In the coming Industrie 4.0 age, managemt such as business model and business system is required rather than just factroy systems to be built. This study suggested perspective combined Hardware with Software architecure is useful to make "make or buy" and "open and close" strategy. By comparative analysis of present German and Japanse FA system makers' businesses, it is considered how Japanese manufacturing companies will establish competitive advantages for the future.

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神戸の代表的な地域産業であるラバー製品のテーラーメイド化を目指し,ラバー製スポーツシューズを対象に,現在,内閣府戦略的イノベーション創造プログラム(SIP)において革新的設計・生産に関する研究開発を進めている.ここでは,その概要と基本的な考え方を紹介するとともに,IoT環境下におけるユーザとメーカの持続的インタラクション,および工場を構成する自律機械間の合理的交渉による「考える工場」の実現に向けた取り組みについて説明を行う.ここで提案する考え方は,アジャイル生産によるプロデューザイノベーションと,デライト設計によるユーザイノベーションの双方を同時に実現することを目指しており,これからの展開が期待される.

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This paper discusses the advantages of manufacturing facility simulation linked with physical systems in the industrial automation. The activities on manufacturing preparation and implementation processes of manufacturing systems have been improved using real and virtual manufacturing models. The standard reference model of enterprise and control integration is described and simulation layers in the hierarchy model are defined. The manufacturing facility simulation is linked with both physical controllers and their simulators by standard communication middleware connecting various communication protocols of the controllers and fieldbus. The applied case studies of improved processes and their advantages are explained.

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TokushimaU-UTeM Academic Center (TMAC) has been successfully established in 2014 to promote the joint collaboration between the two institutions in terms of both education and research. One of the critical factors of this success was a good relationship between the two institutions based on the academic collaboration with alumni network in the past one decade. Presenting the overview of TMAC with its history and some of the critical on-going activities, this paper shows the feasibility of manufacturing system globalization through academic collaboration, and emphasized the importance of global engineer education.

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A380 was reported on missing target in new production and leads to delayed market entry due to their weak product life cycle management (PLM). PLM is a strategic approach in the product development process. As a computer environment has evolved, the PLM also takes the change to be evolved. Accelerating the time in production process become important nowadays in order to capture the market demand and trend. In order to achieve the better glance, footwear manufacturing is taken to be discussed details. Accelerating time in the product development process and global information are two of the benefits of PLM in the cloud environment.

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Due to the heterogeneous and anisotropy composition of the CFRP composite materials, trimming procedures can damage the material in ways that directly affect its mechanical properties. Currently a costly try and error approach is employed, to determine the optimal process conditions. To overcome the traditional approach, a numerical modelling of trimming CFRP composites using cross-nick cutter is proposed to simulate the process. A set of machining tests were performed in order to validate the accuracy of the model. Good agreement between simulation and experimental result shows the validity of the model in handling real-field problems.

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A study on the relationship between wire electrical discharge machine (WEDM) parameters and surface finish are presented. This study analyzed the relationship between cutting parameter as variable input and surface roughness as output. To optimize the surface roughness which was measured both in horizontal and vertical direction, a Box Behnken of response surface methodology (RSM) with three process parameters; voltage, current and feed rate are used. Analysis of variance (ANOVA) was used to study the identified parameters that affecting the machined surface finish. With the results of P-Value and F-Value, machining voltage is known as the most contributing factor, followed by current and feed rate. The direction of measurement was found to be less significant. The linear prediction models were developed with average error of 3.67% and 1.74% horizontal and vertical surfaced roughness measurement direction respectively. The result of the validation also shows a good agreement with predicted values. It is beneficial as to assist machinist in improving the quality of the WEDM surface.

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Customer demand is often crucial in manufacturing industry. There was research conducted to relate customer demand with safety stocks and lot sizes whereas others had included customer demand in Overall equipment effectiveness (OEE) with some assumptions on the characteristics of customer demand. This research proposes the procedure to observe the impact of different customer demand in affecting equipment utilization. Simulation is used to mimic different customer arrival distributions to production line and their corresponding impact on capacity and relationship between effectiveness are both examined. The research outcome is expected to provide new insight on the production planning and capacity expenditure in future.

