Stephen T. Newman

Computer-aided process planning-A critical review of recent developments and future trends

For the past three decades, computer-aided process planning (CAPP) has attracted a large amount of research interest. A huge volume of literature has been published on this subject. Today, CAPP research faces new challenges owing to the dynamic markets and business globalisation. Thus, there is an urgent need to ascertain the current status and identify future trends of CAPP. Covering articles published on the subjects of CAPP in the past 10 years or so, this article aims to provide an up-to-date review of the CAPP research works, a critical analysis of journals that publish CAPP research works, and an understanding of the future direction in the field. First, general information is provided on CAPP. The past reviews are summarised. Discussions about the recent CAPP research are presented in a number of categories, i.e. feature-based technologies, knowledge-based systems, artificial neural networks, genetic algorithms, fuzzy set theory and fuzzy logic, Petri nets, agent-based technology, Internet-based technology, STEP-compliant CAPP and other emerging technologies. Research on some specific aspects of CAPP is also provided. Discussions and analysis of the methods are then presented based on the data gathered from the Elseviers Scopus abstract and citation database. The concepts of ‘Subject Strength’ of a journal and ‘technology impact factor’ are introduced and used for discussions based on the publication data. The former is used to gauge the level of focus of a journal on a particular research subject/domain, whereas the latter is used to assess the level of impact of a particular technology, in terms of citation counts. Finally, a discussion on the future development is presented.

Making CNC machine tools more open, interoperable and intelligent-a review of the technologies

The aim of the next generation of computer numerically controlled (CNC) machines is to be portable, interoperable and adaptable. Over the years, G-codes (ISO 6983) have been extensively used by the CNC machine tools for part programming and are now considered as a bottleneck for developing next generation of CNC machines. A new standard known as STEP-NC is being developed as the data model for a new breed of CNC machine tools. The data model represents a common standard specifically aimed at the intelligent CNC manufacturing workstation, making the goal of a standardised CNC controller and NC code generation facility a reality. It is believed that CNC machines implementing STEP-NC will be the basis for a more open and adaptable architecture. This paper outlines a futuristic view of STEP-NC to support distributed interoperable intelligent manufacturing through global networking with autonomous manufacturing workstations with STEP compliant data interpretation, intelligent part program generation, diagnostics and maintenance, monitoring and job production scheduling.

Development of robust design-for-remanufacturing guidelines to further the aims of sustainable development

Key manufacturing challenges include pollution, natural resource depletion, waste management and landfill space. Remanufacturing, a process of bringing used products to a ‘like-new’ functional state with warranty to match, is being regarded as a vital strategy in waste management and environmentally conscious manufacturing. There is a paucity of remanufacturing knowledge, particularly in design-for-remanufacturing (DFRem) because of its relative novelty in research terms. This paper outlines the elements of the remanufacturing concept, details existing design-for-remanufacturing research and describes findings from recent UK industrial case studies undertaken to verify and augment previous research. It proposes some fundamental steps required to build on past work to improve the robustness of DFRem methodologies.

RFID-enabled real-time wireless manufacturing for adaptive assembly planning and control

Wireless Manufacturing (WM) is emerging as a next-generation advanced manufacturing technology (AMT). WM relies substantially on wireless devices (e.g. RFID—Radio Frequency Identification or Auto ID—Automatic Identification, and on wireless information/communication networks (e.g. Wi-Fi and Bluetooth), for the collection and synchronization of manufacturing data. This paper proposes a WM framework where RFID devices are deployed to workstations, critical tools, key components, and containers of WIP (Work In Progress) materials to turn them into so-called smart objects. The study is based on a simplified product assembly line. Smart objects are tracked and traced and shop-floor disturbances are detected and fed back to decision makers on a real-time basis. Such real-time visibility closes the loop of adaptive assembly planning and control. A facility called assembly line explorer is provided for the line manager to oversee the status of the entire assembly line, and a workstation explorer facility for operators to monitor the status of their operations at corresponding workstations. These facilities improve the effectiveness of managerial decisions and operational efficiency.

Wireless manufacturing: a literature review, recent developments, and case studies

Wireless manufacturing (WM) has emerged as a next-generation advanced manufacturing technology (AMT). WM relies substantially on wireless devices such as RFID (radio frequency identification) or Auto ID (automatic identification) sensors, and wireless information/communication networks such as Wi–Fi for the collection and synchronisation of manufacturing field data. This paper discusses the recent developments in RFID-based WM solutions. The study is conducted by examining related whitepapers, case reports and research articles available in the literature, and by reflecting on the insights recently experienced in developing prototype solutions. Typical motivations are presented to highlight why and how manufacturers can benefit from applying WM solutions in addressing shop-floor challenges and facilitating contemporary manufacturing strategies. Representative WM manufacturing applications and potentials are presented in the areas of product assembly, part fabrication, just-in-time (JIT), mass customisation, manufacturing asset management and maintenance, and product lifecycle management. Different schemes are discussed for deploying smart objects in manufacturing environments in order to achieve real-time traceability and visibility while minimising the total cost. Key issues are discussed for further research.

