Life Cycle Design of Manufacturing Systems for Enhancing Facility Reusability in System Reconfiguration

快速有效地适应大批量生产变化和产品的根本变化是当前制造活动的最重要问题之一。由于技术的快速进步和市场趋势的变化，新产品经常被引入市场，其销售量波动很大。全球化市场的竞争加速了这种趋势。汽车等耐用的大规模生产产品需要大规模的生产设施，科普这些变化非常困难。如何降低“生产惯性”以缩短生产设备重构的提前期和相关成本是一个关键问题。与构建全新的制造系统相比，必须重用已有的系统组件，并重新配置现有系统以适应新的要求。在满足客户需求的同时，有效地再利用现有的可用资源 关于我们 如果允许任意改变产品，则不容易实现现有制造系统的高效和可持续的重构。产品设计与制造系统重构的集成是解决这一难题的有效途径。为了建立制造系统与相关产品之间的一般关系，研究一种系统化的产品设计方法，该方法不需要对制造系统进行大量的重构，并且允许现有设备的高度重用性，为此，建立了产品变化与相关制造资源变化之间的关系。确定了对制造资源变化有很大影响的特定产品变化。对设施变化影响较小的产品进行了分组。如果有效地利用这样的产品组概念，则可以减少由于客户要求而导致的产品变化对制造资源的影响，并增加设备再利用的可能性。通过消除产品和制造资源的不必要的表面变化，并通过关注产品和制造资源之间的本质依赖性来研究这种关系是重要的。所提出的方法的有效性进行了评估的汽车零部件的案例研究减

It is one of the most important issues for recent manufacturing activities to quickly and efficiently adapt to large production volume variations and radical changes of products. Due to the rapid technological advances and changes of market trends, new products are frequently introduced into the market, and their sale volumes heavily fluctuate. Such trends are accelerated by competition in a globalized market. Durable mass-production products, such as automobiles, require large-scale production facilities, and it is very difficult to cope with these changes. It is a critical issue how to reduce "production inertia" to achieve short lead time and relevant cost for reconfiguration of production facilities.Instead of constructing completely new manufacturing systems, it is mandatory to reuse already existing system components, and to reconfigure exiting systems to be adapted to new requirements. While satisfying customers' demands, efficient re-utilization of existing available resources … More is strongly required for achieving sustainable and environmentally benign manufacturing.If arbitrary changes of products are allowed, it is not easy to achieve efficient and sustainable reconfiguration of existing manufacturing systems. Integration of product design with manufacturing system reconfiguration is an effective way to solve this difficulty. The objective of this study is to establish general relationship between manufacturing systems and associated products, and to investigate a systematized method for designing a group of products, which does not require substantial reconfiguration of manufacturing systems, and allows high reusability of existing facilities.For this purpose, a relationship between product variations and associated manufacturing resource changes is established. Particular product variations which have a strong influence on manufacturing resource changes are identified. And varied products which have small effects on facility changes are grouped. If such a product group concept is effectively utilized, it is possible to reduce the influence of product variations due to customer requirements on manufacturing resources, and to increase the possibility of facility reuse. It is important to investigate such relationships by eliminating unnecessary superficial variations of products and manufacturing resources, and by focusing on essential dependency between products and manufacturing resources. The effectiveness of the proposed method has been evaluated by a case study for automobile components Less