Academic literature on the topic 'Master Thesis Manufacturing'

Flash is the unwanted or excessrubber material that presents on the outersurface of themolded rubber product. This will affect the surface finish; it is a cosmetic defect andit can be removed. It forms because of the leak or the excess molded rubber materialbetween the surface of the mold, typically on the parting line, (Jordan Anderson,2014). The presence of flash will reduce customer satisfaction. There are manymethods to remove the flash. The method is selected according to the degree of flashextension and the location where it occurs.The project aims to design a semi/full automated machine, which helps for having asmooth and fine surface finish of the weight plates. These plates are made up of rubberfor the ELEIKO group. The weight plates have different weights from 10 to 20 kg,but the diameter of each plate stays the same, but the thickness will be different foreach plate. The machine should be designed that removes all the excess rubber andshould smoothen the outer surface of the weight. The purpose of this work is to gainknowledge about different product development methods, respective tools, andtechniques that are used. The machine should be user- friendly, should not becomplicated, should not damage the workpiece (marks or trace of the blade), shouldnot put the employer in danger, and economically feasible.This report presents the progress of designing of the product, product development,methods, and literature study. The designed model can construct in the industry fortheir problem they are faced by the flash. The model is very simple and unique so thateveryone can perform the task without any previous experience. Material alternativeswere evaluated as well as manufacturing possibilities. The designed machine was theoffered for free as means for further research and development. Keywords: flashing, additive manufacturing, Ullman method, Pugh matrix, rubberweight plates, lever arm, smoothening tool.

