The Assessment of Industrial Manufacturing Systems

21st IBIMA Conference Vision 2020: Innovation, Development Sustainability, and Economic Growth 27th – 28th June 2013, Vienna, AUSTRIA

The Assessment of Industrial Manufacturing Systems Towards Advanced Operations by Means of Integrated Modeling Approach Numan M. Durakbasa, Department of Interchangeable Manufacturing and Industrial Metrology, Institute for Production Engineering and Laser Technology, Vienna University of Technology, Vienna, Austria, [email protected] Gökcen Bas, Department of Interchangeable Manufacturing and Industrial Metrology, Institute for Production Engineering and Laser Technology, Vienna University of Technology, Vienna, Austria, [email protected] Lukas Kräuter, Department of Interchangeable Manufacturing and Industrial Metrology, Institute for Production Engineering and Laser Technology, Vienna University of Technology, Vienna, Austria, [email protected] Günther Poszvek, Department of Interchangeable Manufacturing and Industrial Metrology, Institute for Production Engineering and Laser Technology, Vienna University of Technology, Vienna, Austria, [email protected] Abstract The industrial sector driven by profitability and competitiveness faces with daunting challenges of energy demand, environmental constraints and credible high-quality performance in its operations. The modern methods of energy management, environmental management and quality management focus on pathways to more efficient, cost-effective and competitive operation within an integrated framework of the standards. Many countries already adopted the national standards and frameworks have proven to have a success report in increased awareness. The common elements of the standards provide the methodology to be integrated systematically. Hence, in this work a systematic modeling approach is proposed that will serve as a guidance to fulfill the required key performance indicators of energy, environmental and quality aspects in an industrial manufacturing system under the guidance of the international standards. Moreover, the industrial and technological developments devoted to the practice of advanced industrial and manufacturing processes are of essence as a part of the strategy to be considered in the proposed systematic modeling approach. In this respect, the measurement technology meets the essential information and know-how to provide solutions to the operations of industrial manufacturing industry development. Therefore, contribution of the metrology is clarified and related within the proposed systematic model together with the international standards defining measurable and correlated parameters that provide furthermore the prospects of advanced manufacturing systems. Keywords: Energy management, environmental management, quality management, metrology, industrial manufacturing systems

1. Introduction The industrial manufacturing sector handling a variety of products and service are vulnerable to the global challenges of climate change, supply security and price volatility of energy. The target

21st IBIMA Conference Vision 2020: Innovation, Development Sustainability, and Economic Growth 27th – 28th June 2013, Vienna, AUSTRIA of energy and environmental impact reduction is now more important than ever becoming a business priority as well as national strategies. In the World Energy Council (WEC) Report (2010), energy efficiency is pointed out as the key solution to achieve the targets at the lowest cost. Moreover, the savings potential of CO2equivalent per year compared to a baseline scenario is estimated 2 to 5.1 Gt by 2030 if energy efficiency opportunities are considered according to the Fourth Assessment Report of the Intergovernmental Panel on Climate Change (IPCC) (2007). After the European Parliament and Council’s legislative Climate & Energy Package and 20-20-20 Targets (reduction of greenhouse emissions by at least 20%, final energy consumption with renewable energy sources by 20%, raising energy efficiency by 20% by 2020) in 2008, the European Commission published a Communication (2010) putting emphasis on the necessity of improved efficiency and decreased energy consumption leading to reduction in greenhouse gas (GHG) emissions. The set of targets that formed the most important legislative framework of EU energy policies are investigated by Bas et al (2006): The “RES-E Directive” 2001/77/EC, The “Biofuels Directive” 2003/30/EC, The “Energy saving in buildings” 2002/91/EC, The “Promotion of Cogeneration” 2004/8/EC, The “Common rules for the internal market in electricity” 2003/54/EC, The “Greenhouse Gas Emissions Trade Directive” 2003/87/EC, The “Joint Implementation / CDM Linking Directive” 2004/101/EC and National Allocation Plans of Member States. Worldwide research is in a sharp transition to meet the demand of global market trends. Today's manufacturing industry is in demand of collective experience and knowledge to establish profitable and competitive operations while overcoming the challenges of volatile energy prices together with environmental constraints and high quality aspects in their operations.

