Reconfigurable Manufacturing Enterprises for Industry 4.0

Description

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. 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