Risk can be viewed as a state where there is a possibility of a loss but also a hope of gain. To realise the existence of a risk, one must be aware of both the gains and losses incurred.Increased number of natural disasters and companies having global supply chains to a higher extent, are both factors which have increased the number of risks that can affect anorganisation’s supply chain negatively. This fact has made it even more important to focus on risk prevention. In the beverage industry market, characterized by fast-moving products,manufacturing companies like Coca-Cola Enterprises Sweden (CCES) can be highly affected if disturbances occur in their supply chain. Risk management is, according to ISO 31000, “coordinated activities to direct and control an organization with regard to risk “. A risk management processes therefore aims at mitigatingnegative impact of external and internal disturbances in order to avoid interruptions in production, product quality issues and financial losses. CCES’s control over internal processes and its disturbances is mostly based on reactive approaches rather than a proactive strategy and there exist no guidelines of how to identify and handle occurring disturbances. The main purpose of the project has therefore been to identify the most critical risks the company is facing within their “Source” and “Make” processes, and find both proactive and reactive mitigation actions. Another significant part of the project delivery is to present a model for how the company should organize and maintain a sustainable risk picture. The model aims to present a dynamic risk management process that can be used by CCES as well as other companies in the future. The project consists of three major phases; Risk Identification, Risk Avoidance Mapping and Implementation of a Risk Management Process. In the first phase, the brainstorming tool Hazard and Operability (HAZOP) has been used during workshop events for risk identification and assessment. Some of the most critical risks identified are; Sabotage during  transport from supplier to CCES, Lack of spare parts for maintenance, Lost production time due to long beverage change overs and Filling bottles with too much beverage. In order to find feasible preventive and reactive mitigation actions for the critical risks, both employee interviews and the Supply Chain Operations Reference (SCOR) model has been applied. Some of the actions recommended to perform are concluded to be; Let suppliers own transports, Standardize the product change process and the shift hand overs and Implement routines of having locked transports from supplier to CCES. The structure of the project has acted as a basis for the recommended way of continuing the risk management work at CCES. The authors have identified the importance of keeping the risk management process dynamic, and therefore a Risk Register have been introduced for documentation and follow-up. Another way of following up the risk management work, is to perform Risk Audits after the event of a disturbance. This will help the organisation to realize the impact a certain disturbance brings, but it will also measure of the recovery work’s effectiveness. The authors highlight the importance of having a dedicated owner of the risk management process in order to keep it dynamic. A complete risk management process has finally been created, adaptable to different kind of organisations. By making this process a part of SCOR, the authors believes that the process can be used to identify individual risks within the management processes Plan, Source, Make, Deliver and Return for all SCOR member companies. Thereafter, a general risk mapping can be created from the individual risks that can be used to share information and experiences among the member companies.<br>En risk kan förklaras som ett tillstånd där det finns en chans att vinna, men också en sannolikhet för förlust. För att vara medveten om en risks existens måste man därför förstå både vad det finns att förlora och vinna. Under de senaste årtiondena har antalet naturkatastrofer och annan extern påverkan ökat. Detta i kombination med att företag idag har globala värdekedjor i allt större utsträckning, har gjort att organisationer utsätter sig för risker till en större grad idag. Därför har betydelsen av att fokusera på riskförmildrande åtgärder ökat. I dryckesindustrin, karaktäriserat av snabbrörliga produkter, kan företag såsom Coca-Cola Enterprises Sweden (CCES) påverkas hårt om störningar sker i deras värdekedja. Risk Management är, enligt ISO 31000, ”koordinerade aktiviteter för att styra och kontrollera riskhantering i en organisation”. En riskhanteringsprocess ämnar därför förmildra negativ påverkan av interna och externa störningar för att undvika till exempel avvikelser i produktion, försämrad produktkvalitet och finansiella förluster. CCES’s kontroll över interna processer och dess störningar baseras främst på reaktiva åtgärder, och företaget har inga riktlinjer för hur de ska identifiera och hantera uppkommande störningar. Syftet med detta projekt har därför varit att identifiera kritiska risker inom företagets leverantörs- och produktionsprocesser och att hitta proaktiva och reaktiva lösningar för att förmildra och undvika störningar. Ytterligare en stor del av projektets syfte har varit att presentera en dynamisk process för hur CCES, samt andra företag, ska organisera en hållbar riskbild. Projektet består av tre huvudsakliga delar; riskidentifiering, riskförmildrande åtgärder och implementering av en riskhanteringsprocess. I den första fasen har verktyget Hazard and Operability (HAZOP) används under workshops för att identifiera och värdera risker. Några av de mest kritiska riskerna som identifierats är; Sabotage under transport från leverantör till CCES, Brist på reservdelar för underhållsarbete, Förlorad produktionstid på grund av för långa dryckesbytartider och Fyller flaskor med för mycket dryck. För att hitta passande reaktiva och proaktiva lösningar för de kritiska riskerna har både intervjuer med anställda genomförts och referensmodellen Supply Chain Reference Model (SCOR) använts. Några av de åtgärder rekommenderade att göra har identifierats till att vara; Låta leverantörerna själva sköta transporter, Standardisera produktbytesprocessen samt skiftöverlämningar och Implementera rutiner för att ha låsta transporter från leverantör till CCES. Strukturen av projektet har använts som en bas för den rekommenderade strukturen på CCE’s fortskridande arbete inom riskhantering. Författarna vill bestryka vikten av att hålla den framtida riskhanteringsprocessen dynamisk och i detta syfte har därför ett riskregister tagits fram för dokumentation och uppföljning. Ett annat sätt att följa upp riskprocessarbetet är att genomföra så kallade audits efter en störning har inträffat. Detta hjälper organisationen både att förstår en störnings påverkan på verksamheten, men fungerar också som ett verktyg för att mäta hur effektivt återhämtningsarbetet efter en störning har varit. Författarna menar också att en dedikerad ägare till riskprocessen är av stor betydelse för ett dynamiskt, framgångsrikt och effektivt riskarbete. En fullständig riskhanteringsprocess har slutligen sammanställts, användbar för många olika typer av organisationer. Genom att göra processen till en del av SCOR-modellen, kan processen i framtiden användas till att identifiera individuella risker inom de fem managementprocesserna Planering, Inköp, Tillverkning, Leverans och Retur för alla SCOR’s medlemsföretag. Därefter menar författarna att en generell kartläggning över de mest kritiska riskerna inom varje managementprocess kan skapas för att dela information och utbyta erfarenheter mellan medlemsföretagen.

