.6 Product Quality (FP)
14.3.4 Effect of Changing Market Demand and Product Design (Case 2)
14.3.4.1 Cost (C)
14.3.4.2 Response (R)
14.3.4.3 System Productivity (SP)
14.3.4.4 People Behavior (PB)
14.3.4.5 Work-in-Progress (WIP)
14.3.4.6 Product Quality (FP)
14.4 Concluding Remarks
References
PART VI: Future for Smart Manufacturing Enterprises
Chapter 15 Designing Manufacturing Enterprises for Industry 4.0
15.1 A Conceptual Framework of DMSFR_I4.0
15.2 Analysis of Reconfiguration
15.3 Concluding Remarks
References
Index