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Job Shop Scheduling (JSP) is widely applied in Industry especially for supply chain scheduling.Since JSP is a typical NP-Hard problem, a lot of researchers from various research disciplines,use algorithms to try to get the minimization of makespan(The time between the start and finish of a sequence of Jobs).However,the last makespan varies from each other due to different in travelling time from machine to machine. This paper shows how to determine the machine layout,and finally test the effectiveness of proposals by using a simulation model.

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不確定需要下における多段階配送システムにおいて,段階の拠点間で移動時間が存在する場合では,需要の変動に対して前もって評価し,配送センターの在庫量をコントロールする仕組みが有効である.配送問題では通常,配送コストの削減が問題とされることから,需要の変動と拠点間の配送コストを同時評価することで拠点間の配送量を決定する方法を検討する必要がある.本研究では,工場から販売店へ直接的な配送量を評価する「仮想配送」モデルを導入し,実配送の数理モデルと組み合わせることで,配送コストと欠品を削減する方法を提案する.発表では,多品目の製品供給について,モデルの適用例を報告する.

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Petri net can represent discrete event systems graphically and mathematically. For the purpose of analysis of 0-1 integer programming problems, we propose the convertion algorithm for 0-1 integer programming problems into an optimal firing sequence problem of Petri net. We compare the solution of 0-1 integer programming problems with that of the optimal firing sequence problem of Petri net. The results show that the solutions for both problems are the same for a variety of instances. Moreover, we propose the algorithm to extract decomposable structure of Petri net into two subnets. The performance of the decomposition is evaluated in order to extract effective decomposable structure. The validity of this algorithm is shown by using Petri net decomposition algorithm.

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近年,東北大震災やタイの洪水などの大規模災害の発生により,サプライチェーンのリスク管理の必要性が高まっている.しかしサプライチェーン全体の長期的な便益とリスクに対する対応策はトレードオフの関係にあり,企業としては発生確率の低い途絶イベントに対し,高い費用をかけて対応策をとることは正当化が困難である.したがってサプライチェーン全体の脆弱性やリスクを定量的に判断する手法や基準が必要である.従来研究においては,予防と復旧の観点から,予備在庫を持つことによるサプライチェーンのリスクの抑制が論じられているが,それでも自動車業界はリーンやJITに代表される少量在庫,関係性強化の方針をとり続けている.これら背景には長期的な便益を優先していることに加えて,インタビューを通じ,少量在庫が復旧活動において,対応効率に優れているという考えを持っていることがわかった.したがって本研究では,予防と復旧の両面を考慮した評価モデルを作成し,任意の条件下における最適な在庫量を求めることで,予備在庫を持つことが途絶に対して有効である条件を明らかにした.

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農業分野では作物の生育期間や刈取量はばらつきが大きく,需要量と供給量に差が生じやすい.そのため農場(圃場)の作物が出荷基準を超え出荷不適合になり廃棄となる優良ロスおよび欠品が発生するという課題がある.本研究では農業生産システムにおける欠品および優良ロスについて定量的に評価するためのモデル化とシミュレーションの手法の開発を行う.圃場の状態遷移モデルを提案し,シミュレーションへの実装法を提案する.ケーススタディを実施し,提案する手法の有効性を評価する.

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大量のエネルギを消費する工場における消費電力の管理は早急の課題であり,生産性を一定水準に保ちながらも,消費エネルギの削減を実現することが望まれている.これまで,工場・ラインにおける生産性と消費エネルギ量の評価のためのシミュレーション手法の提案,および構築をしてきた.本研究では,各種生産条件が生産性とエネルギ消費に及ぼす影響について検討するため,シミュレーション,定式化を行い,生産性とエネルギ消費の関係性について検討を行った.

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産業界において,生産活動における消費エネルギ量の定量的な評価と削減,および,消費エネルギ量を考慮する工場管理が必要となっている.これまでの研究では,工場・ラインレベルの生産性と消費エネルギ量の同時事前評価可能なシミュレーションを提案し,構築した.本報では,生産ラインにおける生産設備の故障を考慮するエネルギ原単位とロットサイズの関係性の理論的な定式化を行う.また,シミュレーションを用いて,その理論の妥当性について検証を行う.

