e-Science

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e-Manufacturing Fundamentals, Applications and
Potentials Professor Kai Cheng Advanced
Manufacturing Enterprise Engineering (AMEE)
Group School of Engineering Design, Brunel
University Uxbridge UB8 3PH, UK Tel
08195-267255 Fax [phone] email
kai.cheng_at_brunel.ac.uk Dr Richard Bateman CERAM
Research Ltd Queens Road, Penkull Stoke-on-Trent,
UK. ST4 7LQ Tel [phone] email
richard.bateman_at_ceram.com
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Outline of the presentation

• Background
• - Why e-manufacturing?
• - What is e-manufacturing?
• e-Manufacturing fundamentals
• - Internet enabled technologies
• - Advanced technologies for e-manufacturing
• - Internet and manufacturing knowledge
  management
• - Computing infrastructure for e-manufacturing
• e-Manufacturing applications and potentials
• - Collaborative design and product development
• - Mass customization and customer oriented
  e-manufacturing
• - Remote control and condition monitoring
• - Virtual manufacturing and systems
• - e-Supply chain management
• - e-Enterprise and global manufacturing
• Conclusions and the future standing

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Why e-Manufacturing?

• The characteristics of e-manufacturing emphases
  the new philosophy through which manufacturing
  will be operated in integration with Internet
  technology. e-manufacturing philosophy results
  from that the way people work is being changed by
  the Internet, for instance
• Digitisation
• Globalisation
• Mobility
• Collaborative work
• Immediacy

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Manufacturing globalization - e-Manufacturing (1)
Manufacturing
Design
Sale
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Distributed manufacturing - e-Manufacturing (2)
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Development of manufacturing technology
Manufacturing
e-Manufacturing
Agile Manufacturing
Digital enterprise
Technology
CAX
Concurrent Engineering
engineering tools
TQM, MRP II
Just-In-Time
engineering tools

• High precision
• Automation

TQM
Lean Manufacturing
engineering tools
Computer Integrated
CAD/CAM, DNC
Manufacturing
robotics
Group technology
Flexible Manufacturing
CNC, robotics
Production line
Mass Production
automation
Towards 21st Century
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Transformation by e-Manufacturing

• Mass production
• Long pipeline
• Sale from stock
• Sequential processes
• Cost of inventory
• Wait in line

• Mass customisation
• Shrinking supply chain
• Make to order
• Simultaneous processes
• Capital working
• First available slot
• - Manufacturing 2020 Foresight Report

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UK e-Science research program (2001
onward)

• What is meant by e-Science? In the future,
  e-Science will refer to the large scale science
  that will increasingly be carried out through
  distributed global collaboration enabled by the
  Internet. Typically, a feature of such
  collaborative scientific enterprises is that they
  will require access to very large data
  collections, very large scale computing resources
  and high performance visualisation back to the
  individual user scientists.
• The Core Program has been structured around 6 key
  elements
• A national e-Science centre linked to a network
  of regional grid centres
• Generic grid middleware and demonstrator
  projects
• Grid IRC research projects
• Support for e-Science testbeds
• Participation in international grid projects and
  activities
• Establishment of a grid network team
• - http//www.rcuk.ac.uk/escience/

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EU 6th Framework - IST program (2004 onward)

• Applied IST research addressing major societal
  and economic challenges
• Towards a global dependability and security
  framework
• Networked business and government
• e-Safety for road and air transport
• e-Health
• Technology-enhanced learning and access to
  cultural heritage
• Applications and services for the mobile user
  and worker
• Cross media content for leisure and
  entertainment
• Grid-based systems for solving complex problems
• Improving risk management
• e-Inclusion
• Products and services engineering 2010
• - http//www.cordis.lu/ist/activities/activities.
  htm

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What is e-Manufacturing? - (1)
e-manufacturing covers a range of online
manufacturing activities for products and
services, including product design, production
control and conditions monitoring, supply chain
management, maintenance and sale services, etc.,
through the Internet/Intranet/Extranet and grid
computing infrastructure.
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What is e-Manufacturing? - (2)
e-manufacturing is the complete electronic
(computer systems and networks) integration of
all factory components. Users range from
operators to technicians to engineers to
managers. - UK Industrial White Paper
(2002)
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e-Manufacturing fundamentals

• Internet Enabled Technologies
• - HTML
• - Java programming
• - XML
• - Client/server architecture
• - Java database connectivity
• Advanced Technologies for e-Manufacturing
• - Agent technology
• - Multi-agent systems
• - Data mining and knowledge discovery
• - Grid computing
• Internet and Manufacturing Knowledge Management
• - Internet characteristics
• - Design agility and the Internet
• - Manufacturing responsiveness and the Internet
• - CBR and web-based computational intelligence

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e-manufacturing applications
e-Science

• Application (1) - case studies
• - Web-based bearing design support systems
• - Web-based manufacturing assembly simulation
• - Web-based intelligent (CBR) selection of
  cutting tool inserts
• - Modelling and simulation of the extended
  enterprise operations based on dynamic Petri nets
  
• - Remote condition monitoring and control of
  manufacturing systems
• - Creative design search engine
• - RFID application for diamond cutting tools
  tooling service
• Application (2) - devolved manufacturing

