タマチ工業(株)は戦前の自動車メーカー(オオタ号)をルーツとし、主力の自動車レース用パーツ生産をはじめ、産学のネットワークを駆使して医療、航空機、ロボット分野まで幅広く手がける。特に高性能カムシャフトは少量多品種生産では価格、品質、納期において海外も含め他社を寄せ付けない強みを持つ.強い生産システム構築のため、独自な会社理念と管理体系、情報転写、社員教育を重視し、常に人的な現場力を強化している。地域との連携も重視し、子供見守りや文化活動へも積極的に関与している。

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現在、民間航空機の市況は活況を示しており、今後も順調な伸びが期待されている。その一方、大きな開発リスクや投資負担、コスト低減やサプライ・チェーンの問題をかかえている。民間航空エンジンにおいて、最近のマーケット、エンジンの構造、技術開発の動向や量産開発での問題を概説する。

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This paper deals with two processes for constructing the mathematical models based on measurement data. The first process is to recognize surfaces composing a physical model by curvature on measured points or variance of coordinate values of measured points. The second process is to approximately define NURBS surfaces by the minimum square method to average positional errors. In this study, primitive and complex shapes are used as evaluation model. The results of constructing surfaces show usefulness of the system based on the proposed methods.

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We propose the method that detects Euclidean symmetries from scanned meshes of mechanical objects based on a combination of ICP and Region Growing algorithms. Our method can robustly detect Euclidean symmetries, including translation, rotation, and planar reflection, from noisy scanned meshes. Our method also can detect maximally large symmetries under the user specified tolerances from scanned meshes that contain many planar regions. The effectiveness of the method is verified by using various scanned meshes of mechanical objects.

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This paper suggests a design method that aggregates product information and its facility information into an integration model to develop assembly machines. The effective design workflow based on the model is proposed and the try and error design process by 3D simulation is considered from the view point of control design. To evaluate the model, a prototype system for an assembly machine in a flexible manufacturing system was built using a 3D simulation tool to verify the concept of the method and the integration model.

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A large amount of mechatoronic equipments for the material handling of vegetables and fruits have been introduced into the agriculture and the food manufactures in Hokkaido. However, the individual differences among the size, shape, and the mass of these products of are very large, and the verification of the mechanisms and the control systems is still verified in the try-and-error way using physical prototypes. This makes the development of the equipments time-consuming and expensive. In this research, a virtual prototyping tool was developed intended for the design of "automatic potato grader". First, 3D grader mechanism model with 3D "potato geometry model" was built, and the operation of the grader part was simulated in cooperation with the control program mounted on the real PLC.

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A manufacturing system often has various descriptions of its past records, present states, and future plans along with time axis. In addition to these variations, models on its virtual system are made as well as real system. We need a conceptual scheme with which various descriptions on a manufacturing system could be integrated and managed consistently. In this paper a complex manufacturing space (CMS) is examined from the viewpoint of real-virtual duality in model description and implementation issues are briefly explained.

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With diverse needs of customers, high-mix low-volume products are manufactured more and more. Man-hour required for preparation of such production is increasing accordingly. Design data are electronically processed; however, those data are not effectively applied to actual production. In this project, we developed a database which centrally controls production data such as production process data and a system which automatically creates required NC (Numeric Control) program from CAD (Computer Aided Design) and BOM (Bill of Materials) data in order to significantly reduce man-hour required for production preparation.

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Recently, because markets of MEMS develop rapidly, it is expected to increase occasions of MEMS device design. However, it is difficult for designers unlearned in MEMS fabrication process to judge whether the device can be fabricated or not. In our study, we developed a process planning system for MEMS device using 3D geometric model based on block segmentation, which derives all fabrication sequences and their recipes.

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Through the CAE support comparison to the production engineering department with to the company-wide engineering department, I explain how CAE support to the production engineering department should be. As one of the realizing method, I introduce the technology development by "The hypothesis & verification method" utilized FAO(First Order Analysis) and CAE Knowledge Data-base.

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This paper presents efficient scheduling methods using the mixture of genetic algorithm and priority rule in larger scale job shop scheduling environments. In order to restrict the search space effectively, two methods are examined. First, the genetic algorithm is applied to a certain length of shifts in the whole schedule. Second, the schedule is sequentially fixed from the earlier shifts. These two methods can be applied simultaneously. Numerical experiments are used to examine the effectiveness of the methods.