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The Social Force Model introduced is to represent physical interactions and congestions among the people and the environment.The Social Force Model computes a force impact from the pedestrian's self-consciousness while the other two illustrate interaction forces from other pedestrians and the walls.The interation force consists of a pspchological force resulting from distance between each other,and a physical force inspired by counteracting body compression and sliding friction.The Social force model is applied to the autonomous distributed AGV in order to avoid the collision and achieve the effective transportation process, in this research. Simulation model is constructed based on the social force model by using multi method simulator AnyLogic.

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Recently, "Industrial Internet" and "Industry 4.0", which refer to the integration of physical industrial machinery with software, interne, along with network sensors, actuators, and other industrial components, are discussed intensively. These technologies provide decantation of manufacturing with cloud-based manufacturing system (CBMS). Since the CBMS enables cross sourcing between connected companies, utilization of manufacturing facilities in these companies. As a result, these companies can reduce production cost. We have developed new concept of CBMS which implements dynamical generation of common manufacturing-bill of materials (M-BOM) from engineering-bill of materials (E-BOM). Simulation study on the effectiveness of the CBMS is summarized.

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In sheet metal processing, reducing the waste of raw materials and managing the suitable production schedule are the important factors for the efficient manufacturing. In order to reduce the waste of sheet metal, the optimal cutting layout is determined by nesting. On the other hand, the manufacturing sequence for all manufacturing processes is decided through scheduling. Nesting and scheduling are affected with each other and there sometimes occur a certain trade-off between them. Therefore, those problems should be considered simultaneously in order to increase the efficiency of entire manufacturing activity. We have proposed the integrated method of nesting and scheduling. We adopted EDD based dispatching rule for scheduling in this method. In the manufacturing activity of sheet metal processing, bending process sometimes become bottleneck. In bending process, all parts are processed individually. On the other hand, in welding and assembling processes those are the post process of bending, some parts are combined and processed simultaneously. In order to create more suitable schedule, the combination of parts at welding and assembling processes should be considered when the operation sequence of bending process is determined. Therefore, in this study, we propose a local search method for improving the initial schedule that is created by using EDD dispatching rule. Finally, we verify the effectiveness of the proposed method through some computational experiments.

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Given a set I = {i|i=1,2, ... ,n} of current n items (for example, n green peppers) with their weights wi and priorities p_i, a lexicographic bi-criteria combinatorial food packing problem asks to find a subset I'(⊆I) so that the total weight Σ_<i∈I'>w_i is no less than a specified target amount t for each package, and it is minimized as the primary objective, and further the total priority Σ_<i∈I'>p_i is maximized as the second objective. The food packing problem has been known to be NP-hard, while it can be solved exactly in O(nt) time if all the input data are assumed to be integral. We have designed a heuristic algorithm such that for a given real ε>0, it delivers a feasible subset I' with the total weight at most (1+ε) times the optimum, and it runs in 0(n^2/ε) time. In this paper, we show a complementary property of an optimal solution in rounded instances to be solved by the heuristic algorithm.

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This study aims at developing a high-efficiency lot assignment method in semiconductor device manufacturing. In the multiproduct-production variable-quantity manufacturing, materials (production lot) flows through the product line disorderly. Then the production lots and equipment resources have multi factors, the combinatorial problem is complicated and difficult. Therefore we propose a model that leads an optimal solution for the situation. Throughout the study, we propose a lot assignment model that applies grouping structure and Combinatorial Auction method.

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セル生産においてOJT(On-the-Job Training)による技能訓練は熟練技能者への最適な手段だと言われている.筆者らはこれまで工程分割型のセル生産システムを対象として,スキルインデックスを使用したOJTによる技能訓練および熟練者から新人への技能伝承が期待できる人員配置のモデルを検討してきた.しかし,より効率的な技能向上を目指す際には,訓練が必要なタスクの作業を積極的に選択していく必要がある.そこで本研究では,人員配置と同時に最適な訓練量と作業手順を決定するモデルの提案を行う.

