Proceedings of the

12th International Conference on Flexible

Automation and Intelligent Manufacturing

July 15 th-17 th, 2002

Dresden University of Technology

Dresden, Germany

Editors

Prof. William G. SullivanVirginia Polytechnic Institute and State University, Blacksburg, Virginia, USA

Prof. Munir AhmadUniversity of Teesside, Middlesbrough, UK

Prof. Dieter FichtnerDresden University of Technology, Dresden, Germany

Prof. Wilfried SauerDresden University of Technology, Dresden, Germany

Dr. Gerald WeigertDresden University of Technology, Dresden, Germany

Dr. Thomas ZernaDresden University of Technology, Dresden, Germany

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Oldenbourg Verlag, Germany

Contents VII

Contents

Modelling and Simulation I

Modeling System for Multiparameter Routing Processes in DistributedSystems 2

O.Ya.Kravets, A.V.Kubakhov, S.L.Podvalny, A.V.Ponomaryov

Optimization Principles of Modern Material Handling Systems 8Nisan Sonmez, Mesut Ozgiirler, Huseyin Sonmez

Simulation and Fuzzy Logic Decision Support System as an IntegratedApproach for Distributed Planning of Production 16

Agostino G. Bruzzone, Roberto Mosca

Analysis of Manufacturing Systems with Asynchronous Motors 26S. Jirkfi and J. Vondfich

Artificial Intelligence and Neural Networks I

Manufacturing and Network Technologies 36Marius Guran and Costel Emil Cotet

Predicting Sheet Metal Manufacturing using Neural Network 44Bin Sun, Petri Huhtala, Seppo Torvinen

Neural Networks and the Life of Insulating Material for Windings inElectric Rotary Machines 55

Milos Hammer, Tomas Kozlovsky, Petr Kratochvil, Milan Baros

Application of Initial Estimate Expert System Focused on Special TypeMould Structure 64

Park Sang-bong

Manufacturing Processes and NC Machining I

Quick and Non-Destructive Testing of Small Laser Drillings 76W. Uffrecht, E. Kaiser

Simulation of the Intermittent Cutting Action of a Bandsaw Blade 84M.Sarwar, H. Hellbergh, A.R. Doraisingam, M. Persson

Agent-based Acquisition and Preparation of Distributed TechnologicalInformation for NC Planning and Calculation Methods in PartManufacturing 93

Dieter Fichtner, Andreas Nestler, Frank Arnold

V I I I 12'h International Conference on Flexible Automation and Intelligent Manufacturing, 2002, Dresden, Germany

An Analysis of Two Isotropic Electrically Conductive Adhesives as aSolder Replacement in SMT 104

F.M. Coughlan and H.J. Lewis

Supply Chain Management I

Intelligent Feature Model for Flexible Manufacturing 116S. Mbang, H. Stroehle, S. Haasis

Inventory Games in a Two-Stage Serial Supply Chain with AsymmetricCost Information 127

Sanghyeok Seo, Sung-Shick Kim

On The Design of Networks in Reverse Logistics 138Kris Lieckens, Nico Vandaele

Inter-Technology Analysis Sharing Model for e-Supply Chain Formation 148Takumi Kojima

Modelling and Simulation II

Improved Genetic-Annealing Algorithm for Complex Functions 156Hai Lan, Xiong Wang

A Tabu Search Heuristic for Solving the CLSP with Setup Carry-over 164Behrooz Karimi - S. M. T. Fatemi Ghomi

Design and Realization of an On-line Optimization System forDistillation Process 175

Chuili Sun, Bowen Xu

Simulation of Cutting Forces in Ball-End Milling 185Matjaz Milfelner and Franc Cus

A Simulation System Approach To Solve The Maintanence PlanningProblems 196

Mesut Ozgurler, Bahadir Gulsun, Ali Fuat Guneri

Production Planning, Scheduling and Control I

The Development and Implementation of a Concise Pseudo RecipeCoding System Within a Multi-Stage Job Shop 206