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It is important for executing the manufacturing processes efficiently to create a suitable production schedule. However, the unscheduled changes such as the operational delay or addition of emergent jobs often occur in the actual manufacturing systems. Therefore, it is difficult to execute manufacturing processes in accordance with the predetermined schedule. In the previous research, Genetic Algorithm based reactive scheduling method have been proposed. It deals with the short-term schedule. In this research, the reactive scheduling method is extended for aggregate production schedule by setting the suitable scheduling range.

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A predetermined production schedule may be often disturbed, due to unscheduled disruptions, such as delays of manufacturing operations and failures in manufacturing equipment. A genetic algorithm based reactive scheduling method was proposed in the previous research, in order to modify and improve a disturbed initial production schedule without suspending the progress of manufacturing process. This paper deals with a new reactive scheduling method, which changes both loading sequences of jobs on each resource and machining sequences of each job simultaneously by using a co-evolutionary genetic algorithm. A prototype of integrated reactive scheduling system was developed to evaluate the effectiveness of the proposed method through some computational experiments.

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Reactive scheduling is one of the solutions for scheduling in huge and complex manufacturing systems. However, it is excessive reaction to rescheduling whenever the delay occures. It is neessary to discuss when-to-reschedule problem in reactive scheduling. This study suggests a new when-to schedule policy by using delay information propagation based on multi agent system.The proposed approach gives more accurate estimation by future prospects of all the agents.The effectiveness of the proposed method is confirmed by preliminary computer simulation results.

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The preplanned project schedule in project management undergoes various kinds of contingency such as activity delay and lack of resources. Under such a dynamic environment, the reactive scheduling strategy will be effective to cope with uncertainties to keep the schedule quality. This paper deals with the reactive scheduling strategy for resource constrained project scheduling problem, and investigates the typical reactive approaches from the viewpoint of when-to-schedule and incremental costs for resources.

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Recently, new distributed architectures of manufacturing systems are proposed, aiming at realizing more flexible control structures of the manufacturing systems. However, the human operators have not yet been discussed for the autonomous components of the distributed manufacturing systems. A real-time scheduling method is proposed, in this research, to select suitable combinations of the human operators, the resources and the jobs for the manufacturing processes. The proposed scheduling method consists of following three steps. In the first step, the human operators select their favorite manufacturing processes which they will carry out in the next time period, based on their preferences. In the second step, the machine tools and the jobs select suitable combinations for the next machining processes. In the third step, the automated guided vehicles and the jobs select suitable combinations for the next transportation processes.

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This paper deals with a scheduling method of manual work in consideration of On-the-Job Training (OJT). As of skillful works such as maintenance works of trains and airplanes, workers have to learn many kinds of works with OJT. While processing time of novice workers is longer than that of experts, the time will be reduced with repeating OJT. Therefore, OJT is important to keep skill level and long-term work efficiency of the organization. It is very difficult to balance between working efficiency and OJT. In this paper, the authors propose to optimize the work dispatching rule by using genetic algorithm(GA) in order to achieve a balance between the two factors.

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This research proposes a dynamic task reallocation method for cellular manufacturing systems. When unforeseen changes, such as delays of assembly processes, occur in the manufacturing systems, the predetermined initial task allocation is dynamically modified, in order to minimize the total tardiness of products. All the tasks are reallocated to the individual workers real-timely by using genetic algorithm, and the execution sequences of the reallocated tasks are determined by using a heuristic rule, called as EDD. A learning curve effect is considered in this research in generation of a suitable production schedule. A prototype of reallocation supporting system is developed based on the proposed method, and the effectiveness of the proposed method is verified through some computational experiments.

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The proportion of the aged in the total population of Japan has increased to a level unprecedented anywhere else in the world. If this proportion continues to increase, markets related to illness prevention and improvement of the quality of medical services will further enlarge. However, Japan has an unfavorable balance of trade in medical equipment or devices. Large Japanese companies hesitate to enter the medical device industry. This paper goes on to investigate the process of the expansion of the American medical industry. It was concluded that the propensity of risk in the U.S.A. and Japan is different. A system called IDE, Investigational Device Exemption, indicates that the US medical industries are in a stronger position than their Japanese counterparts.

