Youichi Nonaka

Development of an impeller grinding robot system and a gyro-moment compensated compliance control

A grinding robot system for casted pieces has been developed. The system applies the compliance control to a manufacturing process. The casted piece grinding requires it to grind the curved surface in tight area without burning and to follow the casted surface having no precise shape. A new model based compliance control has been developed that compensates a gyro-moments which occurs in the robot grinding tool by the robot motion. Previously, the robot could not generate a suitable mechanical compliance because the force sensor on the robot detected this moment as a part of the controlled pressure in grinding. This system is now applied to a manufacturing process of impellers and turbine blades.

TSUNAMI Effect Prediction Methodology for Critical Resource Analysis

Tremendous growth of the home information appliances requests semiconductor manufacturing to respond High Product Mix and Low Production Volume condition. Such condition in manufacturing operations challenges production management to have rapid improvement activities in an environment with uncertain productivity and demand. In this research Visualized Coefficient of Variation Analysis (VCVA) is extended to analyze the correlation between TSUNAMI Effect of productivity fluctuation and manufacturing quality fluctuation. And with the VCVA visualization map, Critical Resource Analysis (CRA) is developed for manufacturing capacity design involved with TSUNAMI Effect prediction. Results show the effectiveness of CRA for manufacturing capacity estimation tool, and a factory began to use CRA in real.

Correlation Analysis of TSUNAMI Phenomena and Failure Rate Fluctuation in Manufacturing System

Abstract Tremendous growth of the home information appliances requests semiconductor manufacturing to respond High Product Mix and Low Production Volume condition. Such condition in manufacturing operations challenges production management to have rapid improvement activities in an environment with uncertain productivity and demand. In this research Visualized Coefficient of Variation Analysis (VCVA) was applied to measure fluctuations in the flow of production material on a time-line basis. Based on this approach a monitoring tool was developed and implemented in a wafer manufacturing system and an assembling system to support production management in root cause analysis and productivity improvement. Results show the effectiveness of the method by visualizing TSUNAMI phenomena, as a typical case of Butterfly Effect in the material flow fluctuation, by identifying the root cause equipment as the source of productivity detractor, and by revealing significant relationship between material flow fluctuation and failure rate fluctuation.

Engineering Support Systems for Industrial Machines and Plants

In the business of industrial machines and plants, rapid and detailed estimates for planning installation, replacement of equipment, or maintenance work are key requirements for meeting the demands for greater reliability, lower costs and for maintaining safe and secure operation. These demands have been addressed by developing technology driven by IT. When replacing equipment at complex building or plants with high equipment density, the existing state of the installation locations and transportation routes for old and new equipment need to be properly measured. We have met this need by developing parts recognition technology based on 3D measurement, and by developing high-speed calculation technology of optimal routes for installation parts. This chapter provides an overview of these development projects with some real business application results.

Integrated Maintenance System Trend and A Maintenance Scheduling System Application

Efficient operation and maintenance management for industrial facilities is one of the key issues of social infrastructure systems. This chapter describes some technology trends of integrated maintenance system, especially about monitoring, parameterizing, predicting, and control. Firstly, a trend from Time-Based Maintenance (TBM) to Condition-Based Maintenance (CBM) is discussed. TBM-based agreement between operation owner and maintenance provider is common one, but uncertainty of facility degradation requests CBM application as future service model. Secondly, this chapter describes an optimization method for facility maintenance scheduling, which focuses on the subject that the conflict between maintenance operations and net operations reduces system efficiency.

A study on proactive maintenance scheduling with distributed cooperative approach

In our study, we propose a distributed cooperative scheduling method and apply the method to maintenance scheduling problem in re-entrant production systems. Lagrangian decomposition and coordination method is one of the distributed cooperative scheduling methods, which has some individual schedulers and each scheduler needs only local information, then it is relatively easy to expand and modify for large production systems. The proposed approach regards maintenance as job within limits of starting and finishing time, so that the schedule can realize not only proper maintenance operations to prevent facility troubles but also high productivity. We show the effectiveness of the proposed concept in simulation experiments.