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This paper proposes a robust method for capacity requirements planning (CRP) that can generate a stable load plan against dynamic changes in manufacturing environment. The proposed method determines the processing periods of operation orders so as to minimize the probability that the resource requirement of each operation order exceeds the capacity of corresponding resource. In numerical experiments, the load plan generated by the proposed method is compared to those using the conventional method and the effectiveness of the proposed CRP method is demonstrated.

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近年の製造業では,大規模化やグローバル化により生産の形態が複雑化し,効果的な生産スケジューリングが求められている.一方,段取り替えやロット編成を有する生産ラインでは問題が複雑化し,厳密解の求解が困難となっている.そこで本研究では,段取り替えやロット編成の存在するフレキシブル・フローショップを対象とした生産スケジューリング問題を扱い,新たな機械割付アルゴリズムとラグランジュ分解・調整法によってスケジユールの立案を行い,その有効性の評価を行う.

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In this study, key decision for the creation of production plans are defined as production-planning attributes. Production-planning attributes correlate complexly in production-planning problems. Traditionally, the production-planning problem splits sub-problems based on experiences, because of the complexity. Such approaches make solution space over-restricted and make it difficult to find a better solution. We have proposed ZDDs' network for addressing larger production-planning problems. The network can be created by linkages of ZDDs that express constraints in individual sub-problems and between sub-problems. In this paper, we describe a solution searching method for the restricted solution space represented by the ZDDs' network.

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This paper describes an optimizing process scheduling on Flexible Manufacturing System (FMS). In the case that each work cell takes different processing times to complete the same process, process scheduling becomes a complicated problem. In this case, process scheduling using a calculator is effective. Process scheduling using a tree search is effective method to obtain an optimizing schedule. As problems become large, so searching answers become difficult. For this reason, method for choosing an option is important. We adopt the methods is based on a method for evaluating a complete schedule and verify the effectiveness of the method through some computational experiments.

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In our previous works, we proposed a multi-agent transport control system for a production system, which uses two types of information : path information obtained by communication with neighboring agents and pheromone information deposited on the tracks of products. In this paper, in order to improve the performance of the proposed method, we modify the update rule of path information, and also provide several type of information, deposited on the tracks of products, as candidates of pheromone information. Then, we estimate the effectiveness of the improved method embedded with one of the candidates information, through a simulation experiment.

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In order to realize the efficient manufacturing thorough intensive manufacturing processes, 5-axis machine tools attract a wide attention. New scheduling systems are proposed by using 3DCAM aimed at high production efficiency for 5-axis machine tools, in this research. The scheduling systems consist of 3axis and 5axis CNC machine tools, 3DCAD database, Customized 3DCAM corresponding to types of machine tools, and the jobs. The proposed scheduling systems carry out following 3 steps. The individual machine tools refer the 3DCAD database to obtain the 3DCAD data of jobs which can be carried out next machining process in the first step. 3DCAM creates the NC data and estimates processing time of all jobs in second step. The individual machine tools and jobs carry out the autonomous distributed scheduling process in order to minimize the make-span in third step.

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Process planning plays an important role of a bridge between product design and manufacturing. Computer-aided process planning (CAPP) has been a topic of discussion in this half century, and numerous researches have been performed. The recent diversification in customers' needs as been driving the development of agile manufacturing that can flexibly adapt to different manufacturing situations. CAPP should also be discussed from this point of view and a set of flexible process planning methods have been proposed. Those methods dealt with process planning only for one product and therefore generate the optimal process plan which achieves the shortest total machining time. However, in real manufacturing, multiple workpieces are machined using multiple machine tools. In this paper, those methods are enhanced from the point of view of total productivity. The selection problem of the optimal process plan in the conventional methods and scheduling problem are merged with each other, and selection a set of the optimal process plans for a set of formulated as a 0-1 integer programming problem.

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This paper deals with job shop scheduling with alternative machines. Genetic algorithm incorporating heuristic rules for job selection and machine selection is used for searching schedules to minimize mean tardiness of jobs. As heuristic rules, SL/RPN + SPT rule is used for job selection and (WINQ+RPT+PT)×PT rule is used for machine selection. Numerical experiments are carried out to evaluate the performance of the proposed method in comparison with a genetic algorithm proposed by Moon et al, a Lagrangian relaxation method and a mixed integer programing method. Experimental results show that the proposed method outperforms the other methods in larger scale of problems.

