Roberto F. Lu

Flexible manufacturing systems for mass customisation manufacturing

This paper presents innovative approaches in realising and exercising mass customisation in theoretical and practical applications. Strategies of generalised production line platform and modularisation are explored to support dynamic reconfigurations of mass customisation. NISTs XML-based Shop Data information integration specification is utilised to derive a data driven reconfigurable mass customisation modelling methodology. A simulation model of a Boeing aircraft major component assembly line is created and driven by a batch control file, which is generated from the XML-based Shop Data specification.

Asynchronous stochastic learning curve effects in engineering-to-order customisation processes

As industrial technology progresses from tailored customisation and mass production all the way to mass customisation, the demand for faster order-to-delivery time keeps increasing, especially for those products that require lengthy customised engineering-to-order (ETO) tasks among multiple partners. Products such as commercial airplanes and ocean vessels, which have delivery demands before the integrated production system has reached a steady production pace, involve partners progressing through their engineering tasks at asynchronous stochastic learning curve (ASLC) rates. This paper aims to contribute to the research by revealing the novel ASLC model and addressing ETO-related processes. An application of the ASLC model in an ETO case study by using sanitised real production data is also presented.

Manufacturing process modeling of Boeing 747 moving line concepts

There are thousands of jobs performed on the Queen of the Sky, the Boeing 747, final assembly line for each airplane. When the decision was made to implement a moving line for the final assembly of the 747 it was absolutely necessary to evaluate many aspects of these jobs. Discrete event simulation models were constructed to analyze numerous 747 final assembly moving line scenarios throughout several phases. These models not only presented a visual understanding of different concepts, but also provided quantitative analysis of suggested scenarios to the moving line team. The results presented highly optimized production flows and processes, reducing cost and flow time from the traditionally 24 days to the targeted possible 18 days. This work outlined some of the moving line concepts, modeling objectives, and simulation analysis. Utilizations of different assembly positions were yielded as the result of discrete simulation modeling of many bundled jobs and stands of the 747 final assembly operation.

Implementation of core manufacturing simulation data in aerospace industry

This presentation will describe how Boeing implements the Core Manufacturing Simulation Data (CMSD) information model. The presentation will include visualization of manufacturing data for parts and tooling visibility in manufacturing industry. Simulation analyses are prepared by extracting and formatting data from real world production databases. This includes automatic data processing, automatic curve fitting for distribution functions, automatic CMSD file generation, and finally data is automatically fed to simulations.

Designing and Planning for Mass Customization in a Large Scale Global Production System

An approach to the analysis of the design, planning, and operation of a global, large scale, mass customization production system is presented. Methods used to perform this analysis include discrete event simulation and statistical analytical modeling techniques. First, a detailed literature survey of the area is presented, followed by a description of the approach and then a short case study.

Panel discussion: business processes for applying de simulation effectively in manufacturing companies

A panel of simulation managers from manufacturing companies discuss the following six topics: (1) How are managers responsible for manufacturing best persuaded to try simulation? (2) How can capturing the benefits of simulation best be made a regular process? What are the roles of model databases and reuse, input databases, standardization, change management, simulation project management, and training in such a process? (3) What other areas should one consider in addition to the ones listed in item 2 above in such a process? (4) Where should the Simulation Services Department reside in the organizational structure of a manufacturing company? Should it be centralized or decentralized? (5) How can simulation usage (“the first project”) best be undertaken to be a success? (6) How can momentum best be maintained after simulation usage is accepted?

A six sigma DMADV project: the 787 LCF scheduling tool

The Boeing 787 program revolutionized many aspects of commercial airplane production. One of the unique aspects of its global production system is that the major 787 structure components are transported via a small fleet of freighter airplanes. These freighter airplanes, called the Large Cargo Freighter (LCF), fly among five production sites to transport the 787 components forward and return their respective carrying tools back to their original sites. Simulating and optimizing LCF logistics related factors is an art as much as a science. This presentation depicts a Six Sigma approach combined with simulation modeling to improving existing tools and methods of the 787 LCF logistics. It is often difficult to start and conclude a LEAN Six Sigma project using simulation modeling. This presentation aims to share the valuable lessons learned through the practice of LEAN Six Sigma using simulation modeling.