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Dr. Marco Bortolini
Alma Mater Studiorum - University of Bologna

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Research Keywords & Expertise

0 Energy & the Environment
0 Production
0 Sustainability
0 Smart Manufacturing
0 Industry 4.0

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Production
Energy & the Environment
Sustainability
Industry 4.0

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Short Biography

Marco Bortolini is Senior Researcher at the Department of Industrial Engineering of Bologna University, Italy. His scientific, teaching, research and technological transfer activities focus on the study and implementation of innovative tools for the design, management, optimization and simulation of production systems, logistic activities and facility service plants from a multi-objective perspective.

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Journal article
Published: 16 July 2021 in Applied Sciences
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Within the Assembly to Order (ATO) production strategy, the common approach is to produce the parts to assemble with a Push-Make to Stock policy.In recent decades, the effects of the modern Just in Time (JIT) moved to a Pull-Make to Order policy. Assembled parts characterized by wide variety and huge storage space utilization are critical, and a proper Push/Pull production policy definition is required. An appropriate balance of storage space utilization and setup times leads to the optimization of the production policy. The aim of this paper is to define a bi-objective mathematical optimization model to assign the most suitable production policy to the parts within the production mix in an ATO industrial context. A numerical simulation and an operative case study showcases the model application, proving the industrial relevance of this research.

ACS Style

Marco Bortolini; Maurizio Faccio; Francesco Galizia; Mauro Gamberi. Push/Pull Parts Production Policy Optimization in the ATO Environment. Applied Sciences 2021, 11, 6570 .

AMA Style

Marco Bortolini, Maurizio Faccio, Francesco Galizia, Mauro Gamberi. Push/Pull Parts Production Policy Optimization in the ATO Environment. Applied Sciences. 2021; 11 (14):6570.

Chicago/Turabian Style

Marco Bortolini; Maurizio Faccio; Francesco Galizia; Mauro Gamberi. 2021. "Push/Pull Parts Production Policy Optimization in the ATO Environment." Applied Sciences 11, no. 14: 6570.

Journal article
Published: 09 April 2021 in Applied Sciences
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Prognostic Health Management (PHM) is a predictive maintenance strategy, which is based on Condition Monitoring (CM) data and aims to predict the future states of machinery. The existing literature reports the PHM at two levels: methodological and applicative. From the methodological point of view, there are many publications and standards of a PHM system design. From the applicative point of view, many papers address the improvement of techniques adopted for realizing PHM tasks without covering the whole process. In these cases, most applications rely on a large amount of historical data to train models for diagnostic and prognostic purposes. Industries, very often, are not able to obtain these data. Thus, the most adopted approaches, based on batch and off-line analysis, cannot be adopted. In this paper, we present a novel framework and architecture that support the initial application of PHM from the machinery producers’ perspective. The proposed framework is based on an edge-cloud infrastructure that allows performing streaming analysis at the edge to reduce the quantity of the data to store in permanent memory, to know the health status of the machinery at any point in time, and to discover novel and anomalous behaviors. The collection of the data from multiple machines into a cloud server allows training more accurate diagnostic and prognostic models using a higher amount of data, whose results will serve to predict the health status in real-time at the edge. The so-built PHM system would allow industries to monitor and supervise a machinery network placed in different locations and can thus bring several benefits to both machinery producers and users. After a brief literature review of signal processing, feature extraction, diagnostics, and prognostics, including incremental and semi-supervised approaches for anomaly and novelty detection applied to data streams, a case study is presented. It was conducted on data collected from a test rig and shows the potential of the proposed framework in terms of the ability to detect changes in the operating conditions and abrupt faults and storage memory saving. The outcomes of our work, as well as its major novel aspect, is the design of a framework for a PHM system based on specific requirements that directly originate from the industrial field, together with indications on which techniques can be adopted to achieve such goals.

ACS Style

Francesca Calabrese; Alberto Regattieri; Marco Bortolini; Mauro Gamberi; Francesco Pilati. Predictive Maintenance: A Novel Framework for a Data-Driven, Semi-Supervised, and Partially Online Prognostic Health Management Application in Industries. Applied Sciences 2021, 11, 3380 .

AMA Style

Francesca Calabrese, Alberto Regattieri, Marco Bortolini, Mauro Gamberi, Francesco Pilati. Predictive Maintenance: A Novel Framework for a Data-Driven, Semi-Supervised, and Partially Online Prognostic Health Management Application in Industries. Applied Sciences. 2021; 11 (8):3380.