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Recently, global supply chain management has an important role for globalization of marketplaces and global production in order to maximize the total profit. The noncooperative game between the supplier and the retailer is generally formulated as a bilevel programming problem. The bilevel programming problem has the nonlinear objective function with demand uncertainty. However, the nonlinear function has some difficulties to be solved and the study on the algorithm to solve the nonlinear bilevel programming has not been addressed so far. In this paper, we propose the algorithm to derive Stackelberg equilibrium in order to solve the nonlinear bilevel programming problem in which the supplier and the retailer make decisions respectively with the demand uncertainty.

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多段階生産・在庫システムは多くの在庫点をもつ。それら各在庫点での最適在庫水準を理論とシミュレーションによって決定する比較的シンプルな最適化法が提案されている。この最適化法では、品切れ率が設定された各在庫点において、シミュレーションで得られた在庫量の度数分布を使い、各在庫点がローカルに在庫水準を調整する方法であるが、その性能について十分な議論がなされていない。本研究では、いくつかの数値実験を行い、シミュレーションを用いた最適在庫水準決定アルゴリズの性能と有用性について議論する。

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In this paper, CF (carbon Fiber) and an Epoxy matrix are used to make a very strong non-corrosive light weight CFRP Coil spring. The CF-Epoxy coil spring is produced by Winding CF cloth/strands on a silicone mold transcribed/produced from a 3D printed ABS coil mold. CF-Epoxy coil spring is subjected to a series of experiments to determine the mechanical properties

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炭素繊維強化プラスチック(Carbon Fiber Reinforced Plastic,CFRP)の筐体の成形において,3Dプリンタを用いて型を製作することで短納期化を目指した.R10,R20,R30,R40のコーナーを有する横幅l50mm,縦幅l50mm,奥行60mm,厚さ2mmの筐体をシリコーンゴム型およびABS型を用いてCFクロスを0-90°で4枚積層して成形した.その結果,コーナーの半径が小さくなると肉厚が増加した.また落下試験を行ったところシリコーン型を用いたCFRP製筐体のコーナーは破損しなかった.

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Recently the development of the prototyping technology using 3D printers is remarkable. However, it is impossible to make a prototype using same resin for the mass production, so that in this case it is necessary to make a mold. It was problem that these methods need high cost and long delivery time. We developed mold core and cavity by using FDM-3D printer (AM) for prototype manufacturing system made of specific-grade of resin, and evaluated as intensity target which produce 10 pcs of prototype less than 8 hours from receiving 3D data by web. To begin with 3D-data was received by web on the assumption, subsequently commenced designing mold core and cavity by using 3D-CAD, manufactured the core and cavity by FDM-3D printer, and mounted them on mold base, and produced prototypes by the mold injection process. Two types of 3D-data as product were provided for this study, which the box shape of 35mm×20mm×10mm (t=2mm) and the wheel shape as a little complex shape(925), and evaluated prototypes of each product about measurements and appearance characteristics.

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The additive manufacturing is very useful for prototyping in design analysis and functional testing. It can reduce lead-time and costs for product development. As one of open issues, it is difficult to make larger models than the machine size and take long time for making solid models because processing point is limited in a very small area. So, we propose an approach that we divide one object into some segments, fabricate them with hollow space by using 3D-printers, and then run polymer into the hollow space by a vacuum pomp to reinforce the model strength. In the present paper, some experiments are conducted to evaluate this approach.

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Color marking of titanium by titanium oxide coatings are widely used in many fields such as medical implants because they are environment friendly and safe to human body due to no dyes used. Laser irradiation is an efficient approach to obtain oxide coatings. But it has not been used widely in the industry as it is regarded difficult and not repeatable. In this research, the coloring mechanism of titanium oxide layers generated by pulsed Nd:YAG laser (3rd harmonic: λ=355nm) treatment in air was discussed. A series of colors were obtained by varying the laser irradiation pulse energy. With the assumption of formation of uniform titanium dioxide layer on titanium surface, it was confirmed that observed colors calculated by light interference theory were in good accordance with the experimental ones. For investigating hues, CIE 1931 x-y color space and Surface Profile Meter were used. In conclusion, intensity decrease according to increasing pulse energy.