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Technology transfer occurring between countries, also known as Horizontal Technology Transfer, has been a widely undertaken activity, serving both the advanced and developing country symbiotically to better position themselves in world business. However, the problem with horizontal technology transfer is still the lack of scientific methodology by which to conduct it. The objective of this research is to propose the Two-Factor Continuum Model to simplify the unveiling of problems or risks during Horizontal Technology Transfer. The Two-Factor Continuum model crosses the resource base of the risk (i.e., human or facilities) and existence of the risk based on the level of integration of the technology. To preliminarily test the usability of the Two-Factor Continuum model being proposed, this research uses the problems identified during actual technology transfers conducted between Japan and the Philippines. This research concludes that the Two-Factor Continuum model shows distinct risks based on the different combinations of conditions represented by the continuum.

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Development of steel industry highly depends on industries which use steel as their input. In Japan and Korea, their automobile industries, which consume large amount of high value-added steel, have made considerable contributions to the growth and grade-up of the steel industries. However Taiwan has been lacking in a competitive auto industry. How can Taiwan's steel industry sustain to develop? My research discovered China Steel Corporation (CSC), the sole integrated steel maker in Taiwan, is expecting some sub-sectors in fabricated metal product and machinery industries such as bolt and nut, hand tools and auto parts for aftermarket to substitute the automobile industry. More important finding of my research is that CSC realized that it needed to change the relationship with its customers in order for them to use higher value-added steel. CSC now support its users' R&D by organizing alliance and sharing knowledge with them.

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In this study, we discuss required conditions for organizing valuable structures of a company or a group of cooperated companies which is a new concept about regional industrial concentration named the Virtual Concentration of Production Bases. Until today, most of researchers focused on the Real Concentration of Production Bases in these domains. However this conventional concept cannot be applied to complex environment of industrial companies in the next generation. Contrary, the virtual concentration of production bases is realized by overcoming long geometrical distances and time differences among production bases, and creates bigger values of products. For this purpose, we consider the organizing the virtual concentration of production bases as a way of optimization strategy of manufacturing industry, and define an objective function represents the degree of virtual concentration. Based on the results of computer simulations and case studies of real companies, the usefulness of this approach is verified.

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At the spot of the production of a thing, in order to perform a make lump of better quality continuously, the next generation (technical acceptance person) is asked for handing down technology, and maintaining and raising technical capabilities. However, many engineers retirement problem, and automation and laborsaving of production progressed so that a problem may see in the 2007 fiscal year, and the problem of technical tradition is discovered from potentiality of manufacturing technique know-how etc. On the other hand, as for the method of coping with these problems, neither rationality nor consistency is accepted in a focus or a route on the spot in many cases. Based on such the actual condition, it can progress with the technical tradition which heightens manufacturing technique power, and the view of sharing, and a direction is examined based on a case of the operation.

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In today's product manufacturing industry, for maintaining a high-quality design, it becomes important to not only reuse past design results, but also share and utilize information about design intention. Research within the CAD industry supports the value of retaining the design information and intention. We focused on retaining the temporary expressions of design intention, and developed a system that is able to exchange and share such information easily. This is a report about the application of this system to an actual product design and manufacturing processes.

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This paper captures an assembly task as a process of transforming an initial contact state concept into that having only the goal state, where a contact state concept is the set of the possible contact states. When choosing a task element to be applied to a contact state concept, the operator has several options. The branch occurs at this point is named the decision branch. In addition, the operator can distinguish the transformed contact state concept into several types according to what she/he has sensed. The branch occurs at this point is called the observation branch. Thus, the whole strategy for a manual assembly task can be expressed with a tree having these branches, which is named the task sequence tree. The paper next discusses how to obtain a simple task sequence tree for a task a priori. Experiments confirm that teaching a simple task sequence tree of a task improves the efficiency of the task and also of further learning.

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The system (ROBO-BLOCK) where students can assemble robots like the blocks was developed. We use this for the education tools of the industrial robots. The order of the joint angle can be given using the PC. And the robots were moved, and they can be directed, too. The examples of the calculation of the inverse kinematics were shown by using the SCARA robot.

