A line-balancing strategy for designing flexible assembly systems

We present a rough-cut analysis tool that quickly determines a few potential cost-effective designs at the initial design stage of flexible assembly systems (FASs) prior to a detailed analysis such as simulation. It uses quantitative methods for selecting and configuring the components of an FAS suitable for medium to high volumes of several similar products. The system is organized as a series of assembly stations linked with an automated material-handling system moving parts in a unidirectional flow. Each station consists of a single machine or of identical parallel machines. The methods exploit the ability of flexible hardware to switch almost instantaneously from product to product. Our approach is particularly suitable where the product mix is expected to be stable, since we combine the hardware-configuration phase with the task-allocation phase. For the required volume of products, we use integer programming to select the number of stations and the number of machines at each station and to allocate tasks to stations. We use queueing network analysis, which takes into account the mean and variance of processing times among different products to determine the necessary capacity of the material-handling system. We iterate between the two analyses to find the combined solution with the lowest costs. Work-in-process costs are also included in the analysis. Computational results are presented.     

Aligning demand and supply flexibility in custom product co-design

Flexibility of supply and demand is essential for successful implementation of a mass customization strategy that delivers sustained competitive advantage. Supply flexibility, i.e., a choice of alternative products designed to perform the same basic function, is made possible by the range of capabilities available in flexible and agile manufacturing systems and in supply chains. Demand flexibility is derived from the degree to which a customer is willing to compromise on product features or performance levels in order to meet budgetary (reflected in price) or schedule (reflected in delivery) constraints. Flexibility of both supply and demand can have significant strategic and financial value if they are properly aligned. However, customers are mostly unaware of mapping of demand flexibility on to supply flexibility and its impact on production cost and time. Recent advances in information technology have made it possible to co-design a product that involves customer on one end and the manufacturer on the other. This creates an aura and an opportunity where a middle ground between the supply and demand flexibility can be explored and a “deal” can be struck where both parties settle for a product that is beneficial to both through a negotiated settlement. In this paper, we develop a framework for such negotiations. The customer requirements are treated as a range of negotiable options instead of a set of fixed inputs. Demand and supply for customization is then matched by aligning the flexibility of manufacturing systems with customers’ requirement options. Based on this framework, a negotiation scheme is developed to assist customers and manufacturers in exploring and utilizing demand and supply flexibility information in co-design. The negotiation scheme is formulated using goal programming. Finally, an interactive problem-solving procedure is developed and implemented with an illustrative example.     

Modeling customized product configuration in large assembly manufacturing with supply-chain considerations

Dynamic variability in low-volume and highly customized products of a large assembly manufacturing system with an integrated supply chain has been very challenging to capture. Design and product configurations most likely impact outcomes of such broad variability. This article presents a framework to encompass this completely integrated system for using discrete event simulation as a modeling method. The system modeling framework addresses factors including customized configuration attributes and individual customer-preferred considerations for customized configurations. The framework is intended to aid decision-making concerning cost and schedule impacts associated with customization options chosen throughout the supply chain. A real-world example drawn from aerospace is included to demonstrate and validate the operational capability of the proposed framework.     

A framework for capacity planning and machine configuration in flexible assembly systems

We consider the problem of simultaneously determining the number of machines (and/or workers), the assignment of tasks (and related tools and components) to these machines, and the number of jobs circulating in a flexible assembly system (FAS), to satisfy steady-state throughput requirements for a family of similar products at minimum cost. We focus on situations where there are precedence relations among the various tasks, as is common in assembly systems. We present a framework for solving this problem based on a heuristic decomposition approach which involves the solution of only a few types of sub-problems. We demonstrate the efficiency and effectiveness of the overall procedure using a number of example problems.     

A software tool to assist business-process decision-making in the biopharmaceutical industry

Conventionally, software tools for the design of bioprocesses have provided only limited business-related information for decision-making. There is an industrial need to investigate manufacturing options and to gauge the impact of various decisions from economic as well as process perspectives. This paper describes the development and use of a tool to provide an assessment of whole flowsheets by capturing both process and business aspects. The tool is demonstrated by considering the issues concerned when making decisions between two potential flowsheets for a common product. A case study approach is used to compare the process and business benefits of a conventional process route employing packed chromatography beds and an alternative that uses expanded bed adsorption (EBA). The tool allows direct evaluation of the benefits of capital cost reduction and increased yield offered by EBA against penalties of using potentially more expensive EBA matrix with lower lifetimes. Furthermore, the tool provides the ability to gauge the process robustness of each flowsheet option.     

