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In today's increasingly globalized industrial competition and rapid technological advancements, manufacturing companies strive to improve the quality and quantity of their products. However, intensive use and occasional overloading of machines can lead to decreased performance, shortened lifespan, and component failures. Machine failures not only cause costly downtime but also pose safety risks to workers. This study focuses on PT. Mah Sing Indonesia's efforts to optimize the injection molding process by addressing machine downtime through effective preventive maintenance strategies and comprehensive management approaches. Data collected over the course of 2023 highlights the application of Overall Equipment Effectiveness (OEE) metrics to evaluate machine performance and identify key areas for improvement. The findings underscore the significance of integrating human resources, technology, management practices, and environmental factors to enhance operational efficiency and productivity in injection molding processes. [ABSTRACT FROM AUTHOR]

This study examines the impact of cutting regimes on determining cutting resistance in the processing of polypropylene (PP) using the CNC lathe EMCO F5. The rationale for this research stems from polypropylene's rarity among thermoplastics in possessing structural stability, allowing for its comparison to metals and practical application in products replacing metal parts. Leveraging its favorable mechanical properties, polypropylene finds utility in producing parts subject to dynamic loads, boasting high resistance to impact loads—particularly undesirable in machining. An advantageous characteristic of polypropylene is its affordability, rendering it an economical choice across numerous applications. Despite these merits, polypropylene's exploration in cutting processing remains limited, underscoring the novelty of this research endeavor. The main method for determining cutting resistance involves measuring electric current strength during processing. This direct measurement, facilitated by input cutting regime parameters, is recorded by the PLC controller, with the current value extracted from the machine tool's ammeter. The experimental approach entails varying cutting regime parameters—cutting speed (v), feed rate (s), and depth of cut (a)—across minimum and maximum values, recognized as pivotal factors influencing cutting force development and the attainment of the desired machined surface quality. [ABSTRACT FROM AUTHOR]

In the face of pandemic-induced emergencies and unpredictable natural disasters, industries are compelled to implement rescue plans to mitigate unexpected risks. In this context, Overall Equipment Effectiveness (OEE) is considered as a key metric, followed by sustainability efforts to manage unforeseen risks, encompassing social, environmental, and economic aspects. OEE is considered as a lean tool to determine the efficiency of equipment or processes on par with the world class OEE standard, i.e., 85%. Performance, Availability and Quality as three main drivers of OEE. This research study explores the implementation of OEE in conjunction with sustainability principles in an auto sector manufacturing firm, aiming to enhance operational efficiency and sustainability practices. The research involves a 12-week initial session from April to June 2022, followed by an analysis of July to September 2022, resulting in an impressive OEE value of 48%. Notable improvements in Availability (89.75%), Performance (72.68%), and Quality (73.82%) contribute significantly. The analysis reveals enhancements in scrap rework (17%), training (16%), maintenance (13%), material availability (12%), and production capability (11%). Achievements include improvements in green profile (25%), health and safety (20%), and energy efficiency (25%), along with reductions in carbon dioxide emissions (21%), waste management (17%), and scrap (15%). This research underscores the commitment of the case study industry to sustainable development and economic growth, showcasing significant enhancements in product quality and efficiency. The integration of sustainability principles into OEE initiatives is pivotal for modern industrial optimization. The study results highlight the profound significance of this synergistic relationship, particularly within the blending section, driving substantial positive outcomes in manufacturing processes and operational excellence. The implementation of sustainability efforts not only mitigates risks and fosters growth for automotive manufacturers but also yields environmental benefits. Based on findings of this study, a roadmap for automotive manufacturers is devised to achieve robust OEE while concurrently reaping economic and environmental rewards by employing sustainability principles. [ABSTRACT FROM AUTHOR]