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工業製品の形状は多様化、複雑化し、自由曲面の利用が増えているが、自由曲面に関する情報はデータ量が膨大であり、実際の切削加工にそのまま利用することは難しい。そこで、本研究では、ポリゴンメッシュで三次元形状を表現した製品モデルを効率よく加工することを目標として、CG画像簡略化技術を応用し、加工工程を考慮した粗加工モデルを生成するアルゴリズムを提案し、その有用性について検討した。

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Freeform surfaces are machined in many different methods. In this research, Z-level finishing machining tool path generation method is studied. The machining strategy by separating the freeform surface into horizontal area and vertical area by the maximum slope angle of the surface inclination create best possible surface finishing. Four different tool motion patterns: zigzag, offset, spiral, and morphing are compared in terms of machining time, rapid machining length, and feed machining time. Tool path generation pattern setting can machine the complex surface in an efficient way with good quality.

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近年,機械の設計や製造において,CADICAMの進展は著しいものがあるが,未だCADICAMによる加工の完全自動化は実現されていない.工具の選択や加工条件の決定は,熟練技能者の経験と勘にゆだねられているといっても過言ではない.そこで本研究では,品質工学の手法(パラメータ設計法)と切削シミュレーションを組み合わせて,NCデータの最適化を行い,加工品質と生産性を同時に満足する方法を提案する.これにより,経験の乏しい技能者も加工に関する知見やノウハウを短期間で得られることが期待できる.

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NC data analysis is one of the efficient methods for acquisition and retaining the machining knowledge. However, code interpretation of actual NC data (ISO 6983) differs among CNC controllers. Typical examples of interpretation difference are fixed cycle orders which are significant for the machining of hole feature. Thus, it is difficult to analyze actual NC data directly. In this research, for obtaining the machining knowledge, actual ISO 6983 NC data is transformed into a next-generation CNC control language (IS014649) which contains the technical information. In this report, the method for extracting Workingstep which consists of Machining feature, Machining strategy from NC code depending on the controller based on Form-shaping function is described.

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For the machining of elastomers, the mold tool is usually employed. However, fabrication of the mold tool is expensive and time-consuming process. So, the method is unsuitable for small lot production. Elastomer machining by endmilling can be an effective approach because of its flexibility. The objective of the research is to realize a high-precision elastomer machining in small lot production. At the milling of elastomer, it is very important to control the deformation of to workpiece. Dedicated supporttools for each machining step can help to control the deformation. Rapid prototyping technology enablesto realize the fabrication of dedicated support tools. Experimental results of elastomer machining are described in this paper. The results show the proposed method is a promising approach.

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It is necessary for keeping high productivity to adjust demands with changes of production capacity in the Demand Synchronized Production system. This paper includes a considering of the way to loading to the system according actual orders. Firstly, a conceptual relation about equipments of the Demand Synchronized Production system is assumed. Secondly, two workload leveling that Kuring and Rolling are named are compared. Finally, the usage of these leveling methods is summarized.

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Installation of a production control system to a factory is a long lasting project requiring a lot of time and labor. After the decision which system is to be installed is made and the basic software system is developed, the confirmation of the completeness and the correctness of various files and the proper setting of parameters for effective operation are pursued in the real operation. In this study, we propose to develop a distributed virtual factory as a platform to test the newly installed system at various aspects in the installation stages substituting a real factory. The paper discusses the effectiveness of such a platform by developing a virtual factory installed with a commercial MRP system.

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There is a great deal of external fluctuation such as order change or delayed delivery of materials and uncertain component such as machine trouble and process delay in the real shop floor. It is difficult to process production according to the schedule established in advance. Therefore, a new production management technique which considers both external fluctuation and uncertain component exist in the real shop floor is strongly demanded. In this paper, a real-virtual interaction method for production management is proposed, which the model plant exists in real space and the computer simulation exists in virtual space interact with each other, and consider both dynamic external fluctuation and uncertain component adaptability and effectly. The effectiveness of the real-virtual interaction method is verified by computer experiments.

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For realization of the next generation thin-film pattern formation technology by the lift-off method, the inversely-tapered resist profile with interstice has been proposed, and its fundamental effectiveness was shown. Furthermore, a method was given, for calculation of thickness distribution of the film pattern formed with the proposed resist profile, and a design method of the proposed resist profile based on the calculation method was also suggested. However, in these methods, there are some problems in identification of process parameters and definition of proper resist profile. This paper proposes a systematic method for identification of the parameters and a design method of proper resist profile.

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With the higher density of semiconductor devices, the yield prediction simulations such as the CAA (Critical Area Analysis) generally have to take a few days. Therefore, faster calculation is needed to reduce the elapsed time of the prediction. This study aims to propose a management structure of the design layout data which enable the elapsed time of CAA simulation to be considerably faster than the current one while still keeping the simulation accuracy unchanged. A management structure of the layout data using the range tree and interval tree and a prediction method of the query range size were developed to make the 2-dimensional range query in the CAA faster. The CAA calculation which is 10 times to 500 times faster than the current one was achieved.