This thesis describes a system which is able to track and imitate human motion. The system is divided into two major parts: computer vision system and robot arm motion control system. Through the use of two real-time video cameras, computer vision system identifies the moving object depending on the colour features, as the object colour is matched within the colour range in the current image frame, a method that employs two vectors is used to calculate the coordinates of the object. After the object is detected and tracked coordinates are saved to a pre-establish database in the purpose of further data processing, a mathematical algorithm is performed to the data in order to give a better robotic motion control. Robot arm manipulator responds with a move within its workspace which corresponds to a consequential human-type motion. Experimental outcomes have shown that the system is reliable and can successfully imitate a human hand motion in most cases.

This report is the result of a conducted Minor Field Study (MFS), to the greatestextent funded by the Swedish International Development Cooperation Agency(SIDA), in an attempt to design a system for evaluating smaller solar power systems indeveloping countries. The study was to the greater part conducted in Nairobi, Kenyain close collaboration with the University of Nairobi. The aim was to develop asystem that would use easily available components and keep the costs to a minimum,yet deliver adequate performance. The system would measure certain parameters of asolar power system and also relevant environmental data in order to evaluate theperformance of the system. Due to the specific competence of the collaboratinggroup at the University of Nairobi, a Kinetis Freescale K64-microcontroller with anARM-Cortex processor was selected as the core of the design. Components wereselected, schematics were drawn, a circuit board was designed and manufactured andsoftware was written. After 12 weeks a somewhat satisfying proof-of-concept wasreached at the end of the field study in Kenya. The project however proved howdifficult it is to go from first idea to a functional proof-of-concept during a limitedtimeframe, and also in an East-African country. The final proof-of-concept was testedat Mpala Research Centre in Kenya and despite containing some flaws proved that itwould indeed be possible to design a working system on the principles discussed inthis report. The system is open-source, so anyone may use and modify it.

The strategies to employ when a small to medium sized enterprise (SME) enters the international market are important issues for a business to consider. This research study addresses the question “What strategies will position New Zealand manufacturing small and medium sized enterprises for international markets?” It is intended to compare various strategies for going global, discovering these through a literature review and personal interviews with New Zealand businesses who have successfully globalised. The research studies globalisation within manufacturing small and medium sized enterprises (SMEs) in New Zealand. It explores strategies available in order to discover their advantages and disadvantages, and suggests key strategic directions for New Zealand manufacturing SME’s to use when entering into international markets. The research is intended to benefit New Zealand SME’s considering entering the international market place, which in turn will contribute towards benefiting New Zealand as a whole as it endeavours to position itself in the international competitive arena. Specific strategies for New Zealand manufacturing SME’s wishing to establish global markets are explored with implications for theory, research, and business practices. A case study approach was adopted, with multiple research methods used to gather information for the study. An experience survey in the form of personal interviews was used to gather a range of views from people with knowledge and experience in exporting to international markets. Documents were analysed, together with information gained through the interviews to compile case histories of the businesses that participated in this research. Strategies relevant to going global were identified in a literature review and these strategies were compared with actions and directions taken by the businesses interviewed. The analysis of the findings reveals congruence with theoretical strategies for globalisation of SMEs identified in previous studies; however it was found that decisions made when going global were highly dependent on the individual circumstances that a business finds itself in, rather than committing to strategies based on assumptions from academic studies. The businesses involved in this study went global through opportunities more so than strategic purpose. They had not set out to be a global enterprise, however when the opportunities arose their globalisation effort needed total commitment. Their experiences are discussed in this study and have relevance for other firms looking to go global.