CAD/CAM solutions for STEP-compliant CNC manufacture

The ability to generate an NC tool path is now commonplace in CAD/CAM systems, but the technology used for programming and control of NC machines is still based on 1950s standards. Today, under the IMS project called STEP-NC in Europe and Asia, and Super Model in USA, industrialists and academics are collaborating to deliver a new data model as an ISO 14649 standard for CNC machines. This standard will enable software vendors to revolutionize the programming of these machines. This paper provides a futuristic view of how this standard could be used in manufacturing and highlights a number of possible generic frameworks for how CAD/CAM systems may evolve using the ISO 14649 standard. Finally, the paper proposes a prototype STEP-compliant CAD/CAM system based on one of these frameworks using the new ISO 14649 standard for milling components.

Big Data for supply chain management in the service and manufacturing sectors

A state-of-the-art research on Big Data in SCM is reviewed.A discussion from analyzing current movements on the Big Data for SCM in service and manufacturing world-wide is presented.Current challenges, opportunities, and future perspectives Big Data are highlighted. Data from service and manufacturing sectors is increasing sharply and lifts up a growing enthusiasm for the notion of Big Data. This paper investigates representative Big Data applications from typical services like finance & economics, healthcare, Supply Chain Management (SCM), and manufacturing sector. Current technologies from key aspects of storage technology, data processing technology, data visualization technique, Big Data analytics, as well as models and algorithms are reviewed. This paper then provides a discussion from analyzing current movements on the Big Data for SCM in service and manufacturing world-wide including North America, Europe, and Asia Pacific region. Current challenges, opportunities, and future perspectives such as data collection methods, data transmission, data storage, processing technologies for Big Data, Big Data-enabled decision-making models, as well as Big Data interpretation and application are highlighted. Observations and insights from this paper could be referred by academia and practitioners when implementing Big Data analytics in the service and manufacturing sectors.

A review of hybrid manufacturing processes – state of the art and future perspectives

Today, hybrid manufacturing technology has drawn significant interests from both academia and industry due to the capability to make products in a more efficient and productive way. Although there is no specific consensus on the definition of the term ‘hybrid processes’, researchers have explored a number of approaches to combine different manufacturing processes with the similar objectives of improving surface integrity, increasing material removal rate, reducing tool wear, reducing production time and extending application areas. Thus, hybrid processes open up new opportunities and applications for manufacturing various components which are not able to be produced economically by processes on their own. This review paper starts with the classification of current manufacturing processes based on processes being defined as additive, subtractive, transformative, joining and dividing. Definitions of hybrid processes from other researchers in the literature are then introduced. The major part of this paper reviews existing hybrid processes reported over the past two decades. Finally, this paper attempts to propose possible definitions of hybrid processes along with the authors’ classification, followed by discussion of their developments, limitations and future research needs.

State-of-the-art cryogenic machining and processing

This article is a state-of-the-art review of the use of cryogenic cooling using liquefied gases in machining. The review is classified into two major categories, namely cryogenic processing and cryogenic machining. In cryogenic processing also known as cryo-processing, the cutting tool material is subjected to cryogenic temperatures as a part of its heat treatment process. The majority of the reported studies identify that cryo-processing can considerably increase cutting tool life especially for high speed steel tools. It also identified that, in cryogenic machining, a cryogen is used as a cooling substance during cutting operations. The cryogen can be used to freeze the workpiece material and/or cutting tool. This article concludes that cryogenic cooling has demonstrated significant improvements in machinability by changing the material properties of the cutting tool and/or workpiece material at the cutting zone, altering the coefficient of friction and reducing the cutting temperature.

Intelligent Manufacturing in the Context of Industry 4.0: A Review

Abstract Our next generation of industry—Industry 4.0—holds the promise of increased flexibility in manufacturing, along with mass customization, better quality, and improved productivity. It thus enables companies to cope with the challenges of producing increasingly individualized products with a short lead-time to market and higher quality. Intelligent manufacturing plays an important role in Industry 4.0. Typical resources are converted into intelligent objects so that they are able to sense, act, and behave within a smart environment. In order to fully understand intelligent manufacturing in the context of Industry 4.0, this paper provides a comprehensive review of associated topics such as intelligent manufacturing, Internet of Things (IoT)-enabled manufacturing, and cloud manufacturing. Similarities and differences in these topics are highlighted based on our analysis. We also review key technologies such as the IoT, cyber-physical systems (CPSs), cloud computing, big data analytics (BDA), and information and communications technology (ICT) that are used to enable intelligent manufacturing. Next, we describe worldwide movements in intelligent manufacturing, including governmental strategic plans from different countries and strategic plans from major international companies in the European Union, United States, Japan, and China. Finally, we present current challenges and future research directions. The concepts discussed in this paper will spark new ideas in the effort to realize the much-anticipated Fourth Industrial Revolution.