In modern manufacturing systems, efficient production scheduling plays a crucial role in optimizing resource allocation and minimizing production time. This study addresses a complex production scheduling problem in a manufacturing environment with five machines, seven parts, and the integration of two collaborative robots (cobots). The primary objective is to develop an optimized production schedule that allocates machines to parts and tasks to cobots, thereby minimizing the overall production time. To achieve this, a genetic algorithm-based approach is proposed, which iteratively evolves a population of potential solutions over multiple generations. The algorithm considers various factors, including processing times, setup times, and idle times for machines and cobots, while adhering to constraints to ensure a feasible production schedule. The results demonstrate the effectiveness of the genetic algorithm in finding near-optimal solutions that significantly reduce production time and enhance manufacturing efficiency. In the first scenario, the model investigates the production schedule without the integration of cobots. It analyzes the allocation of machines to parts while considering the associated processing times, setup times, and idle times. The results highlight the efficiency gains achieved by optimizing the machine-part assignments. In the second scenario, the model introduces cobots as collaborative agents in the production process. It explores the allocation of tasks to cobots, taking into account the task-specific time requirements. The integration of cobots demonstrates substantial reductions in production time, showcasing the potential of automation in enhancing manufacturing productivity. Overall, this study provides valuable insights into production scheduling optimization, with and without cobot integration, offering practical implications for modern manufacturing systems seeking to improve operational efficiency. [ABSTRACT FROM AUTHOR]

This study examines the impact of cutting regimes on determining cutting resistance in the processing of polypropylene (PP) using the CNC lathe EMCO F5. The rationale for this research stems from polypropylene’s rarity among thermoplastics in possessing structural stability, allowing for its comparison to metals and practical application in products replacing metal parts. Leveraging its favorable mechanical properties, polypropylene finds utility in producing parts subject to dynamic loads, boasting high resistance to impact loads—particularly undesirable in machining. An advantageous characteristic of polypropylene is its affordability, rendering it an economical choice across numerous applications. Despite these merits, polypropylene’s exploration in cutting processing remains limited, underscoring the novelty of this research endeavor. The main method for determining cutting resistance involves measuring electric current strength during processing. This direct measurement, facilitated by input cutting regime parameters, is recorded by the PLC controller, with the current value extracted from the machine tool’s ammeter. The experimental approach entails varying cutting regime parameters—cutting speed (v), feed rate (s), and depth of cut (a)—across minimum and maximum values, recognized as pivotal factors influencing cutting force development and the attainment of the desired machined surface quality.

Innovative carbon reduction and sustainability solutions are needed to combat climate change. One promising approach towards cleaner air involves the utilization of lithium-ion batteries (LIB) and electric power vehicles, showcasing their potential as innovative tools for cleaner air. However, we must focus on the entire battery life cycle, starting with production. By prioritizing the efficiency and sustainability of lithium-ion battery manufacturing, we can take an essential step toward mitigating climate change and creating a healthier planet for future generations. A comprehensive case study of the leading LIB manufacturers demonstrates the usefulness of the suggested hybrid methodology. Initially, we utilized the Malmquist model to evaluate these firms' total efficiency while dissecting their development into technical and technological efficiency change components. We employed the Epsilon-Based Measure (EBM) model to determine each organization's efficiency and inefficiency scores. The findings show that the EBM approach successfully bridged the gap in the LIB industry landscape. Combined with the Malmquist model, the resulting framework offers a powerful and equitable evaluation paradigm that is easily applicable to any domain. Furthermore, it accurately identifies the top-performing organizations in specific aspects across the research period of 2018–2021. The EBM model demonstrates that most organizations have attained their top level, except for A10, which has superior technology adoption but poor management. A1, A2, A4, A6, A8, A9, and A10 were unable to meet their targets because of the COVID-19 pandemic, despite productivity improvements. A12 leads the three highest-scoring enterprises in efficiency and total productivity changes, while A3 and A5 should focus on innovative production techniques and improved management. The managerial implications provide vital direction for green energy practitioners, enhancing their operational effectiveness. Concurrently, consumers can identify the best LIB manufacturers, allowing them to invest in long-term green energy solutions confidently. [ABSTRACT FROM AUTHOR]

The global production tends towards more sustainable manufacturing, which forces manufacturers to constantly change and adapt. In our case, we are considering the FESTO CP LAB 400 production line, primarily designed for the training of personnel in the field of automation, which is essential for maintaining competitiveness in today's world. The production line consists of seven fully automated workstations and one manual assembly workstation, which represents the bottleneck of the production system. The paper presents a comparative study of the lines (human assembly vs. collaborative robot assembly) with an emphasis on economic and environmental aspects. The input parameters of the production line were obtained based on real-world measurements, while the assembly time of the collaborative robot was determined through simulation studies. The results of the study are presented graphically and numerically and confirm the contribution of the introduction of a collaborative robot to the assembly workstation in both financial and environmental terms. [ABSTRACT FROM AUTHOR]

The global production tends towards more sustainable manufacturing, which forces manufacturers to constantly change and adapt. In our case, we are considering the FESTO CP LAB 400 production line, primarily designed for the training of personnel in the field of automation, which is essential for maintaining competitiveness in today's world. The production line consists of seven fully automated workstations and one manual assembly workstation, which represents the bottleneck of the production system. The paper presents a comparative study of the lines (human assembly vs. collaborative robot assembly) with an emphasis on economic and environmental aspects. The input parameters of the production line were obtained based on real-world measurements, while the assembly time of the collaborative robot was determined through simulation studies. The results of the study are presented graphically and numerically and confirm the contribution of the introduction of a collaborative robot to the assembly workstation in both financial and environmental terms.