Scenario Modelling in Prospective LCA of Transport Systems. Application of Formative Scenario Analysis (11 pp)

Background Tools and methods able to cope with uncertainties are essential for improving the credibility of Life Cycle Assessment (LCA) as a decision support tool. Previous approaches have focussed predominately upon data quality. Objective and Scope. An epistemological approach is presented conceptualising uncertainties in a comparative, prospective, attributional LCA. This is achieved by considering a set of cornerstone scenarios representing future developments of an entire Life Cycle Inventory (LCI) product system. We illustrate the method using a comparison of future transport systems. Method Scenario modelling is organized by means of Formative Scenario Analysis (FSA), which provides a set of possible and consistent scenarios of those unit processes of an LCI product system which are time dependent and of environmental importance. Scenarios are combinations of levels of socio-economic or technological impact variables. Two core elements of FSA are applied in LCI scenario modelling. So-called impact matrix analysis is applied to determine the relationship between unit process specific socio-economic variables and technology variables. Consistency Analysis is employed to integrate unit process scenarios, based on pair-wise ratings of the consistency of the levels of socio-economic impact variables of all unit processes. Two software applications are employed which are available from the authors. Results and Discussion The study reveals that each possible level or development of a technology variable is best conceived of as the impact of a specific socio-economic (sub-) scenario. This allows for linking possible future technology options within the socio-economic context of the future development of various background processes. In an illustrative case study, the climate change scores and nitrogen dioxide scores per seat kilometre for six technology options of regional rail transport are compared. Similar scores are calculated for a future bus alternative and an average Swiss car. The scenarios are deliberately chosen to maximise diversity. That is, they represent the entire range of future possible developments. Reference data and the unit process structure are taken from the Swiss LCA database 'ecoinvent 2000'. The results reveal that rail transport remains the best option for future regional transport in Switzerland. In all four assessed scenarios, four technology options of future rail transport perform considerably better than regional bus transport and car transport. Conclusions and Recommendations. The case study demonstrates the general feasibility of the developed approach for attributional prospective LCA. It allows for a focussed and in-depth analysis of the future development of each single unit process, while still accounting for the requirements of the final scenario integration. Due to its high transparency, the procedure supports the validation of LCI results. Furthermore, it is well-suited for incorporation into participatory methods so as to increase their credibility. Outlook and Future Work. Thus far, the proposed approach is only applied on a vehicle level not taking into account alterations in demand and use of different transport modes. Future projects will enhance the approach by tackling uncertainties in technology assessment of future transport systems. For instance, environmental interventions involving future maglev technology will be assessed so as to account for induced traffic generated by the introduction of a new transport system.     

Intersection of RNA processing and the type II fatty acid synthesis pathway in yeast mitochondria

Distinct metabolic pathways can intersect in ways that allow hierarchical or reciprocal regulation. In a screen of respiration-deficient Saccharomyces cerevisiae gene deletion strains for defects in mitochondrial RNA processing, we found that lack of any enzyme in the mitochondrial fatty acid type II biosynthetic pathway (FAS II) led to inefficient 5′ processing of mitochondrial precursor tRNAs by RNase P. In particular, the precursor containing both RNase P RNA (RPM1) and tRNA^Pro accumulated dramatically. Subsequent Pet127-driven 5′ processing of RPM1 was blocked. The FAS II pathway defects resulted in the loss of lipoic acid attachment to subunits of three key mitochondrial enzymes, which suggests that the octanoic acid produced by the pathway is the sole precursor for lipoic acid synthesis and attachment. The protein component of yeast mitochondrial RNase P, Rpm2, is not modified by lipoic acid in the wild-type strain, and it is imported in FAS II mutant strains. Thus, a product of the FAS II pathway is required for RNase P RNA maturation, which positively affects RNase P activity. In addition, a product is required for lipoic acid production, which is needed for the activity of pyruvate dehydrogenase, which feeds acetyl-coenzyme A into the FAS II pathway. These two positive feedback cycles may provide switch-like control of mitochondrial gene expression in response to the metabolic state of the cell.     

Life cycle assessment as a tool for improving process performance: A case study on boron products

This paper explores the use of LCA as a tool for process environmental management, thereby moving the focus from product to process oriented analysis. The emphasis is on Improvement Assessment in which the “hot spots” in the system are targeted for maximum environmental improvements. In this context, it is useful to use multiobjective optimisation which renders Valuation unnecessary. The approach is illustrated by the case study of the system processing boron ores to make five different products. The results of Inventory Analysis and Impact Assessment are presented and discussed. In Improvement Assessment, a number of improvement options are identified and evaluated, using system optimisation. It is shown that the site environmental performance can be improved over current operation by an average of 20% over the whole life cycle. Thus the study demonstrates that the optimisation approach to environmental process management may assist in identifying optimal ways to operate a process or plant from “cradle to grave”. This may help the process industries not only to comply with legislation but also provide a framework for taking a more proactive approach to environmental management leading to more sustainable industrial operations and practices.     