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Web-based Intelligent (CBR) Selection System for
Cutting Tool Inserts
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A proposed system architecture
Main CBR loop
Standard e-Catalogue search
CBR validation loop
Language selection
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Modelling and Simulation of the Extended
Enterprise Operations Based on Dynamic Petri Nets
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INTERNET
ORGANISATION MODELS
PROCESS MODELS
CO-ORDINATOR
DESIGN
MANAGEMENT
MANUFACTURING ENTERPRISE
INTRANET/ INTERNET
REAL-TIME VISUALISATOIN
JAVA SIMULATION
DATABASE
INTRANET/ INTERNET
RESOURCES
PRODUCTS
EVENTS
EVENTS
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Remote Condition Monitoring and Control of
Manufacturing Systems
e-Science
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Creative Design Search Engine
e-Science
A search engine for innovative/creative

• 3D models

Creative Design Innovative Manufacturing
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RFID Application for Diamond Cutting Tools
Tooling Service
e-Science
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Selected Milestone Publications (in
e-manufacturing) from the AMEE Group
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Books (1) K. Cheng, D. Webb and R. Marsh,
Advances in e-Engineering and Digital Enterprise
Technology I (Editors), Professional Engineering
Publishing, London, September 2004. (2) K. Cheng,
e-Manufacturing, Fundamentals and Applications,
WIT Press, London, February 2005. Journal
Papers (1) K. Cheng, P.Y. Pan and D.K. Harrison,
Internet as a tool with application to agile
manufacturing a web-based engineering approach
and its implementation issues, International
Journal of Production Research, Vol.38 No.12,
2000, pp.2743-2759. (2) K. Cheng, P.Y. Pan and
D.K. Harrison, Web-based design and manufacturing
support systems implementation perspectives,
International Journal of Computer Integrated
Manufacturing, Vol.14 No.1, 2001, pp.14-27. (3)
K. Cheng, M.L. Yang, G.E. Taylor and A. Dow,
Petri net as a tool with application in modelling
an Internet based virtual manufacturing
enterprise, International Journal of Agile
Manufacturing, Vol.4 No.2, 2002, pp.100-109. (4)
J. Toussaint and K. Cheng, Implementation of
design agility and manufacturing responsiveness
on the web two case studies, Integrated
Manufacturing Systems, Vol.13 No.5, 2002,
pp.328-339. (5) R. Bateman and K. Cheng, Devolved
manufacturing, Concurrent Engineering Research
and Applications, Vol.10 No.4, December 2002,
pp.291-297. (6) K. Cheng and Y. Popov, Internet
enabled modelling of extended manufacturing
enterprises using the process based techniques,
International Journal of Advanced Manufacturing
Technology, Vol.23 No.1, 2004, pp. 148-153. (7)
J. Toussaint and K. Cheng, Web-based CBR
(case-based reasoning) as a tool with the
application to tooling selection, International
Journal of Advanced Manufacturing Technology,
Vol. 26, 2006. (8) R. Bateman and K. Cheng,
Extending the product portfolio with devolved
manufacturing methodology and case studies,
International Journal of Production Research,
Vol.45, 2006.
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Devolved Manufacturing (1)
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• Current developments in e-manufacture are
  generally factory-centric
• Transport/logistics problems increasing
  (gridlock Europe)
• New technologies are available or emerging
• New possibilities
• Need to Think outside the box

Key areas for integration
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Devolved Manufacturing (2)
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Mass Customisation
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MASS PRODUCTION
Outcome of industrial revolution Driven by
production and cost needs
Concept developed in 1980s Increases product
range by allowing customers to choose from range
of options Needs to be set up with care to avoid
extra overheads associated with increased product
variety
MASS CUSTOMISATION
MASS INDIVIDUALISATION
Ultimate goal of MC ?
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Rapid Manufacturing (RM)
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1. The CAD model is sliced into layers
2. RM machine creates model
3. Finished Object
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End-user Practitioner Surveys
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Breakdown of Systems by Type
Rise in Annual Sales of RP/RM machines (000s)
Global RP/RM Installations
Number of Patents Issued for RP/RM Technology
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Case One CAL system
e-Science
Typical Race Clutch Construction
Central Splines in Friction Plate Hub
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Case One CAL system
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System Menu
Search Existing Products
Input Spline Dimensions
View 3D Model
Send files for manufacture
Test Mfg at Brunel
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Case Two wydiwyg.co.uk
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Use mini-CAD program
Home page
Details
Download mini-CAD program
View model in 3D
Stage ONE
Stage TWO
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Case Two wydiwyg.co.uk
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Home Page
Upload CAD file
Make payment
Register
Find outlet
Confirmation
Outlet details
Test part
Stage THREE
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Case Three Creatorium Portal
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Stakeholders in the CREATORIUM Portal
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Case Three Creatorium Portal
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CREATORIUM relationship with Cases One and Two
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Discussions
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• Implementation key issues
• Start points and direction
• Organisational issues
• Technology adoption
• Strategies for DM
• Design, legal and ethical issues
• Control and management of a DM venture

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Acknowledgements

• EPSRC
• Royal Society
• DTI TCS / Faraday Schemes
• NATO Scientific Program
• HEFCE
• SHEFC

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Thank You!