One of the goals of the Industry 4.0 paradigm is the sustainable success within a mass customization environment, which in turn, depends on the manufacturing efficiency of the transformation processes. In this paper we propose to represent manufacturing efficiency within the context demand fulfillment. The main original contribution of this paper are two demand fulfillment analytical expressions. Their novelty is on the way they are expressed, that is, in terms of the structural elements that define a mass customization environment. Their usefulness was put to the test via a Discrete Event Simulation (DES) model of two different demand fulfillment strategies (namely inventory-oriented level and capacity-oriented chase strategies). The obtained results suggest that the analytical expressions act as a fairly good trend indicator of the missed demand values increase/decrease. A discussion of the managerial implications of these findings are presented at the end of this document.

In the era of Industry 4.0 and the introduction of new technologies, collaborative workplaces represent the potential to increase the efficiency of manufacturing systems. The presented research focuses on studying the impact of changing the speed and acceleration of a Cobot to the number of finished products at a collaborative workstation, the average assembly time, and the utilization of the Cobot and worker. In a laboratory experiment, it was demonstrated that changing the parameters of the Cobot significantly affects the optimization parameters of the collaborative workstation productivity. The results indicate an increase in production capacity with an increase in the speed and acceleration of the Cobot, while at the same time highlighting the importance of uniform utilization and occupancy of the Cobot and worker. The findings are particularly interesting from the influence of the Cobot's audio and video effects on worker, when reducing the average assembly time while increasing the Cobot's capabilities. The results and findings presented open up important new areas of research in the field of social, time and financial justification of collaborative workplaces. [ABSTRACT FROM AUTHOR]

The paper presents the use of simulation modelling methods to evaluate the impact of the collaborative workplaces (human-robot collaboration) importance in correlation to the sustainable manufacturing. Based on an example, numerical simulation results of an existing manual assembly workplace and a newly proposed collaborative workplace are presented using production parameters that describe all three key aspects of sustainable manufacturing: economic, social and environmental aspect. A datadriven simulation model was used, mainly using the input parameters of the real-world production system and numerical assumptions obtained from the literature, with the main objective of detailing the impact on the sustainable orientation of the production process. The results presented in the paper demonstrate the high suitability of simulation modelling methods in the evaluation of existing and newly proposed technologies from the sustainable manufacturing point of view. The results demonstrate that collaborative workplaces, if implemented appropriately and using correct input data, are a possible solution that can cope with limited human resources and ensure high production efficiency. [ABSTRACT FROM AUTHOR]

One of the goals of the Industry 4.0 paradigm is the sustainable success within a mass customization environment, which in turn, depends on the manufacturing efficiency of the transformation processes. In this paper we propose to represent manufacturing efficiency within the context demand fulfillment. The main original contribution of this paper are two demand fulfillment analytical expressions. Their novelty is on the way they are expressed, that is, in terms of the structural elements that define a mass customization environment. Their usefulness was put to the test via a Discrete Event Simulation (DES) model of two different demand fulfillment strategies (namely inventory-oriented level and capacity-oriented chase strategies). The obtained results suggest that the analytical expressions act as a fairly good trend indicator of the missed demand values increase/decrease. A discussion of the managerial implications of these findings are presented at the end of this document. [ABSTRACT FROM AUTHOR]

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Digital Twins (DTs) are one of the disruptive technologies associated with the Industry 4.0 concept. A DT connects the physical manufacturing system with the digital cyberspace, via the synchronization of the simulation (i.e., physical configurations) and data models (i.e., product, process, and resource models) of the manufacturing system. This synchronization of both worlds—the physical and digital—allows one to address the issue of manufacturing customized products. This challenge of mass customization (1) puts forward the goal of achieving the highest level of customer satisfaction, and (2) creates the need for the optimization of the complete value creation process. Within an Industry 4.0 context, the latter is translated as the interlinking of production resources and systems, via a DT, as it is in the physical world where the actual value-creation process takes place. The success of an Industry 4.0 mass customization environment (or mass customization 4.0), depends on its degree/level of sustainability. For these reasons, the present paper presents a review of relevant concepts related to the role of DTs in the achievement of a mass customization 4.0 environment, plus some proposals of how to address the identified research challenges. A future research agenda is proposed at the end of the paper.