D. Lavelle and C. Sheahan

Information Systems for the Real Time Control of an IntegratedProduction Environment 219

Thanigai Kumar S. Vellore, R.S. Venkatesh, Suresh Balasubramanian,Jorge Craik, and K. Srihari

Capacity Requirements Planning for Electronics Manufacturing 229Ji Hyon Mun and K. Srihari

Contents IX

Reuse of Existing Product/Process Solutions for Design of ManufacturingFacility 237

Fabrice Alizon, Yves Dallery, Jean-Marc Celerier

Heuristic Precedence Graph Generation for Product Families 247Pierre De Lit and Alain Delchambre

Manufacturing Processes and NC Machining II

Stock Optimization of a Kanban-based Assembly Line 258M. Dub, G. Pipan and Z. Hanzalek

Machining and Tolerances in a Flexible and Integrated ManufacturingContext 268

Moroni G. and Polini W.

EXPRESS/XML based Data Modeling for Tool Data Management 279Takeshi Kishinami, Satoshi Mitsui, Fumiki Tanaka and Akihito Kobayashi

Tool Paths for Belt Grinding with Predefined Grinding Directions 289Hans Kurt Tonshoff and Volker BOB

Monitoring Tool Conditions for Drilling 295Igor Vilcek, Jan Madl

Supply Chain Management II

Agile Supply Chain Management for Virtual Enterprise 302Guang-Yu Xiong and Hannu Koivisto

Planning for Distribution Networks where Demands are UpdatedRegularly 310

Ick-Hyun Kwon, Sung-Shick Kim, Jun-Geol Baek

Distributed Scheduling in Extended Value Chain Management 319Tobias Teich, Joachim KSschel, Dirk Grossmann, Alexander Heuke and Hendrik JShn

Agent-based In-house Process Planning and Production Control forEnterprises in Supply Chains 329

H.K. Tonshoff and P.-O. Woelkand O. Herzog and I.J. Timm

Supply Chain/Network Management: Basis of a Conceptual Framework 339P. Samaranayake

Modelling and Simulation III

A Simulation Study of Comparison Job Shop System and CellularManufacturing System: A Case Study 352

Bahadir Gulsun, Ali Fuat Guneri

}C 12'h International Conference on Flexible Automation and Intelligent Manufacturing, 2002, Dresden, Germany

Distributed Simulation an Efficient Approach for Modeling ComplexManufacturing Systems 360

Gilnther Seliger, Markus Ciupek and Woo Ok Lee

Development of a Design Simulator for the Logistic CIM System Basedon Agent-oriented Concept 371

Masashi Furukawa, Asako Onuma and Michiko Watanabe

Generation of Dynamic Geometry for Procedural Visualization ofManufacturing Processes 381

Dusan N. Sormaz and Prashant A. Borse

Simulating Cycle Duration of Tower Cranes Operations 393Brana, P., Culo, K., Sigmund, V.

Modeling and Simulation of Metal Cutting Production 403Robert Gabriel

Production Planning, Scheduling and Control II

Flexible Manufacturing System Scheduling Using Petri Net Models 410S K Mukhopadhyay

A MAS Reinforcement Learning Approach for Indeterministic Multi-Layer Job-Shop Scheduling 419

Le Chang and Jiaben Yang

A Due-Date Based FAB Scheduling Scheme 428Jong-Kwan Baek, Chang-Ouk Kim, Jun-Geol Baek, Sung-Shick Kim

Intelligent Machine Maintenance Scheduling Model Using IncrementalDecision Tree and Dynamic Programming 438

Jun-Geol Baek, Chang-Ouk Kim, Jong-Kwan Baek, Sung-Shick Kim

Analysis of Multi-Stage, Multi-Product, Decentralized, Pull-TypeProduction Systems with Dynamically Changing Switching Priorities 450

Cigdem Z. Gurgur and Tayfur Altiok

Just-in-sequence Material Supply - A Simulation Based Solution inElectronics Production 461

Sebastian Werner, Marc Kellner, Eberhard Schenk and Gerald Weigert

Artificial Intelligence and Neural Networks II

Agility Index of Manufacturing Firm -A Fuzzy Weighted AverageApproach 470

Ching-Torng Lin, Yuh-Chuan Shih, ...