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Recently demand for 5-axis machine tools rises by the need of the complexity of the machining shape and the machining process integration. Furthermore, 5-axis machine tools come to be used for machining the dies, molds or the high-accuracy parts. As a result, further high-speed and high-accuracy control is requested for NC controller for 5-axis machine tools. In this study, the new NC control method for 5-axis machining is proposed. The proposed method is aimed at the smooth posture change of cutting tools by filtering to the angle change of rotary axis. The effectiveness of the proposed method was confirmed by the cutting test.

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We developed a method for in-situ monitoring of silicon thickness during wet chemical eching. The principle of the measuring is near infrared optical intereference caused by the reflection at both surface of the silicon diaphragm. Wide wave length variable Laser makes it possible to monitor absolute thickness of rough surfaced silicon. Using this system, we could automate etching process and increase productivity of micro electro mechanical sensors.

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生産現場の情報の活用範囲が生産業務に直接関係のない業務へも広がっている.これらの業務には、現場情報を業務の目的に合うよう活用するために、生産現場と情報系システムを有機的に結合したシステム化が望まれる.我々は、このようなシステム化への対応に、業務を熟知している業務担当者自身によるアプリケーション構築が有効であると考えている.本論文では、機能ブロック型アプリケーションモデルを元にした、業務担当者によるアプリケーション構築のコンセプトを提案する.

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Conventional collision prevention systems for machine tools are based on simulation methods using 3-D models of materials and jigs which are made in advance. Then, if settings of materials and jigs in the factory are different from the simulation models, collision accidents can not be avoided. Moreover, most collision prevention systems use open NC controllers. Then, these systems can not adapt to usual type NC controllers. Therefore, a collision prevention system for machine tools based on standard technologies is proposed. The system uses materials and jigs measurement data which is gathered using 3-D laser scanner while executing a NC program. This paper describes a concept of the system and development of a prototype system for usual type NC controllers.

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Closed-loop manufacturing systems (CLMS), where products are made from used products, reused parts and materials from market, as well as new ones, has gained researchers' interest in recent years due to growing concern about environmental problems. In order to operate and control CLMS effectively, quick and adequate matching of demand and supply of recovered materials is indispensable. This paper proposes a multi agent algorithm for matching supply and demand of recovered components considering various fluctuations in user preference and physical conditions of recovered components. Effectiveness and feasibility of our method are demonstrated by a simplified simulation of CLMS for laptop computers.

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To cope with the growing environmental problems, it is necessary to close the manufacturing system in terms of reduce, reuse and recycling. For this purpose, life cycle options should be adequately selected at the beginning of life phase. In the case of long-life products, however, these life cycle options should be reexamined at the end of life phase because of various changes during the life cycle, such as demand for reused parts and market price of recycled material. In this study, we propose a support system for selecting optimal life cycle options taking both environmental and economical aspects into account. The effectiveness of the system is verified by applying it to automobile parts.

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This paper performs a simulation based on an optimization technique for a reconfigurable manufacturing system (RMS), and realizes the optimal system design. The RMS is the system that we can change configuration of parts and mechanical structure in short time due to correspond a sudden market change and various manufacturing demands, etc. Recently, simulators are often utilized to regulate design factors in manufacturing systems. But, in modem complex systems, it is hard for designers to decide them with trial and errors. Therefore, the simulator that uses the optimization algorithm is requested to be made. This research performs the simulation using a genetic algorithm to the complicated production system RMS. In addition, from the simulation result, the optimal solution of each parameter is calculated and the optimal performance is evaluated.

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In this paper, product parts and machine agents are proposed for the construction of an autonomous flexible assembly system. The main part's agent takes the initiative in this system. When a new main part is put on to the production line, the main part's agent is dynamically generated with the product model. The main part's agent plans the assembling process by itself and selects assembly machines that execute the assembly operations by communicating with assembly machine agents. The parts agents are deleted when a product is completed. The assembly machine agent has a machine model of itself and can determine which operations can be processed by the machine itself, The product model and machine model are described using XML. Trial implementation of main part agents, sub parts agents and assembly machine agents were done and assembly production simulation will be reported in this paper.

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