Innovative carbon reduction and sustainability solutions are needed to combat climate change. One promising approach towards cleaner air involves the utilization of lithium-ion batteries (LIB) and electric power vehicles, showcasing their potential as innovative tools for cleaner air. However, we must focus on the entire battery life cycle, starting with production. By prioritizing the efficiency and sustainability of lithium-ion battery manufacturing, we can take an essential step toward mitigating climate change and creating a healthier planet for future generations. A comprehensive case study of the leading LIB manufacturers demonstrates the usefulness of the suggested hybrid methodology. Initially, we utilized the Malmquist model to evaluate these firms’ total efficiency while dissecting their development into technical and technological efficiency change components. We employed the Epsilon-Based Measure (EBM) model to determine each organization’s efficiency and inefficiency scores. The findings show that the EBM approach successfully bridged the gap in the LIB industry landscape. Combined with the Malmquist model, the resulting framework offers a powerful and equitable evaluation paradigm that is easily applicable to any domain. Furthermore, it accurately identifies the top-performing organizations in specific aspects across the research period of 2018–2021. The EBM model demonstrates that most organizations have attained their top level, except for A10, which has superior technology adoption but poor management. A1, A2, A4, A6, A8, A9, and A10 were unable to meet their targets because of the COVID-19 pandemic, despite productivity improvements. A12 leads the three highest-scoring enterprises in efficiency and total productivity changes, while A3 and A5 should focus on innovative production techniques and improved management. The managerial implications provide vital direction for green energy practitioners, enhancing their operational effectiveness. Concurrently, consumers can identify the best LIB manufacturers, allowing them to invest in long-term green energy solutions confidently.

Digital Twins (DTs) are one of the disruptive technologies associated with the Industry 4.0 concept. A DT connects the physical manufacturing system with the digital cyberspace, via the synchronization of the simulation (i.e., physical configurations) and data models (i.e., product, process, and resource models) of the manufacturing system. This synchronization of both worlds—the physical and digital—allows one to address the issue of manufacturing customized products. This challenge of mass customization (1) puts forward the goal of achieving the highest level of customer satisfaction, and (2) creates the need for the optimization of the complete value creation process. Within an Industry 4.0 context, the latter is translated as the interlinking of production resources and systems, via a DT, as it is in the physical world where the actual value-creation process takes place. The success of an Industry 4.0 mass customization environment (or mass customization 4.0), depends on its degree/level of sustainability. For these reasons, the present paper presents a review of relevant concepts related to the role of DTs in the achievement of a mass customization 4.0 environment, plus some proposals of how to address the identified research challenges. A future research agenda is proposed at the end of the paper. [ABSTRACT FROM AUTHOR]

Abstract Background The United Nations’ Sustainable Development Goals remind us of the urgent need for every business to operate in ways that are good for planet and people. Manufacturing is a critical sector to address, where industry is compelled to rethink the acts of sourcing, producing, consuming and handling goods and their subsequent ‘waste’ components. Over the last decade in particular, lean and green thinking has emerged as a desirable strategy to improve efficiency and environmental outcomes towards sustainable business practices that meet circular economy objectives. However, moving beyond ad hoc and champion-based take-up by organisations with deep pockets, there is generally a lack of momentum towards mainstreaming such lean and green focused operations in the many small and medium-sized enterprises (SMEs) internationally. This research used case study analysis within the manufacturing sector in Queensland, Australia, to investigate how SMEs could readily engage in lean and green processes to achieve sustainable business practice with regard to the ‘3Ps’ of the triple bottom line (i.e. Planet, Profit and People). ‘Natural resource-based view theory’ and ‘Institutional theory’ were used to develop a conceptual framework to explain the findings. Results The paper describes the lean and green practices observed in the SMEs, drivers for implementation, and the perceived benefits within the realm of sustainable business practice. Building on case study findings, the authors provide the first 3P Model for lean and green strategy, presenting four steps that SMEs can follow, including a 3P matrix of tools to selectively engage with lean and green actions towards sustainable business practice. This model guides SMEs to use the best tools and processes given their circumstances and aspirations. Conclusions The model has the immediate benefit of focusing SME time and resources towards circular economy enquiry, reducing uncertainty and enabling forward-planning. The findings provide practical guidelines to enable SMEs to achieve sustainable business practice while appreciating the ‘triple bottom line’ approach. The findings also have immediate policy and governance implications within the public and private sector, providing guidance on integrating lean and green thinking to advance from doing ‘business as usual’.