Aluminum alloy castings are being integrated increasingly into automotive and aerospace assemblies due to their extraordinary properties, especially high strength-to-density ratio. To produce high quality castings, it is necessary to understand the mechanisms of the formation of defects, specifically pores and inclusion, in aluminum. There have been numerous studies on pore formation during solidification which lead to hot tearing and/or reduction in mechanical properties. However, a comprehensive study that correlates pore formation theory with in situ observations and modeling assumptions from the literature as well as experimental observations in not available. The present study is motivated to fill this gap. An in-depth discussion of pore formation is presented in this study by first reinterpreting in situ observations reported in the literature as well as assumptions commonly made to model pore formation in aluminum castings. The physics of pore formation is reviewed through theoretical fracture pressure calculations based on classical nucleation theory (i) for homogeneous and heterogeneous nucleation, and (ii) with and without dissolved gas, i.e., hydrogen. Based on the fracture pressure for aluminum, critical pore size and corresponding probability of vacancies clustering to form the critical-size pore have been calculated by using thermodynamic data reported in the literature. Calculations show that it is impossible for a pore to nucleate either homogeneously or heterogeneously in aluminum, even with dissolved hydrogen. The formation of pores in aluminum castings can only be explained by inflation of entrained surface oxide films entrained during prior damage to liquid aluminum (bifilms) under reduced pressure and/or with dissolved gas, which involves only growth, avoiding any nucleation problem. This mechanism is consistent with reinterpretations of in situ observations as well as assumptions made in the literature to model pore formation. To determine whether damage to liquid aluminum by entrainment of surface oxides can be observed and measured, Reduced Pressure Tests (RPT) have been conducted by using high quality, continuously cast A356.0 aluminum alloys ingots. Analyses of RPT samples via micro-computer tomography (μ-CT) scanning have demonstrated that number of pores and volume fraction of pore in aluminum casting increased by raising the pouring height (i.e., velocity of the liquid). Moreover, pore size distributions were observed to be lognormal, consistent with the literature. Cross-sections of RPT samples have been investigated via scanning electron microscopy. In all cases, the presence of oxygen was detected inside, around and between the pores. The existence of oxide films inside all pores indicates that oxide films act as initiation sites for pores and hydrogen only assist to growth of pores. For the first time, the pore formation is reconciled with physical metallurgy principles, supported by observations of oxide films in aluminum castings. Results clearly indicate that pores are extrinsic defects and can be eliminated by careful design of the entire melting and casting process.

Denna rapport är ett resultat av utförd fallstudie på Siemens Industrial Turbomachinery AB. Studien utfördes som ett DMAIC-projekt i syfte att utvärdera befintlig processtyrning och ge förslag på nya styrparametrar för att styra och övervaka tillverkningsprocessen av rotorer. En rotor skapas genom montage av turbinmodul på kompressorrotor. För att säkerställa rotorns funktionalitet mäts rotorkast kontinuerligt under tillverkningprocessen. Stora rotorkast uppstår sporadiskt vid montaget varpå nuvarande avhjälpningsmetod  innefattar tids- och kostnadskrävande demontage och återmontage av turbinmodul på kompressorrotor.  Rekommendationer har utformats och baserats utifrån historiskt analyserad data, insamlad mellan åren 2013 och 2020, 19 intervjuer och 2 workshops. Rekommendationer innefattar implementering av statistisk processtyrning. Ett av argumenten till implementeringen är att börja utvärdera effekten av genomförda förbättringsprojekt. Denna studie identifierade ett förbättringsprojekt, genomfört år 2016, som ökade andelen defekter med 454%. Då förbättringsprojektet tros bidragit med en förbättring i ett annat processteg ges rekommendationen att utvärdera helheten av implementerad förbättringsåtgärd. Avslutningsvis rekommenderas att uppdatera dagens bristfälliga processtyrning genom beräknandet av nya toleranser baserat på önskad kvalitetsnivå och eliminera diskrepanserna mellan de idag använda toleranserna.<br>This report is a result of a case study carried out at Siemens Industrial Turbomachinery AB. The study was conducted as a DMAIC project with the aim of evaluating existing process control and proposing new control parameters for controlling and monitoring the manufacturing pro- cess of rotors. A rotor is created by the assembly of a turbine module on a compressor rotor. In order to ensure the functionality of the rotor, rotor-runout is continuously measured during the manufacturing process. Large rotor-runouts occur sporadically during assembly and the current method to fix the abnormalities includes time- and costly disassembly and re-assembly of the turbine module on the compressor rotor. Recommendations have been designed after analysis of historical data collected between 2013 and 2020, 19 interviews and 2 workshops. Recom- mendations include implementation of statistical process control. One of the arguments for the implementation is to start evaluating the effects of completed improvement projects. This study identified an improvement project, completed in 2016, which increased the proportion of defects by 454%. Since the improvement project is believed to have contributed to an enhancement in another part of the process, a more holistic way of evaluation is needed to follow up effects of improvements projects. Finally, it is recommended to update the tolerances by calculating new ones based on the desired quality level while also eliminating the discrepancies between the different tolerances used today.

