Enhancing Manufacturing Efficiency Through Alarm Flexibility in Smart Systems
Disruption of a workstation is the major contributor to the downtime in any manufacturing process, and it impacts the performance, cost, consumer’s centric value, and efficiency. The effect cascaded in the whole assembly line by blockage and starvation caused by defective workstations. Co...
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| Format: | Article |
| Language: | English |
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IEEE
2023-01-01
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| Series: | IEEE Access |
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| Online Access: | https://ieeexplore.ieee.org/document/10185544/ |
| _version_ | 1797771677599268864 |
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| author | Ihtisham Ul Haq Hamza Ahmad Khan Ghassan Husnain Latif Jan Sangsoon Lim |
| author_facet | Ihtisham Ul Haq Hamza Ahmad Khan Ghassan Husnain Latif Jan Sangsoon Lim |
| author_sort | Ihtisham Ul Haq |
| collection | DOAJ |
| description | Disruption of a workstation is the major contributor to the downtime in any manufacturing process, and it impacts the performance, cost, consumer’s centric value, and efficiency. The effect cascaded in the whole assembly line by blockage and starvation caused by defective workstations. Consequently, the key to appropriately allocating resources and limiting downtime is an accurate understanding of the aftermath of each disturbance. The work presented here investigates how disruptions at a single workstation can affect nearby workstations. The researchers modified the Alarm Trip Point (ATP) by setting a threshold value for a malfunctioning workstation. This can increase or decrease the ATP depending on the state of the workstation. By using this strategy, downtime and batch rejection can be reduced. The researchers then extended their study from a single workstation to multiple workstations, creating a more general model. They deployed their strategy to an asphalt processing plant as an experimental case study in order to illustrate how effective it is in decreasing downtime, frequent starts and stops, and numerous rejections. The proposed approach in the study resulted in a decrease in the number of starts and stops, downtime, and a number of rejections by a significant amount. The number of start-stop events was reduced by 60%, resulting in a significant decrease in the number of rejections and downtime, and finally increasing the consumer-centric value and efficiency. The study also presented a comparison of the proposed approach with the ATP approach by Yu et al., which showed that the proposed approach outperformed the ATP approach in terms of reduction in downtime and rejection. |
| first_indexed | 2024-03-12T21:40:03Z |
| format | Article |
| id | doaj.art-0b49fdd3939c4d9b93e7951a0427068c |
| institution | Directory Open Access Journal |
| issn | 2169-3536 |
| language | English |
| last_indexed | 2024-03-12T21:40:03Z |
| publishDate | 2023-01-01 |
| publisher | IEEE |
| record_format | Article |
| series | IEEE Access |
| spelling | doaj.art-0b49fdd3939c4d9b93e7951a0427068c2023-07-26T23:00:43ZengIEEEIEEE Access2169-35362023-01-0111757157572410.1109/ACCESS.2023.329649110185544Enhancing Manufacturing Efficiency Through Alarm Flexibility in Smart SystemsIhtisham Ul Haq0https://orcid.org/0000-0003-1756-7954Hamza Ahmad Khan1Ghassan Husnain2https://orcid.org/0000-0001-6637-6754Latif Jan3https://orcid.org/0000-0003-4355-5412Sangsoon Lim4https://orcid.org/0000-0001-9924-7115Department of Mechatronics Engineering, University of Engineering and Technology Peshawar, Peshawar, PakistanDepartment of Mechatronics Engineering, University of Engineering and Technology Peshawar, Peshawar, PakistanDepartment of Computer Science, Iqra National University, Peshawar, PakistanDepartment of Computer Science, Iqra National University, Peshawar, PakistanDepartment of Computer Engineering, Sungkyul University, Anyang, South KoreaDisruption of a workstation is the major contributor to the downtime in any manufacturing process, and it impacts the performance, cost, consumer’s centric value, and efficiency. The effect cascaded in the whole assembly line by blockage and starvation caused by defective workstations. Consequently, the key to appropriately allocating resources and limiting downtime is an accurate understanding of the aftermath of each disturbance. The work presented here investigates how disruptions at a single workstation can affect nearby workstations. The researchers modified the Alarm Trip Point (ATP) by setting a threshold value for a malfunctioning workstation. This can increase or decrease the ATP depending on the state of the workstation. By using this strategy, downtime and batch rejection can be reduced. The researchers then extended their study from a single workstation to multiple workstations, creating a more general model. They deployed their strategy to an asphalt processing plant as an experimental case study in order to illustrate how effective it is in decreasing downtime, frequent starts and stops, and numerous rejections. The proposed approach in the study resulted in a decrease in the number of starts and stops, downtime, and a number of rejections by a significant amount. The number of start-stop events was reduced by 60%, resulting in a significant decrease in the number of rejections and downtime, and finally increasing the consumer-centric value and efficiency. The study also presented a comparison of the proposed approach with the ATP approach by Yu et al., which showed that the proposed approach outperformed the ATP approach in terms of reduction in downtime and rejection.https://ieeexplore.ieee.org/document/10185544/Disruption handlingalarm trip pointmanufacturing process |
| spellingShingle | Ihtisham Ul Haq Hamza Ahmad Khan Ghassan Husnain Latif Jan Sangsoon Lim Enhancing Manufacturing Efficiency Through Alarm Flexibility in Smart Systems IEEE Access Disruption handling alarm trip point manufacturing process |
| title | Enhancing Manufacturing Efficiency Through Alarm Flexibility in Smart Systems |
| title_full | Enhancing Manufacturing Efficiency Through Alarm Flexibility in Smart Systems |
| title_fullStr | Enhancing Manufacturing Efficiency Through Alarm Flexibility in Smart Systems |
| title_full_unstemmed | Enhancing Manufacturing Efficiency Through Alarm Flexibility in Smart Systems |
| title_short | Enhancing Manufacturing Efficiency Through Alarm Flexibility in Smart Systems |
| title_sort | enhancing manufacturing efficiency through alarm flexibility in smart systems |
| topic | Disruption handling alarm trip point manufacturing process |
| url | https://ieeexplore.ieee.org/document/10185544/ |
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