The manufacturing of hard disk drive storage is a highly competitive industry due to ever changing technology and the introduction of solid-state storage. Therefore manufacturers have introduced business improvement techniques to help leverage manufacturing advantages over competitors. This paper aims to investigate the integration of business improvement methodologies with intelligent techniques for the improvement of manufacturing efficiency. The authors use a case study based on the disentangling of causal relationships during the manufacturing of hard disk drive components. This paper reports on the application of intelligent system techniques to aid implementation of business improvement methodologies within this manufacturing environment. The results reported highlight that significant gains may be made when utilizing such a hybrid approach. The approach is validated by determining the secondary effects that degraded a previously implemented six-sigma project and also by identifying areas of investigation that enabled engineers to improve process yield. [ABSTRACT FROM AUTHOR]

Abstract Manufacturing efficiency improvement can be achieved by different means, e.g., effective load of equipment, reduced manufacturing time, production cost decrease and Lean manufacturing. The paper reviews the mentioned improvements and focuses on production scheduling aimed to reduce the overall production time. The sequence of simultaneous launch for production is often not considered, but it affects the overall production time. The elaborated production sequence eliminates waste waiting time, reduces production cost and manufacturing time, and thus improves the manufacturing efficiency. The authors propose to apply a software agent, which is engaged with production scheduling and production process improvement that includes the following tasks: effective workload of equipment, production lead-time decrease, organization of continuous product flow on production department. The agent uses such priority levels, as order deadline and class affiliation of ABC analysis in its production scheduling. The paper presents a case study on elaborated production scheduling for manufacturing efficiency improvement. [ABSTRACT FROM AUTHOR]

This article offers an overview of 14 grinding wheel construction modifications used in the peripheral grinding of flatshaped internal and external cylindrical surfaces, when grinding wheels made of conventional abrasive grains are used (Al2O3, sol-gel alumina, SiC, etc.). The text contains characteristics of grinding wheels with mixed grains, glass-crystalline bond, a centrifugal provision of the coolant into the grinding zone, aggregate grains, zones of different diameters, radial rough grinding zone, extended finish grinding segments, active surface macro- and micro-discontinuities, as well as multiporous, impregnated (self-lubricating), sandwich, sectional and segment grinding wheels. Each of the presented structural modifications was described by giving construction scheme, used abrasive grains, range of applications, advantages as well as disadvantages. Modifications of the grinding wheel construction allow for effective improvement of both the conditions and the results of the grinding process. A wide range of the known modifications allows for their proper selection depending on the required criteria of effective evaluation and taking into account the specific characteristics of conventional abrasive grains. As a result, it is possible to obtain positive influence on a number of technological factors of the grinding process. The described modifications of the grinding wheel structure can be also an inspiration and the basis for creating new solutions in this field. [ABSTRACT FROM AUTHOR]

This article offers an overview of 11 grinding wheel construction modifications used in the peripheral grinding of flat, shaped, internal, and external cylindrical surfaces, when grinding wheels made of superabrasive grains are used (natural and synthetic diamonds, as well as mono- and microcrystalline cubic boron nitride). The text contains characteristics of grinding wheels with: bubble corundum grains, glass-crystalline bond, conic chamfer, zones of different diameters, a centrifugal provision of the coolant into the grinding zone, aggregate grains, zone-diversified structure, as well as impregnated (self-lubricating), multiporous, segment and ''intelligent'' grinding wheels. Each of the presented structural modifications were described by giving construction scheme, used abrasive grains, range of applications, advantages as well as disadvantages. Modifications of the grinding wheel construction allow for effective improvement of both the conditions and the results of the grinding process. A wide range of the known modifications allow for their proper selection depending on the required criteria of effective evaluation and taking into account the specific characteristics of superabrasive grains. As a result, it is possible to obtain positive influence on a number of technological factors of the grinding process. The described modifications of the grinding wheel structure can be also an inspiration and the basis for creating new solutions in this field. [ABSTRACT FROM AUTHOR]