The developed methodology for the modernization of the enterprise’s production system, based on a step-by-step method of managing production processes (6 sigma), the concept of lean manufacturing and statistical data analysis, can be used in projects to modernize the production systems of metallurgical enterprises, increasing their efficiency and competitiveness by: rational use of resources; increase labor productivity; staff involvement. The developed project for the modernization of the enterprise’s production system can be “replicated” at metallurgical enterprises, allowing them to reduce losses, rationally use resources and increase labor productivity. The concept of a project to modernize the enterprise’s production systems using lean manufacturing technologies and project management has found its practical application at the non-ferrous metallurgy enterprise KUZOTsM OJSC.<br>Разработанная методика модернизации производственной системы предприятия, основанная на пошаговом методе управления процессами производства (6 сигм), концепции бережливого производства и статистическом анализе данных, может быть использована в проектах по модернизации производственных систем металлургических предприятий, повышая эффективность их деятельности и конкурентоспособности за счет: рационального использования ресурсов; повышения производительности труда; вовлеченности персонала. Разработанный проект модернизации производственной системы предприятия может «тиражироваться» на металлургических предприятиях, позволяя сокращать потери, рационально использовать ресурсы и повышать производительность труда. Концепция проекта модернизации производственных систем предприятия с использованием технологий бережливого производства и проектного управления нашло свое практическое применение на предприятии цветной металлургии ОАО «КУЗОЦМ».

Приведен обзор случаев использования изделий, изготовленных по аддитивной технологии для имплантации. Проанализирован международный стандарт на испытания пористых материалов, изготовленных по аддитивной технологии. Выявлены проблемы и предположительные пути их решения при использовании изделий, изготовленных аддитивным методом из сплавов на основе титана. решена краевая задача определения напряженно-деформированного состояния ячеистого имплантат методом конечных элементов в программном модуле ABAQUS. Рассмотрен вопрос влияния геометрии ячеек испытываемого материала на механические свойства конечного изделия для трех различных форм ячеек. Рассмотрен вопрос влияния трения между испытываемой заготовкой и бойками испытательной машины на свойства конечного изделия при различных уровнях трения.<br>An overview of the cases of using products made using additive technology for implantation is given. The international standard for testing porous materials manufactured by additive technology is analyzed. The problems and possible ways of their solution are revealed when using products manufactured by the additive method from titanium-based alloys. the boundary value problem of determining the stress-strain state of a cellular implant by the finite element method in the ABAQUS software module has been solved. The question of the influence of the geometry of the cells of the test material on the mechanical properties of the final product for three different cell shapes is considered. The question of the influence of friction between the tested workpiece and the strikers of the testing machine on the properties of the final product at various levels of friction is considered.

Robotic haptics has been and continues to be an area of intense research, primarily in medical and exploration industries. This is due to an ability to provide high data throughput between human and machine. In medical applications, it is possible to detect and compensate errors such as a hand tremor in a surgeon. It is possible to apply scaling factors to assist in microsurgery situations, and can allow leading experts to perform procedures from anywhere on the globe. As part of a collaboration to develop a robotic method of femur fracture realignment between Auckland University, Auckland District Health Board, and Massey University, the project seeks to provide a haptic driven HMI for the realignment system. To reduce construction required, an existing manipulation arm (Mitsubishi RV-M1) is used as the hardware interface device. A new motor controller is designed to provide additional functionality as the standard controller provides no force control or real-time feedback of position. A software interface is developed (using version 3 of the C# programming language, developed by Microsoft, and version 3.5 of the Microsoft .NET Framework) with the ultimate specification of becoming being the primary interface platform for the realignment system. The interface has been implemented to the point of providing a simulated environment for the haptic device. It was found that the configuration of the RV-M1 provides a tight area of high dexterity as a haptic device, and as such, similar kinematic configurations are poor candidates for practical implementation. The implication of which, is that a new manipulator should be designed which grants a larger volume of high dexterity space.