Chicago/Turabian Style

Francesca Calabrese; Alberto Regattieri; Marco Bortolini; Mauro Gamberi; Francesco Pilati. 2021. "Predictive Maintenance: A Novel Framework for a Data-Driven, Semi-Supervised, and Partially Online Prognostic Health Management Application in Industries." Applied Sciences 11, no. 8: 3380.

Journal article
Published: 30 January 2021 in Journal of Manufacturing Systems
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In the last decade, traditional industrial and market features were replaced by emerging factors, such as the variable market demand, the need for flexibility, the shorter product life cycles and the mass personalisation, which drastically modified the production environment, pressing industrial companies to embrace and implement new types of production paradigms. Reconfigurable Manufacturing Systems (RMSs) rose as effective systems able to meet the current challenges rapidly changing their hardware, i.e. physical, and software, i.e. logical, structures to address changes in market needs. The manufacturing environment is usually characterised by dynamic cells, i.e. Reconfigurable Machine Cells (RMCs), including intelligent machines called Reconfigurable Machine Tools (RMTs). Such machines consist of fixed parts, i.e. basic modules, and dynamic parts, i.e. auxiliary modules, which allow performing different tasks, i.e. operations. This paper aims at proposing an optimisation linear programming model for the dynamic management of RMSs best balancing the RMTs reconfiguration, considering the auxiliary modules availability, i.e. the efforts to install and disassemble the auxiliary modules on/from the machines, and the part flows among the RMTs. The application to an operative case study widens the model discussion and a multi-scenario analysis concludes the study analysing how the overall system performances change varying the available auxiliary modules. Globally, results show the joint presence of multiple parts on the same RMT in each period allow concluding about the key role of the auxiliary modules to create useful and flexible structures suitable for multiple part processing.

ACS Style

Marco Bortolini; Emilio Ferrari; Francesco Gabriele Galizia; Alberto Regattieri. An optimisation model for the dynamic management of cellular reconfigurable manufacturing systems under auxiliary module availability constraints. Journal of Manufacturing Systems 2021, 58, 442 -451.

AMA Style

Marco Bortolini, Emilio Ferrari, Francesco Gabriele Galizia, Alberto Regattieri. An optimisation model for the dynamic management of cellular reconfigurable manufacturing systems under auxiliary module availability constraints. Journal of Manufacturing Systems. 2021; 58 ():442-451.

Chicago/Turabian Style

Marco Bortolini; Emilio Ferrari; Francesco Gabriele Galizia; Alberto Regattieri. 2021. "An optimisation model for the dynamic management of cellular reconfigurable manufacturing systems under auxiliary module availability constraints." Journal of Manufacturing Systems 58, no. : 442-451.

Journal article
Published: 29 January 2021 in Applied Sciences
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Industry 4.0 emerged in the last decade as the fourth industrial revolution aiming at reaching greater productivity, digitalization and operational efficiency standard. In this new era, if compared to automated assembly systems, manual assembly systems (MASs) are still characterized by wide flexibility but poor productivity levels. To reach acceptable performances in terms of both productivity and flexibility, higher automation levels are required to increase the skills and capabilities of the human operators with the aim to design next-generation assembly systems having higher levels of adaptivity and collaboration between people and automation/information technology. In the current literature, such systems are called adaptive automation assembly systems (A3Ss). For A3Ss, few design approaches and industrial prototypes are available. This paper, extending a previous contribution by the Authors, expands the lacking research in the field and proposes a general framework guiding toward A3S effective design and validation. The framework is applied to a full-scale prototype, highlighting its features together with the technical- and human-oriented improvements arising from its adoption. Specifically, evidence from this study show a set of benefits from adopting innovative A3Ss in terms of reduction of the assembly cycle time (about 30%) with a consequent increase of the system productivity (about 45%) as well as relevant improvements of ergonomic posture indicators (about 15%). The definition of a general framework for A3S design and validation and the integration of the productivity and ergonomic analysis of such systems are missing in the current literature, representing an element of innovation. Globally, this research paper provides advanced knowledge to guide research, industrial companies and practitioners in switching from traditional to advanced assembly systems in the emerging Industry 4.0 era matching current industrial and market features.

ACS Style

Marco Bortolini; Maurizio Faccio; Francesco Gabriele Galizia; Mauro Gamberi; Francesco Pilati. Adaptive Automation Assembly Systems in the Industry 4.0 Era: A Reference Framework and Full–Scale Prototype. Applied Sciences 2021, 11, 1256 .

AMA Style

Marco Bortolini, Maurizio Faccio, Francesco Gabriele Galizia, Mauro Gamberi, Francesco Pilati. Adaptive Automation Assembly Systems in the Industry 4.0 Era: A Reference Framework and Full–Scale Prototype. Applied Sciences. 2021; 11 (3):1256.

