Adam Hamrol

Application of Virtual Reality Techniques in Design of Ergonomic Manufacturing Workplaces

This paper presents possibilities of application of the immersive VR and the haptic technologies during the complex process of design and virtual prototyping of the manufacturing workplaces characterized with a high level of ergonomic quality. Two case studies are presented: a workplace for stud welding and a set of two workplaces, for hole drilling and manual assembly. In the first case study, haptic device with force feedback effect was used to improve ergonomics of main operator activities. In the second case study, immersive approach was used, namely Head-Mounted Device, tracking and gesture recognition systems, to test and improve ergonomics of the whole workplace. Application of VR techniques allows to present the virtual prototype of the workplace in its real operation environment, limiting the need for use of real mock-ups. Therefore, Virtual Reality allows to conduct a number of analyses related to designed prototypes, such as: dimensions of devices and possibilities of adjustment to height of the human operator, and arrangement of control and signaling devices according to the rules of ergonomic design. To conduct these analyses, full interaction between user and workplace must be programmed, including collision detection, kinematics of the devices and possibilities of activating their various functions in relation with other objects in the virtual scene.

Excellence toolbox: Decision support system for quality tools and techniques selection and application

The paper presents a decision support system for quality tools and techniques (QT&T) selection and application. While solving problems and improving enterprise processes and products, there is often a significant problem connected with fast, easy and flexible choice of appropriate tools for solution activities. The premise of the system elaboration was richness and variety of quality tools – ranging from technological solutions (e.g. statistical process control (SPC)) to organisational and behavioural techniques (e.g. nominal groups technique (NGT)), as well as the lack of applications, making fast and apt selection of QT&T, especially in the production conditions. The system includes knowledge about management tools and techniques and, in contrast to traditional handbooks, is written in structured form. It should be stressed that this knowledge not only describes the possibilities of tool usage (theoretical view), but also points out the constraints in their practical implication (knowledge captured from enterprise experts). The system contains also the so-called dynamic knowledge, resulting from learning processes, based on the history about previous users’ choices concerning QT&T and their effectiveness in practice (evaluated also within the system). Both of them allow support of the final decision about tool selection, taking multi-criteria (defined by the user) into consideration.

Virtual 3D Atlas of a Human Body - Development of an Educational Medical Software Application

Abstract This paper presents a process of building a prototype of an educational application for teaching anatomy with elements of physiology, with use of a Virtual Reality environment. Preparation of mesh models of individual human organs is described, along with further visualization techniques, which were used to ensure a proper level of a visual representation. Stages of user interface preparation are also described – both visual and functional aspects covered – with a detailed review of a visual programming process, which was used to obtain a logical structure of connections inside the VR environment. Process of preparation of dynamic graphical data-namely animation of the pulmonary alveoli – and integration it with the virtual environment is also presented. The final application can be used in a number of ways, including large-screen stereoscopic projection with on- screen graphical user interface and single-user immersive stereoscopic projection using a head-mounted device with an optical tracking system. Results of assessment of the application advantages and disadvantages at the current stage of development allowed to formulate several directions of further advancement.

Application of agent technology for recycling‐oriented product assessment

Purpose – The paper aims to describe ideas and implementation of the computer tool for computer‐aided and recycling‐oriented design. Currently, there is a strong tendency to take into account the impact of a product on the natural environment. The authors concentrated on the issue of the recycling process of the product, taking into account the phase of its design. The purpose, structure, technology and example results are presented in this paper.Design/methodology/approach – It was assumed that analysis will be performed based on a set of measures of a product. These measures (developed by the authors), describing the product from the recycling point of view, are calculated automatically, according to the changes (variants) in the products model. The presented tool is based on agent technology. The structure of the system – the agents, its roles and communication between them – has been described.Findings – The main achievement of the work presented in this paper is the method supporting eco‐design base...

Computation of Mechanical Properties of Parts Manufactured by Fused Deposition Modeling Using Finite Element Method

The paper focuses on a problem of evaluation of strength of products manufactured using Fused Deposition Modelling technology. The presented research was aimed at developing a method for computation of deformation and stresses in any product manufactured using FDM technology, with consideration of important, strength-affecting process parameters. Finite Element Method calculations were realized using digital CAD models of the products, obtained by simulation of FDM process in a virtual environment. These models represent the macrostructure of additively manufactured elements. Results of calculations for sample geometries were verified by experimental studies. The obtained results are mostly correct, changes in approach are needed to make the computations possible to be performed in shorter time and with better results.