An Expert System Aid for Technological Decisions in Planning SheetMetal Forming Operations 483

S. Teleionis, G.C. Vosniakos and T. Giannakakis

Contents XI

Selecting Co-operation Partners for Non-hierarchical ProductionNetworks 493

H. Diirr, J. Mehnert, O. Gorlitz, R. Neubert

Optimization of Cutting Conditions During Machining by Using NeuralNetworks 502

Uros Zuperl and Franc Cus

Genetic Algorithm Approach for Manufacturing Facility Layout Design 512S.K.Deb, B.Bhattacharyya, S.K.Sorkhel

The Neural Nets with Distributed Architecture 522Kalinin A.V., Podvalny S.L. and Balashov A.A., Chernikova I.A.

Robotics and Sensing Systems I

Optimized Grasping Planning for Robotic Sheet Metal Bending 530Shigeru Aomura and Atsushi Koguchi

Machining of Plaster Prototypes Using a 6-Axis Robotic System 541Jose Filipe C. P. Antunes SimOes, Timothy James Coole, David George Cheshire, MariaElisa Antunes Simoes

Implementation of Machine Vision in Auto-Calibrating Robot System 552Dennis S.H. Ling, Grier C.I. Lin, Sang-Heon Lee, and Hendra Wahyudi

Development of a Postprocessor for a Dual-Robot Machining Center 562Hsuan-kuan Huang and Grier C. I. Lin

Laser Based Sensor Systems for Automation and IntelligentManufaturing 572

Hossein Golnabi

Design and Performances of a Piezoelectric Stick-Slip Nano-Actuator 582Pierre Lambert, Benoit Lagrange, Arianna Valentini, Pierre De Lit,Consuelo Marsico and Alain Delchambre

Business Processes, ERP and Quality I

Developing a Model of the Strategy Process with Business Process Re-engineering Modelling Techniques 594

Eduardo Munive, Kevin Barber and Frank Dewhurst

To Realize Enterprise Integration of Virtual Pulp & Paper Enterprise 603Gang Xiong, Guang-Yu Xiong and Timo R. Nyberg

Reinventing the Wheel: Adapting the CASA Manufacturing EnterpriseModel to the Contemporary Virtual Enterprise 614

William A. Estrem, Robert B. Rowen, Anthony C. Mills

Advanced Resource Planning 624Nico Vandaele, Liesje De Boeck

X I I 12th International Conference on Flexible Automation and Intelligent Manufacturing, 2002, Dresden, Germany

Production Planning, Scheduling and Control III

Batch Scheduling of Unrelated Parallel Machines with Setup Times usingSearch Heuristics 634

Dong-Gil Na and Dong-Won Kim and F. Frank Chen

Coordinated Scheduling of Production and Delivery from Multiple Plants 645J.M. Garcia, S. Lozano, F. Guerrero, K. Smith and M. Calle

New Directions of Developing a Production Planning Model Based onthe Cost of Unused Capacity Approach 654

Zoltan Sebestyen and Tamas Koltai

Sequencing for Mixed-model Assembly Lines with Bottleneck Resourcesusing Tabu Search 664

Sameh M. Saad and Anna M. Lassila

Case Studies in Manufacturing I

An Interactive Multi-Media Training System for CNC Machining 676G.C. Vosniakos and P. Katsiris

The Competitive Advantage of Flexible Automation 686Jannes Slomp and Gerard Gaalman

The Successful Key Factors Analysis of New Product Introduction inElectronics Manufacturing Services industry 696

Sheng-Hung Chang, Jui-Lung Yu, Tsai-Chi Kuo and Rong-Kwei Li

A Study on an Evaluation of Workers for the Muffler Assembly Lineusing Tendency Equation 708