Structured Under‐Specification of Life Cycle Impact Assessment Data for Building Assemblies

The existence of uncertainties and variations in data represents a remaining challenge for life cycle assessment (LCA). Moreover, a full analysis may be complex, time‐consuming, and implemented mainly when a product design is already defined. Structured under‐specification, a method developed to streamline LCA, is here proposed to support the residential building design process, by quantifying environmental impact when specific information on the system under analysis cannot be available. By means of structured classifications of materials and building assemblies, it is possible to use surrogate data during the life cycle inventory phase and thus to obtain environmental impact and associated uncertainty. The bill of materials of a building assembly can be specified using minimal detail during the design process. The low‐fidelity characterization of a building assembly and the uncertainty associated with these low levels of fidelity are systematically quantified through structured under‐specification using a structured classification of materials. The analyst is able to use this classification to quantify uncertainty in results at each level of specificity. Concerning building assemblies, an average decrease of uncertainty of 25% is observed at each additional level of specificity within the data structure. This approach was used to compare different exterior wall options during the early design process. Almost 50% of the comparisons can be statistically differentiated at even the lowest level of specificity. This data structure is the foundation of a streamlined approach that can be applied not only when a complete bill of materials is available, but also when fewer details are known.     

A Geometrical Perspective for the Bargaining Problem

A new treatment to determine the Pareto-optimal outcome for a non-zero-sum game is presented. An equilibrium point for any game is defined here as a set of strategy choices for the players, such that no change in the choice of any single player will increase the overall payoff of all the players. Determining equilibrium for multi-player games is a complex problem. An intuitive conceptual tool for reducing the complexity, via the idea of spatially representing strategy options in the bargaining problem is proposed. Based on this geometry, an equilibrium condition is established such that the product of their gains over what each receives is maximal. The geometrical analysis of a cooperative bargaining game provides an example for solving multi-player and non-zero-sum games efficiently.     

Mitochondrial acyl carrier protein (ACP) at the interface of metabolic state sensing and mitochondrial function

Acyl carrier protein (ACP) is a principal partner in the cytosolic and mitochondrial fatty acid synthesis (FAS) pathways. The active form holo-ACP serves as FAS platform, using its 4′-phosphopantetheine group to present covalently attached FAS intermediates to the enzymes responsible for the acyl chain elongation process. Mitochondrial unacylated holo-ACP is a component of mammalian mitoribosomes, and acylated ACP species participate as interaction partners in several ACP-LYRM (leucine-tyrosine-arginine motif)-protein heterodimers that act either as assembly factors or subunits of the electron transport chain and Fe-S cluster assembly complexes. Moreover, octanoyl-ACP provides the C8 backbone for endogenous lipoic acid synthesis. Accumulating evidence suggests that mtFAS-generated acyl-ACPs act as signaling molecules in an intramitochondrial metabolic state sensing circuit, coordinating mitochondrial acetyl-CoA levels with mitochondrial respiration, Fe-S cluster biogenesis and protein lipoylation.     

Design for the Next Generation: Incorporating Cradle-to-Cradle Design into Herman Miller Products

In the late 1990s, office furniture manufacturer Herman Miller, Inc., entered into a collaboration with architect William McDonough to create a system for designing cradle-to-cradle products. This collaboration led to the creation of a tool—the Design for Environment (DfE) product assessment tool—that evaluates progress towards cradle-to-cradle products. The first product Herman Miller designed using the DfE product assessment tool was the Mirra chair. Over the course of the chair's development, the DfE process generated a number of design changes, including selecting a completely different material for the chair's spine, increasing recycled content in chair components, eliminating all PVC (polyvinyl chloride) components, and designing the chair for rapid disassembly using common tools.
The areas of greatest success in designing the Mirra chair for the environment were the increased use of recyclable parts and increased ease of disassembly, whereas the areas of greatest challenge were increasing recycled content and using materials with a green chemistry composition. The success in recyclability reflects the use of metals, materials that have a well-established recycling infrastructure. The success in disassembly reflects the high degree of control that Herman Miller has over product assembly. The challenge to increasing recycled content is the use of plastics in chairs. Unlike the metals, which all contain some recycled content, most plastics are made from virgin polymers. The challenge to improving materials chemistry is the limited range of green chemicals and materials on the market.
The Mirra chair exemplifies the value of incorporating the environment into design and the need for tools to benchmark progress, as well as the challenges of creating a truly cradle-to-cradle product. Herman Miller recognizes that working toward cradle-to-cradle products is a journey that will involve continuous improvement of its products.     