Chicago/Turabian Style

Marco Bortolini; Maurizio Faccio; Francesco Gabriele Galizia; Mauro Gamberi; Francesco Pilati. 2021. "Adaptive Automation Assembly Systems in the Industry 4.0 Era: A Reference Framework and Full–Scale Prototype." Applied Sciences 11, no. 3: 1256.

Journal article
Published: 29 December 2020 in Applied Sciences
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In the last decades, Reconfigurable Manufacturing Systems (RMSs) rose as an emerging manufacturing strategy matching the modern industrial and market requirements asking for a wide variety of products in flexible batches. A traditional reconfigurable manufacturing environment consists of dynamic cells, called Reconfigurable Machine Cells (RMCs), including a set of machines called Reconfigurable Machine Tools (RMTs). Such machines are characterized by fixed elements, i.e., basic modules, and dynamic elements, i.e., auxiliary modules, allowing them to perform different operations. Despite their automation level, these systems require the intervention of the human operators in performing specific tasks, e.g., handling of the auxiliary modules from the warehouse to the RMTs and their assembly/disassembly to/from the RMTs. This issue rises relevant ergonomic and safety questions due to the human–machine collaboration. Following this stream, this paper proposes and applies a bi-objective optimization model for the design and management of RMSs. The technical objective function minimizes the reconfiguration time, i.e., the time needed to equip the RMTs with the required auxiliary modules, and the part and auxiliary module travel time among the RMCs. The ergonomic objective function minimizes the repetitive movements performed by the human operators during the working activities according to the ISO 11228-3 standard. Results show the existence of a good trade-off between the two objective functions, proving the possibility to improve the ergonomic conditions of the human operators without excessively increasing the total time needed for RMTs reconfiguration and for part and auxiliary module travelling.

ACS Style

Marco Bortolini; Lucia Botti; Francesco Gabriele Galizia; Alberto Regattieri. Bi-Objective Design and Management of Reconfigurable Manufacturing Systems to Optimize Technical and Ergonomic Performances. Applied Sciences 2020, 11, 263 .

AMA Style

Marco Bortolini, Lucia Botti, Francesco Gabriele Galizia, Alberto Regattieri. Bi-Objective Design and Management of Reconfigurable Manufacturing Systems to Optimize Technical and Ergonomic Performances. Applied Sciences. 2020; 11 (1):263.

Chicago/Turabian Style

Marco Bortolini; Lucia Botti; Francesco Gabriele Galizia; Alberto Regattieri. 2020. "Bi-Objective Design and Management of Reconfigurable Manufacturing Systems to Optimize Technical and Ergonomic Performances." Applied Sciences 11, no. 1: 263.

Journal article
Published: 08 December 2020 in Computers & Industrial Engineering
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Motivated by real-world applications from the non-perishable food and beverage industry, we consider a general optimization problem that involves production, distribution and warehouse logistics. The problem deals with the logistic network design and material flow management to supply the multi-product and multi-period customer demand. Decisions on production site use, including lot-sizing, setup and minimum batches are taken from a cost saving perspective together with warehouse management decisions, including shipments to external warehouses. We present a mathematical formulation of the problem that is based on a Mixed Integer Linear Programming (MILP) model and takes into account all the nasty constraints that are present in the real problem. We show that such a model is computationally hard even using a state-of-the-art commercial solver, and introduce a metaheuristic algorithm that we use to compute approximate solutions. We test the proposed algorithms on two real-world test-cases and on a large set of realistic problems. The results show that, in all cases, the algorithm is very fast and produces solutions whose quality is very close to those that can be obtained by running a state-of-the-art commercial solver on the mathematical model for a very long time, thus providing for an efficient method for evaluating effective policies to be used under different scenarios. The models and the solving algorithms are of help to the industrial practitioners for the mid-term tactical management of their logistic networks.

ACS Style

Vincenzo Bo; Marco Bortolini; Enrico Malaguti; Michele Monaci; Cristina Mora; Paolo Paronuzzi. Models and algorithms for integrated production and distribution problems. Computers & Industrial Engineering 2020, 154, 107003 .

AMA Style

Vincenzo Bo, Marco Bortolini, Enrico Malaguti, Michele Monaci, Cristina Mora, Paolo Paronuzzi. Models and algorithms for integrated production and distribution problems. Computers & Industrial Engineering. 2020; 154 ():107003.

Chicago/Turabian Style

Vincenzo Bo; Marco Bortolini; Enrico Malaguti; Michele Monaci; Cristina Mora; Paolo Paronuzzi. 2020. "Models and algorithms for integrated production and distribution problems." Computers & Industrial Engineering 154, no. : 107003.