Shun'ichi Nakayama and Hiroshi Nakayama

Manufacturing Processes and NC Machining III

A Complex Optimization of the Technological Process andTechnological Procedure of Machining 716

Sava St. Sekulic

Octree-Based Volumetric NC Simulation System 724K.P. Karunakaran, Pawan K. Modani, Nitin Gupta, P. Vivekananda Shanmuganathan,Saurabh Garg, D. Fichtner

A Linear Approximation Technique for Evaluation of Form Tolerances 735Saeid Motavalli, Helen Zong and Behrooz Falahi

Web-based Manufacturing

Information Sharing Architecture Using Internet's SOAP and XML 744Puskar Adhikari, Sudhakar Paidy

Contents Xl l l

Modelling the Effects of EDI Usage on the Distribution Industry 756Peggy Chang

Management of Production Networks - A New Approach to Work withProbabilities of Delivery 762

Tobias Teich, Lars Zschorn and Hendrik Jahn

Web-Based and Sensor-Driven Device Monitoring and Control UsingJava 3D 771

Lihui Wang, Ryan Sams, Marcel Verner, Fengfeng Xi

Business Processes, ERP and Quality II

Developing a Safety Culture in Manufacturing Engineering 784TJ. Hickey and W.F. Gaughran

ERP-controlled Manufacturing Environment Disturbed by Uncertainty 794S.C.L. KohandS.M.Saad

Making Improvements in Key Performance Indicators 804M. Ahmad, N. Dhafr

Designing an Internet-Based Group Decision Support System 812Wang, Kung-Jeng, Chien, Chen-Fu

A General Data Mining Model of Lifetime-Based Quality Evaluation andProduction for Maintenance 824

Q.M. Jiang, C.H. Chen and L.P. Khoo

Production Planning, Scheduling and Control IV

An Integrated Optimization Tool for Flow Shop Scheduling 836Celano, G., Costa, A. and Fichera S.

High-Speed Smooth Cyclical Motion of a Hydraulic Cylinder 846Nebojsa I. Jaksic

Reducing Set-up Times of Manufacturing Lines 858Dirk Van Goubergen and Hendrik Van Landeghem

Look-ahead Strategies for Controlling Batch Operations in Industry -Basic Insights in Rule Construction 868

Durk-Jouke van der Zee

Capacity Management of Heat Treatment Process in a ManufacturingEnvironment 878

C. F. Oduoza

X I V 12"' International Conference on Flexible Automation and Intelligent Manufacturing, 2002, Dresden, Germany

Case Studies in Manufacturing II

Bluetooth Wireless Technology for Industrial Applications 890Nik A. Salleh and Hannu Koivisto

Kaizen Applications in Just-In-Time Manufacturing and TimeMeasurements in Improving Manufacturing Productivity 898

Mesut Ozgttrler and Nisan Sonmez

Performance Parameters Optimization of a Pneumatic ProgrammablePalletizer 908

Alfredo Lambiase and Salvatore Miranda

Group Technology Manufacturing System: A Case Study 919AH Fuat Guneri, Bahadir Gulsun, Mesut Ozgurler

Ensuring Health Safety and Fish Products Quality Integrated System 925P. Zukowski and I. Kaczmarek

Robotics and Sensing Systems II

Reconstruction and Refinement of Revolution Surfaces from 3-D DataMeasured by CMM 934

Calio F., Moroni G., Rasella M.

Analytical Determination of the CNC Machine Tool Position Loop Gain 944Zoran Pandilov and Vladimir Dukovski

The Optimal Movement of Industrial Robots in Space with Constraintsand Obstacles 951

Jan Cvejn

Internet System For Programming Robots For Distance LearningApplications 963

Mayur Pangrekar, William A. Miller

Technologies, Components and Equipment for Intelligent ProductionSystems 971

Neugebauer, R.; Harzbecker, C; Drossel, W.; Ihlenfeldt, S.