2. A Methodology based on the Integrated Management System Integration Approach The quality management system that can be integrated with the environmental and energy management systems in compliant with the international standards of ISO 9001 (2008), ISO 14001 (2009) and ISO 50001 (2011) is the fundamental strategy to obtain the required operation conditions for a competitive manufacturing organization. Durakbasa et al studied the operating models to the manufacturing plants that are developing to keep up with the robotic and automation applications for advanced industrial processes. The simulation of the control systems for development of computer aided, automated production is demand driven aspects that states the future of the manufacturing industry. Many countries already adopted the energy management systems as a part of their national standards or specifications with voluntary agreements and have proven to support the energy efficiency policy by operating green in every sector. Fig 1 represents some of these countries in chronological order.


Fig 1. The National Energy Management Standards of some countries The trend of automation, process monitoring and control is modeled under the integrated management approach of international standards as represented in the Fig. 2. The management system is modeled based on the continuous improvement approach. The closed loop represents the integrated management system approach that can be applied under the guidelines of the international standards.

Fig 2. The integrated management system approach model

3. The Manufacturing Industry Applications It’s of extreme importance in present time of worldwide international competition in industry and production engineering to save time on the one hand and on the other hand to keep an eye on increasingly higher costs of energy and raw materials. Comprehensive knowledge in the areas of market requirements, product and process development and design, intelligent metrology and end of life management are important presuppositions to achieve rapid, agile, waste free and costeffective production of innovative, customized complex products using next-generation materials as well as to protect the environment by making zero emissions and improve environmental sustainability and reduce the use of energy by using smart manufacturing systems. Today the fast-changing market needs require manufacturing processes, which allow rapid adaptation. The continuous more used processes are rapid technologies. Through additive manufacturing, they enable inexpensive and variable production components. Applications through rapid technologies are diverse and can be used in many different areas. Therefore, it is important for small and medium-sized enterprises to use these production methods. That is the reason for following question: Which criteria are to be followed by small and medium-sized enterprises in choosing a method? In addition to the economic aspects, that relate to the different methods, you have to pay attention whether the service is purchased or self-produced. Due to these criteria, it was possible to create guidelines for small and medium enterprises in Austria.


3.1 The Rapid Technology as Criteria in the Manufacturing Industry The topic of generative production in particular with rapid prototyping using advanced metrology methods is essential in the advanced manufacturing industry. The motivation of this implementation work assessment is the need for higher cost efficiency in production and economical operations. To create quick and easy prototypes has been an increasingly important process for businesses. The use of the rapid technology and the correct method provides fast customization. Using an example, a planetary gear, results and experiences could be gained correspondingly. Rapid Prototyping (and its applications Rapid Tooling and Rapid Manufacturing) are generally regarded as a synonym for additive manufacturing processes whose generic name is generative manufacturing processes. A comprehensive description of all aspects of the Rapid Prototyping is studied by Gebhardt (2003). The most frequently used generative manufacturing processes in the industry are detailed in the Table 1. Table 1: The The most frequently used generative manufacturing processes in the industry. Process (generic name)

Abbr.

Stereolithography SL

SL

Extrusion; Fused Layer Modeling 3D-Printing; Three Dimensional Printing

FLM

3DP

Laser Sintering

LS SLS

Layer Laminate Manufact.

LLM

Process Description Polymerisation of liquid Monomers Extrusion of thermoplastic Materials Joining of powders using binders Local melting of thermoplastic Materials Joining of foils, e.g. by gluing

Process (brand name)

Abbr.

Manufacturer

Stereolithography

SL

3D-Systems, Objet

Fused Deposition Manufacturing

FDM

Stratasys

3D Printing

3DP

Z-Corp, ProMetal

Selective Laser Sintering; Laser Sintering

SLS LS

3D Systems, EOS, Phenix,

Laminated Object Manufacturing

LOM

Cubic Technologies

The rapid technology applications offer a roadmap for decision making in the process of which choosing the relevant model. The challenging part is that one method may be better suited for large companies than for smaller ones. This work intends that small-and medium-sized enterprises get an overview and find out the most convenient generative manufacturing method to use in the future. To solve the problem, explanation of general operation and an overview of the already popular rapid technology applications are fulfilled as the first step. Then, elaboration of the different process variants are performed to meet the need of minimizing a gear and to find the corresponding manufacturing method. A literature review with subsequent summary of the most important aspects of rapid prototyping process is essential.