Statistical Approach to Making Decisions in Manufacturing Process of Floorboard

The study was conducted at a Polish company operating in the wood industry under the R&D project “Increasing the effectiveness of use of wood in manufacturing processes”, aimed at reducing raw material waste in the surface layer manufacturing process. Results of our studies on the improvement of the wet cutting technology are presented in this paper. Minimization of variability is the first step to reduce material consumption in the process of cutting wood into lamellas. Appropriate values of factors which significantly affect lamella thickness after the cutting operation can be determined through real-life experiments. The methodology is to improve and/or reduce operational allowances and to redesign the tolerance and machine parameters/setting.

Measurement System Analysis Combined with Shewhart’s Approach

The paper presents new procedure of methodology for statistical assessment of measurement systems variation (methodology known in the literature as Measurement Systems Analysis, MSA). This procedure allows for calculation and monitoring in real time (that is on-line) of measurement system (MS) characteristics which determine its usability for manufacturing process control. The presented solution pointed out the gap in process control, which consists in lack of methods for monitoring measurement processes in the on-line way. Their key point consists of taking samples that are also needed for the process control chart for the needs of the MSA method. This means that the samples are taken directly from the production line and during the production process. The method is combined with the standard procedure of statistical process control (SPC) with the use of process control charts. It is based on two control charts. The first one is called AD-chart (Average Difference chart) and it allows to estimate the variation between the operators and stability of the monitored measurement system. The second control chart illustrates the %R&R index (Repeatability and Reproducibility) and allows to monitor the MS capability.The paper also presents authors’ proposal of guidelines about the reference value for the %R&R index calculation and assessment. Recommendations and guidelines for choosing the reference value are based on two criteria: information about sample and manufacturing process variation and the purpose of using MS (product or process control).

Information quality in design process documentation of quality management systems

Information attributes for evaluating quality of process information have been established.A methodology of evaluating quality of process information is proposed.When designing the process documents, the information requirements of the process executor need to be taken into consideration.There exists a relation between attributes of process information and the type of process realized. Information is the main constituent of documents that make up a quality management system. The main function of information found in process documents is to provide knowledge regarding how to executing a process and to standardize this process by providing a specific path of execution. However, it is not easy to determine a standard level of quality of process information optimal from the viewpoint of the owner and the process executor. Since there is no universal standard that would allow evaluation of the quality of process information, the purpose of the presented studies was to solve the aforementioned problems and to provide practical solutions for document makers to design proper process descriptions. To achieve the main purpose, a methodology for examination of influence characteristics of processes on information requirements of users of process documents was created. The paper presents findings carried out in processes at enterprises and is aimed at finding relation between attributes describing information and characteristics of processes. The paper proposes a set of guidelines developed by the authors for selection of appropriate document characteristics. These guidelines are based on findings collected from the conducted research.

Preparation and Production Control in Smart Factory Model

Implementing the smart factory concept places demands not only for enterprises but also for scientific units. In order to be able to effectively develop solutions in compliance with the Industry 4.0 concept, it is necessary to improve qualifications of scientific personnel and students who are supposed to implement those assumptions in practice. The paper describes the structure of smart factory model, developed at Poznan University of Technology, which enables both learning about such solutions and doing research work in that scope. The model includes issues connected with the field of production management – starting from interpretation of client requirements, to automation of product design development, to preparing and controlling the production process.

The Role of Human Motivation in Quality Inspection of Production Processes

Despite fast technological progress, machine-oriented production solutions and more demanding customer needs still human presence in production is evident, important and needed. In quality inspection human uses own senses when deciding about products quality. Decisive step is then the most complex part of inspection with regard to big number of product attributes, variable attributes and often limited possibility to measure product characteristics. Attribute inspection is much more difficult than control based on measurements and figures. Effectiveness of attribute inspection is always lower than based on measurements due to risk of human mistake during inspection. It can appear two types of failures during inspection: defects overlooking, improper classification. Human is unreliable part of inspection. One of key factors influencing on inspection performance is motivation. Motivation types differs people. With regard to that fact it is stated that human motives investigation needs to be carried out already on personnel selection phase.