Manufacturing Education

Design and Implementation of the Computer Integrated EngineeringEnterprise (CIEE) - the Learning Factory at Robert Morris University 986

Winston F. Erevelles

PRIME - the Partnership for Regional Innovation in ManufacturingEducation 995

Winston F. Erevelles, Karen Harris, Pearley Cunningham, Sunday Faseyitan,Robert Myers

Contents X V

Systems Engineering - A New International Programme of Study 1006H. DUrr, S. Wirth

New Evaluation Criteria for Manufacturing Engineering Programs in theUnited States 1014

R.D. Dryden and H.C.M. Erzurumlu

Education of Students at a CIM-compatible CAM-training System 1024Hellmuth Kubin, Klaus Kabitzsch

Virtual Organizations

Virtual Organizations in Manufacturing: Trends and Challenges 1036Luis M. Camarinha-Matos

Design and Product Development I

Automatic Generation of Disassembly Sequences of Product Design forRecycling 1056

JunfangNi, Martin Richter, Ralf-Stefan Lossack, Hans Grabowski

Offset Surfaces Construction 1063Ivana Linkeova

An Analytical Model for Design Iterations in an IntegratedManufacturing Environment 1073

Limin Jiao, Chun-Hsien Chen, Li Pheng Khoo

A Linguistic Approach Using Natural Language Processing forMechanical Parts Design 1083

J.C.Linhares, A. Dias, F. Chagas

A Feature-Based Process to Reuse Data in the Mechanical Design 1093Raimundo Ricardo Matos da Cunha and Altamir Dias

Virtual Manufacturing

Virtual Manufacturing and Internet Oriented Process Planning 1104Predrag Cosic, Danijela Sever

A Re-configurable Architecture for Error Recovery in a Multi-AgentProduction System 1115

Nicholas G. Odrey and Gonzalo Mejia

The Development Architecture of Distributed Component Based System 1126Burkovsky V.L., Smolyanin V.V., Mordasov A.G., Podvalny E.S. and Turchin A.N.

Modeling and Optimization of Process Plans on Internet 1135Dusan N. Sormaz, Sridharan Thirupalli, Prashant Borse, Jaikumar Arumugam,Sachin Jain

X V I 12lh International Conference on Flexible Automation and Intelligent Manufacturing, 2002, Dresden, Germany

Evolutionary Technology for Design of Global World-ClassManufacturing for the World Markets 1145

Hassan Farsijani

Cost Issues in Manufacturing

Process Based Cost Modeling for Engineering Applications 1154Han P Bao and Uday A Kulkarni

The Relevance of Activity Based Costing in a Flexible ManufacturingEnvironment 1164

Tamas Koltai and Kathryn E. Stecke

A Manufacturing Cost Analysis Tool for 3D Design 1174Howard L., Lewis H.

Predictability and Optimisation of the Earliness/ Tardiness Penalty-CostPerformance in a Dynamic Multi-Agent Single-Machine Model 1185

Yuki Indrayadi, Hendrik Van Brussel and Paul Valckenaers

Optimization of Quality Costs 1195M. Oppermann, W. Sauer, H. Wohlrabe

Semiconductor Manufacturing I

MaxFlow Theory for Availability Calculation of Automated MaterialHandling Systems 1206

Alin Beschorner, Detlev Gliler

Continuous Improvement Techniques for Automated Material HandlingSystems 1214

Detlev GlUer

An Evaluation Of Scheduling And Dispatching Algorithms in High TechManufacturing Environments with Uncertainty 1224

Michele Pfund, John W. Fowler, W. Matthew Carlyle

A Modified Shifting Bottleneck Heuristic for Scheduling WaferFabrication Facilities 1231

John W. Fowler, Steven Brown, W. Matthew Carlyle, Esma Senturk Gel,Scott J. Mason, Lars Moench, Oliver Rose, George C. Runger, Roland Sturm

Single Wafer Stocker for 300 mm Manufacturing 1237Rudy Federici, Bertram Wttstrich, Mathias Schulz, Gerd Jungmann,Erhard Orthgiess

Design and Product Development II

Handling Disturbances in Small Volume Production 1246Monica Bellgran, Emanuela Aresu