21st IBIMA Conference Vision 2020: Innovation, Development Sustainability, and Economic Growth 27th – 28th June 2013, Vienna, AUSTRIA Generally the classic laser or lamp based stereolithography process is called Stereolithography. The ongoing research is focused on the objet machines and that’s the reason why we do our first steps in producing a gearbox at the Institute of Production Engineering and Laser Technology at the Tu-Vienna.

3.2 The Gear Box A planetary gear designed for a measuring robot is an example of advanced technology implementation. In this respect the general term "Geometrical Product Specifications and Verification - GPS" has become recently well-known for the area of mechanical engineering. It defines on a technical drawing the shape (geometry), dimensions and surface characteristics of the workpiece under discussion. The optimal function of the respective part is supposed to be guaranteed considering certain manufacturing tolerances. Greatest emphasis is placed at the definition of the technical drawings on strict compliance with appropriate normative regulations. To represent a work object in an enlarged scale is not a challenge for today's CAD programs. However, production in a manufacturing environment shows the limits of the manufacturing methods. The application of the scaled rows has not been considered here for size gradation. For the choice of the transmission size and the ratio ranges both technical and economic aspects are generally prevail Roloff/Matek as stated by Wittek (2011). The focus is on the production possibilities of small and minimized parts and their determination by means of the geometrical product specification requirements, hereinafter referred to as GPS. In the tooth flanks of the individual gearing mechanism components perfectly surfaces and shapes can be found that are defined in the nanoscale (see Fig 1).

Fig 1. The gearbox model Downscaling of the workpiece brings the tooth flanks (see Fig 2) and their geometry to the nano range. The functionality of the critical surfaces is very important. The planetary gear has to fulfill its function as a whole without any losses or defects. The form and position deviations play an important role and require special attention. A linear transmission occurs on the tooth surface caused by contact with the sun gear. It is examined in this phase to evaluate how far miniaturization can be implemented with a generative process. The creation of records for objects is reduced to the CAD systems. No problems have appeared during production of STL files, so they can be generated easily. However, it is required now to lay the form and position tolerances

21st IBIMA Conference Vision 2020: Innovation, Development Sustainability, and Economic Growth 27th – 28th June 2013, Vienna, AUSTRIA of the workpiece firmly that leads to the challenges in the metrology tasks. To measure tooth flanks are no easy task, especially when the overall dimension present in such a reduced scale of micro or nano-dimensions.

Fig 2. The cut-out profile of a gear-wheel

Therefore, different methods for measuring surface are performed to cope with the challenges considering the dimensions. Functional quality and production costs of a module are significantly influenced by the defined tolerances of the individual components. The ever-increasing quality and efficiency requirements therefore represent today the designer with the task to determine optimal tolerances. The quality and reliability of technical products is mainly determined by the geometric properties of the individual components and assemblies. To ensure the quality of the items and their development process, it is necessary, among other things, establish clear geometric tolerances and to monitor compliance. Generally, one can assume, according to the current state of development of science that practically almost everything can be measured, which is used in product development and in the production of different products, but also for almost any other task. A few limits are still there, on the one hand the economic need was not given and on the other hand there is no market, some measurement methods have been developed by the ever progressive reduction to the nanoscale so that we can perform measurements this area. The modul m is a standard size, all other sizes of the remaining teeth are based on it. The modul is the number which when multiplied by p is the transverse pitch. The modul can be calculated m=d/z, one pair of teeth must always have the same Modul or have to have the same pitch p as studied by Wittel et al (2011). m = d/z = p/π With the downsizing of the modules, the relationships within the assemblies remain in the same proportion. It is thus placed on the functionality according to the value. The measurements are recorded at 99% of the area between the base circle and usable tip and the tooth width. The measurements require the 3D data of the workpiece, both for programming and for the analysis and display the log. The actual measuring is done in scan mode. The measurement is accomplished within a reasonable time range. The advantages of scanning survey are: • fast and accurate measurements with high point density • detecting an almost complete element geometry • objective graphical representation of contours as • roundness • flatness • degree characteristics

21st IBIMA Conference Vision 2020: Innovation, Development Sustainability, and Economic Growth 27th – 28th June 2013, Vienna, AUSTRIA • as well as general shape deviations Functional quality and production costs of a module are significantly influenced by the defined tolerances of the individual components. The ever-increasing quality and efficiency requirements therefore represent today the designer with the task to determine optimal tolerances. To cope with this task statistical tolerance tools can be helpful. The standard deviation σ is a statistical parameter. It characterizes the dispersion of the values of a distribution around the mean µ: in the range µ ± σ, 68% of all values and the range µ ± 3σ (6σ range) already 99.73% of all values.