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レイアウトの研究はロボットセル生産システムに対して極めて重要な研究である.しかし,挙動が複雑なロボットを複数台含めるシステムのレイアウト最適化は複雑な問題である.また,レイアウトの設計問題に遺伝的アルゴリズムを用いる研究があるが,膨大な計算時間が必要である.さらに解の精度と妥当性について疑問点が残る問題もあり,これらを克服する手法が求められている.そこで,本研究は遺伝的アルゴリズムと差分進化法の2つの最適化法を結合するハイブリッド手法を提案する.2つの方法を結合することにより従来手法の弱点を克服し,より高い質のパレート解集合が得られた.

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A new planning method is proposed to invest manufacturing equipment based on asset management in order to cope with fluctuations in demand for manufacturing systems, in this research. Some portfolios are set to consider candidates of the equipment investment. Returns and risks of the individual portfolios are required to select the best portfolio in the invest planning based on the asset management. The returns and the risks of the portfolios are obtained by using the returns and the risks of the investment of the individual manufacturing equipment. The returns and risks of the investment of the individual manufacturing equipment are calculated based on the averages and the variances of profit for the cases where the individual manufacturing equipment are invested under assumptions that candidate production plans and their probabilities are obtained.

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In the assembly process of high-mix low-volume production line, the control system must be flexible and robust to adapt to changes in state of manufacturing line such as switching product types, stopping for a short time, and out of stock of parts. We proposed a multi-agent based control system of the assembly process. In the proposed control system, a built-in controller in equipment autonomously performs functions of scheduling and load adjustment with the use of a multi-agent system. In this paper, we show mechanism to connect agents automatically by using IEC61499 function blocks. In addition, function block definition tool is developed to define system configuration and equipment behavior.

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現在の市場では,顧客ニーズの多様化や製品ライフサイクルの短命化によって,生産工程では多品種少量生産が求められ,混流生産を導入することで対応している.多くの工場の混流生産では需要変動や調達材料の遅延に対して柔軟に対応するために平準化が行われている.また,バッファの導入によって手待ち時間やブロッキングの減少により生産性が向上すると考えられている.一方でバッファの導入によって作業領域の拡大や中間在庫の増加を招く可能性がある.本研究では,平準化における生産性向上とともに工程間の仕掛り在庫量を削減し,必要となるバッファ量を最小限にするための数理モデルを構築し,数値実験により生産性の評価を行うとともに特徴を調べる.

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Recently, when performing maintenance plant, consider the advance path and interference during loading using the three-dimensional shape data of the plant structure during device loading. However, it is necessary to perform to know the multiple measurements of the position measuring accurately the measurements of plant structure. Therefore, it is required a lot of effort. In this study, self-propelled simultaneously to obtain the measurement position and the measurement point cloud using a robot, a structure in shape to develop a system for creating fully automatically. As a result, it was possible to create the retrieved structures the shape point cloud coordinates around while moving.

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A workpiece produced by die-casting or other casting process has a relatively low level of accuracy. Thus, finish machining is often required for such workpieces. However, it is difficult to set up a workpiece in the designated position with the work holding table. To easily make cutter paths for the workpiece in the designated position, this paper proposes machining operation method. This relies on coordinating the workpiece and cutting paths to make it easy to find the correct position. In this study, reverse engineering is used to obtain the 3D model of a workiece. The model is scanned by a 3D laser scanner. The 3D lattices point data were then constructed by interpolating and thinning the scan data. The RANSAC method is applied to primitive shape recognition for unorganized point clouds to detect planes, cylinders and spheres. The system also recognizes primitive shapes: namely, planes, cylinders, and spheres, from the STL data and match the scan data with STL data. After fitting, the system can know the position of workpiece and the machine tool table. Thus, the position can be used to set the origin of coordinated workpiece and cutting tool path for the machining operation can be generated.

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