A comparative study of FMS tool allocation and part type selection approaches for a varying part type mix

Hankins and Rovito (1984) examined the impact of different tool policies on cutting tool inventory levels and spindle utilization for a flexible manufacturing system (FMS). This study provides a broader perspective of the impact of tool allocation approaches on flow times, tardiness, percent of orders tardy, machine utilization, and robot utilization. Part type selection procedures have been suggested for the FMS prerelease planning problem. However, very little research has specifically evaluated the part type selection procedures across different tool allocation approaches. Also, with the exception of Stecke and Kim (1988, 1991) no other known study has provided any insights on what tool allocation approaches are appropriate when processing different mixes of part types. This research is devoted to addressing those issues. Three tool allocation approaches, three production scheduling rules, and three levels of part mix are evaluated in this study through a similation model of a flexible manufacturing system. The specific impacts of the tool approaches, their interaction effects with the part type selection rules, and their effectiveness at different part type mix levels are provided through the use of a regression metamodel.     

Evaluating Environmental Performance of Pulp and Paper Manufacturing Using the Analytic Hierarchy Process and Life-Cycle Assessment

This article addresses the need for a structured and compre-hensive methodology for assessing the environmental perfor-mance of manufacturing processes. The analytic hierarchy pro-cess (AHP) is used as the basic framework for analyzing environmental impacts and improvement options following a streamlined life-cycle assessment (LCA) approach that is fo-cused on the manufacturing operation. The multicriteria de-cision analysis approach of the AHP is consistent with the LCA concept because the environmental factors can be hierarchi-cally structured into impacts and improvement options. Its po-tential as a valuation tool for impact and improvement assess-ment addresses both qualitative and quantitative issues in environmental decision making.
Through application to a pulp and paper manufacturing case study, the viability of the AHP for evaluating environmen-tal impacts and prioritizing process improvement options rela-tive to these impacts is demonstrated. AHP was used to pro-vide a quantitative tool for the design of a set of weighting factors for impact and improvement analyses.     

Modeling and design optimization of asynchronous flexible assembly systems with statistical process control and repair

This article presents the implementation of hybrid procedures involving the use of analytical performance evaluation techniques, discrete event simulation, and Monte Carlo optimization methods for the stochastic design optimization of asynchronous flexible assembly systems (AFASs) with statistical process control (SPC) and repair loops. AFASs are extremely complex and difficult to analyze in that such systems are subject to starvation and blocking effects, random jam occurrences at workstations, and splitting and merging of the assembly flow due to repair loops. Hence, an integrated approach simultaneously analyzing the interactions between product quality and optimal/near optimal system design is pursued. In the analytical analysis stage, a model based on GI/G/1 queueing network theory is used. In the Monte Carlo optimization stage, two alternative stochastic optimization approaches, namely, heuristic versions of stochastic quasigradient and simulated annealing algorithms, are implemented and compared in terms of their capabilities of solving complex AFAS design problems. The hybrid procedures presented appear to perform reasonably well in designing AFASs to reach a target production rate.     

Catalytically inactive condensation domain C1 is responsible for the dimerization of the VibF subunit of vibriobactin synthetase

Nonribosomal peptide synthetases (NRPS), fatty acid synthases (FAS), and polyketide synthases (PKS) are multimodular enzymatic assembly lines utilized in natural product biosynthesis. The oligomeric structure of these assembly line enzymes has been a topic of interest because higher order oligomeric quaternary structural arrangements allow for alternate paths of acyl intermediate elongation and present unique challenges for the chimeric engineering of hybrid assembly lines. Unlike other NRPS systems that in general appear to be monomeric, the six domain (Cy1-Cy2-A-C1-PCP-C2) VibF subunit of vibriobactin synthetase has previously been shown to be dimeric, the same oligomeric state as that observed for FAS and PKS assembly lines. It has been demonstrated that the C1 domain within VibF is catalytically inactive and is not required for vibriobactin production. Utilizing sedimentation equilibrium analytical ultracentrifugation experiments to determine the oligomeric states of several VibF subfragments, we report that the C1 domain is largely responsible for VibF dimerization. Comparative rates of vibriobactin production, coupled with dissociation constants for VibF subfragment pair heterocomplexes, suggest that the mere presence of C1 does not detectably enhance the catalytic rates of neighboring domains, but it may properly orient Cy1-Cy2-A relative to PCP-C2.     

Tool addition strategies for flexible manufacturing systems

The allocation of tools to machines determines potential part routes in flexible manufacturing systems. Given production requirements and a minimum feasible set of tools, the decision of how to fill vacant slots in tool magazines to maximize routing flexibility is shown to be a minimum cost network flow problem for the cases when routing flexibility is a function of the average workload per tool aggregated over tool types, or of the number of possible routes through the system. A linear programming model is then used to plan a set of routes for each part type so as to minimize either the material handling requirement or the maximum workload on any machine. The impact of these tool addition strategies on the material handling and workload equalization is investigated and computational results presented. The advantage of the overall approach is computational simplicity at each step and the ability to react to dynamic changes.