4. The High Precision Metrology as a Tool of Assessment in Manufacturing Industry The manufacturing industry as developing in micro and nano-scale production requires assessment tools that can be applied and proved in the global market. Hence, important tasks emerge for the measurement technique at the implementation of effective measures. The intelligent measurement process which can be carried out simultaneously in all product realization steps in modern factories - from the design process to the assembly procedures as well as from the after use to the recycling and reuse is the future of the assessment in manufacturing industry. In order to realize automatic measurement and to deal with complex, variable and dynamic quality control problems of the production processes in this environment, the intelligent measurement system will be enhanced comprehensively through self-optimizing processes thrust in the design system and all manufacturing production processes of this environment. Integrated management system with intelligent, associative, concurrent, interactive, modular, integrative, learning, autonomous, self optimizing and self organizing functions will be realized in modern manufacturing industries. The needs of the industry for ultra-high precision engineering and workpieces with a surface roughness less than few nanometers call for measurement instrumentation that can be applied reliably in modern production processes, together with international standards defining parameters and tolerances in the nanometer scale. As presented in the Fig 3, the surface topography as well as the geometrical assessment is the key solution to develop high precision components in the advanced manufacturing industry. The requirements on the measurement systems and the measurement strategy to determine suitable parameters, time, costing and the guarantee of predetermined process stability by means of measurable and correlated parameters come into focus.


Fig 3. The nano scale assessment of surface structure and geometrical topography using a laser scanning microscope

5. Conclusion The integrated management system is a strategic key to the solution of today’s manufacturing industry challenges covering high quality, environmental friendly and energy efficient operations. The international standards that provide the guidelines for any type and size of organizations lay out the key mechanisms in this work. The methodology developed in this work using the integrated management system is applicable for the intelligent design and advanced metrology in all production processes in industrial organizations.

21st IBIMA Conference Vision 2020: Innovation, Development Sustainability, and Economic Growth 27th – 28th June 2013, Vienna, AUSTRIA There exists close interaction between measurement techniques and industrial and technological developments. Special points of interest are quality, environment and energy management, automation and micro and nano technology. Introducing the integrated management approach, the operation of advanced manufacturing industry is assessed by means of high precise metrology techniques. This work provides a methodology for assessment of industrial manufacturing systems towards advanced operations by means of integrated management approach and high precision metrology techniques. This enables the industry to achieve the required efficient and economical performance in the competitive global market. References WEC (World Energy Council) (2010). Energy Efficiency : A Recipe for Success, London, UK, ISBN: 9780946121007. IPCC (Intergovernmental Panel on Climate Change) (2007). Climate Change 2007: Synthesis Report, Summary for Policymakers, Valencia, Spain. European Commission (2010). Commission staff working document accompanying the communication from the Commission to the European economic and social committee and the Committee of the regions, SEC(2010) 650. Bas, G., Kundakci, B. and Ulgen, K. (2006). “The Evaluation of the Renewable Energy Sources in Harmony with the European Union Directive 2001/77/EC in European Union and Turkey”, World Renewable Energy Congress IX, 2006, Florence, Italy. ISO 9001 (2008). Quality management systems - Requirements. ISO 14001:2004 + Cor. 1:2009. Environmental management systems - Requirements with guidance for use. ISO 50001 (2011). Energy management systems - Requirements with guidance for use. Durakbasa N.M., Bauer J.M., Bas G., Riepl D. (2012) “Telepresence and teleoperation in work concept of multifunctional intelligent factories: experience of telepresence in the micro and nano metrology laboratory AuM-TU-Wien”, Quality-Access to Success Journal, Vol.13, S5, 131-136. EN/ISO 9004: 2009; Managing for the sustained success of an organization - A quality management approach. Gebhardt, A. (2003) Rapid Prototyping, Hanser-Gardner Publ., Cincinatti, 1st ed. Wacker, K. (2012), Topographische Zahnradvermessung, [Online], [Retrieved May 20, 2013], http://blog.geomess.de/2012/05/19/topographische-zahnradvermessung. Wittel, H., Muhs, D., Jannasch, D., Voßiek, J., (2011), Roloff/Matek Maschinenelemente: Normung, Berechnung, Gestaltung, 20., überarbeitete und erweiterte Auflage, Vieweg + Teubner Verlag, Springer Fachmedien Wiesbaden GmbH, 5.