Contents XVII

Study on Integration of CAD and CAM in Autobody Panel 1258An Cui, Asko Riitahuhta, Tieli Ma, Longshan Wang

Development of a Flexible Gripping System Part 1 - Guidelines forFlexible Gripper Design 1265

Cynthia Sexton, Grier C.I. Lin, Sang-Heon Lee and Sev Nagalingam

Development of a Flexible Gripping System Part 2 - A Case Study on theDevelopment of a Flexible Gripping System for Sheet Metal BendingOperations 1272

Cynthia Sexton, Grier C.I. Lin, Sang-Heon Lee, Sev Nagalingam,Ian James and David Godfrey

A Product Data Documentation Approach using Feature-based Models 1281G. S. Silva and A. Dias

Strategies for Creative Engineering 1289William. F. Gaughran

Production Planning, Scheduling and Control V

Production Mix Partitioning and Cyclic Scheduling to MinimizeCompletion Time in Job Shop Environment 1300

G. Passannanti and N. Scalzo

An Improved Method for Dodin's Approach to Approximate theDistribution Functions in Stochastic Networks 1311

S. M. T. Fatemi Ghomi and E. Teimouri

Optimising the Batch Production of Bacterial Cellulose 1320A.M. Gerrard, R.H. Cumming, M. Hornung and H.-P. Schmauder

Minimizing the Mean Flow Time in a Two-Machine Group SchedulingProblem with Carryover Sequence Dependency 1327

Rasaratnam Logendran, Chelliah Sriskandarajah, Cumhur A. Gelogullan

Developing an Integrated Manufacturing Information System usingObject Analysis 1340

Niederauer Mastelari and Nivaldo Lemos Coppini

Development of a Flexible Production Activity Control and AutomatedProcess Planning System for an Engineer-To-Order Small to MediumEnterprise 1350

F. Connolly and C. Sheahan

Next Generation Manufacturing System

Information Technology and Knowledge Management in Manufacturing 1364J. P. Keane, K. D. Barber

X V I I I 12lh International Conference on Flexible Automation and Intelligent Manufacturing, 2002, Dresden, Germany

Intelligent Manufacturing - Applying Constraint Theory toManufacturing Practice 1374

Ted Hutchin

Intelligent Agent-based Open Architecture Cell Controller for IntelligentManufacturing System(IMS) 1384

S.C. Kim, E.S. Jeong, J.H. Hwang and K.H. Choi

Emergence of Intelligence in Next-generation Manufacturing Systems 1394Miran Brezocnik and Joze Balic

Optimization of Cutting Process by GA Approach 1403Franc Cus and Joze Balic

An Immune based Scheduling for Solving Multi-Objective Flow-ShopProblem 1413

Yang Jianguo, Li Beizhi, Mao Zhimin, Ding Huimin

Semiconductor Manufacturing II

Cycle Time Management during Production Ramp-up 1424Martin Haller, Andreas Peikert, Josef Thoma

Semiconductor Wafer Fabrication Subproblem Solution Procedures forthe Shifting Bottleneck Heuristic 1434

W. Matthew Carlyle, John W. Fowler, Michele Pfund, Ravi Abraham,Hari Balasubramanian, Amit Gadkari

Event and Data Triggers for Rescheduling in Wafer Fabs 1440Esma S. Gel, George Runger, Michele Pfund, John W. Fowler,Andy Burhanuddin and Cem Vardar

Trouble Systematic Based Maintenance (TSBM) in a ContinuousTransport-System in the Semiconductor Industry 1446

Harald Heinrich and Torsten Niekisch

Testing, Comparison, and Implementation Issues 1457Oliver Rose, Lars Monch and Roland Sturm

Scheduling and Rescheduling Methodologies 1464Scott J. Mason, Geoffrey Skinner, Peng Qu, Song Jin, Chris Wessels,Michele Pfund, John W. Fowler, W. Matthew Carlyle, Bosun Kim

Index of Authors 1473