Cranfield University

- the UKs university for Business Dr Benny Tjahjono

Senior Lecturer (Associate Professor) Manufacturing Systems Engineering Director of the Manufacturing Masters Programme

UK Manufacturing Footprint

Research
Top 5 research intensive UK universities*, with Oxford, Cambridge, Imperial College & University College London

*research income as percentage of turnover

Leader in direct industrial funding

16% 14% 12% 10% 8% 6% 4% 2% 0%

Research income earned from UK industry as a proportion of total income

Learning close to practice

Build synergies between academia, industry and policy makers Cranfield is actually the kind of institution that is a model of what I am proposing
Richard Lamberts review of Business-University Collaboration (2003)

Industry-sponsored Group & Individual projects Industry-case studies during lecture

Manufacturing systems

Niche technology areas

Ultra Precision & MicroMachining Lab

Doctoral research

I was seen as a more attractive employee by the industry than before doing my postgraduate courses. I also felt more confident. Once I got a job after my MSc & PhD, the courses helped me to grow further in my company

Research quality World class facilities Core research skills training Outstanding staff International networking Attend conferences

Dr Enrique Miarro Viseras President Emerson Industrial Automation

Personal research profiles

Research theme

Methods

Modelling & Simulation

Multi disciplinary
Applications

Grants

In total ca 1.1M Sponsors:

Research council 4 EPSRC/IMRC projects Directly from industry: Ford, Airbus, Bosch, Unilever

Involvements:
TSB (Dept of Trade & Industry) European Union University bilateral agreements

EPSRC grants

EP/K504221/1 LINE-TRACK: technology to improve overall yield during the manufacturing process (P) EP/I033246/1 EPSRC Centre for Innovative Manufacturing in Through-life Engineering Services (C) EP/E037631/1 An Evolutionary Approach to Rapid Development of Simulation Models (P)

Direct industry funding

Publications

>45 academic publications >20 journal papers >25 conference papers >5 articles in trade/industry journals/magazines >20 industry reports and working papers

Postgrad Supervision

7 completed PhDs 4 current PhD students 42 completed MSc 5 current MSc students

Research group
Kevin

RapidSim

Zainal

Online simulation Modelling & Simulation

NextGen Sim tools

PSS Modelling

Evandro

Sarocha

Simulation Documentation

New recruit

Heijunka
Patricia Jrg

Research examples

10

Reduce Manufacturing Cost

Increase production output

Improve machine efficiency

efficiency

Filling line

Performance

11

Online data collection

Captures uptime, downtime & other stoppages Can be used to analyse production losses, sources of inefficiency, flags up urgent problems Identifies critical machines (greatest impact on overall productivity) However, only considers the loss detection from the point of view of time and production rate

Ingredients

12

Yield monitoring

Traces process yield and diagnoses the potential sources of yield losses Carries out an online mass balance Losses towards the end of the production batch can be predicted based on the performance degradation Need fault prognostic functions to forecast the projected yield

Challenges

What is the most effective method to track yield? Can prognostics or predictive techniques be used on non-mechanical systems? How to capture a healthy balance of ingredients? What measuring equipment/sensor technologies are available? How is the algorithm be formed?

13

New manufacturing paradigm

Reduce Maintenance Cost

Know exactly when the trains need maintenance

Improve scheduling, spare parts efficiency

14

Maintenance of coupled-systems

Need guaranteed performance Penalties imposed if performance not met! More accurate maintenance is needed

Coupled-systems

Characterised by dependencies between its components; exhibits symbiotic reliability Scheduling of preventive maintenance, spare part provision/inventory, resource allocation, etc. is challenging Need a mathematical modelling of imperfect maintenance: safe, economically justified, just-intime and just enough in order to ensure continuity of operations

15

Online simulation

Reduce Overall Cost

Balancing the cost of operations and energy

Improve layout, buffer sizes, scheduling

16

Manufacturing Systems Design

Production outputs are primary key metric used to measure the performance Fixed costs (mainly labour) per shift Need to produce a lot to reduce unit cost Assess operating scenarios to maximise profit

Environmentally conscious

Scarcity of natural resources, soaring cost of energy and the pressure from environmental legislations, many other key metrics have a significant cost implication Power used by the machines, disposal of waste, building heating/cooling requirements, removal of waste material, usage of water, gas and electricity have now become top priorities Should be incorporated into the design of sustainable manufacturing systems.

17

Machining line

Energy monitoring (Hall effect) Data acquisition

18

Host of International researchers

Dr Gustavo Pelaez
Holonic approach to Service-oriented Manufacture Universidade de Vigo, ES

Dr Ornella Benedettini
Modelling and Simulation Politecnico di Bari, IT

Dr Francesco Zammori
Module-based simulation Universita di Pisa, IT

Mr Evandro Leonardo
Online simulation University of Brasilia, Brazil

International links

Italy: Pisa, Genoa, Bari Spain: Vigo, Madrid, Valencia Portugal: Catolica de Portuguesa, UNINOVA France: Ecole de Mines dAlbi Brazil: University of Brasilia Malaysia: Universiti Kebangsaan Singapore: SimTech

19