Original article
Published: 28 October 2020 in The International Journal of Advanced Manufacturing Technology
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Non-traditional warehouses rise as effective solutions to shorten the travelled distances to store and retrieve unit loads, adding aisles crossing the parallel racks. Multiple warehouse configurations are proposed by the literature discussing the enhancements toward standard layouts. In previous contributions, the authors introduced the diagonal cross-aisle model, concluding about its positive impact on the handling performances under single command operations. This paper extends the previous works, integrating dual command operations, through an original analytic model supporting the design of non-traditional warehouses with a couple of symmetric straight diagonal cross-aisles and random storage assignment strategy. The closed-form expressions to compute the expected cycle travel distances are provided, optimising the aisle position. An industrial case study applies the model, getting distance savings ranging from 11 to 17%, compared to standard layout and further considering the loss of storage space due to the presence of the additional aisles.

ACS Style

Marco Bortolini; Francesco Gabriele Galizia; Mauro Gamberi; Francesco Gualano. Integration of single and dual command operations in non-traditional warehouse design. The International Journal of Advanced Manufacturing Technology 2020, 111, 2461 -2473.

AMA Style

Marco Bortolini, Francesco Gabriele Galizia, Mauro Gamberi, Francesco Gualano. Integration of single and dual command operations in non-traditional warehouse design. The International Journal of Advanced Manufacturing Technology. 2020; 111 (9):2461-2473.

Chicago/Turabian Style

Marco Bortolini; Francesco Gabriele Galizia; Mauro Gamberi; Francesco Gualano. 2020. "Integration of single and dual command operations in non-traditional warehouse design." The International Journal of Advanced Manufacturing Technology 111, no. 9: 2461-2473.

Journal article
Published: 01 January 2020 in IFAC-PapersOnLine
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Nowadays, manufacturing environment is characterized by the necessity of customized flexibility as well as responding rapidly and cost-effectively to changing market demands while minimizing impacts on environment and society. To reach these goals, a key paradigm called sustainable manufacturing can be coupled with reconfigurable manufacturing systems (RMSs). The coupling of RMS characteristics and sustainability concerns is a basis to develop a new generation of sustainable production systems. This paper outlines sustainability in a reconfigurable environment from an energy consumption point of view. A nonlinear mathematical model is developed to optimize the energy consumption of a RMS through a redefinition of its core characteristics—modularity and integrability. The objective is to minimize the energy consumption of the system by selecting the most suitable modular machines from a set of candidate machines. The optimization problem is addressed using an exhaustive search heuristic. Finally, the applicability of the proposed approach is illustrated through a simple numerical example and the discussion of the obtained results.

ACS Style

Elisa Massimi; Hichem Haddou Benderbal; Lyes Benyoucef; Marco Bortolini. Modularity and Integrability-based Energy Minimization in a Reconfigurable Manufacturing Environment: A Non-linear Mixed Integer Formulation. IFAC-PapersOnLine 2020, 53, 10726 -10731.

AMA Style

Elisa Massimi, Hichem Haddou Benderbal, Lyes Benyoucef, Marco Bortolini. Modularity and Integrability-based Energy Minimization in a Reconfigurable Manufacturing Environment: A Non-linear Mixed Integer Formulation. IFAC-PapersOnLine. 2020; 53 (2):10726-10731.

Chicago/Turabian Style

Elisa Massimi; Hichem Haddou Benderbal; Lyes Benyoucef; Marco Bortolini. 2020. "Modularity and Integrability-based Energy Minimization in a Reconfigurable Manufacturing Environment: A Non-linear Mixed Integer Formulation." IFAC-PapersOnLine 53, no. 2: 10726-10731.

Journal article
Published: 01 January 2020 in IFAC-PapersOnLine
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This paper addresses the so-called integrated process planning and scheduling (IPPS) problem in a reconfigurable manufacturing environment. Process planning and scheduling are two important and complex functions in manufacturing. To reduce the problem complexity, they are considered sequentially by traditional approaches. In this paper, we consider the simultaneous integration of both functions by developing a heuristic approach to solve the IPPS problem in a reconfigurable environment. Reconfigurable manufacturing systems (RMSs) comprise of a set of machines distinguished by multiple working configurations and tools. Each machine can perform a certain number of operations based on its configurations and their availability. The purpose of the proposed heuristic approach is to find the best assignment of operations to machines while considering process-quality. Finally, to demonstrate the approach applicability, an illustrative numerical example is presented and the results discussed.

ACS Style

Luca Morganti; Hichem Haddou Benderbal; Lyes Benyoucef; Marco Bortolini; Francesco Gabriele Galizia. A New Process Quality-based Multi-objective Multi-part Approach for the Integrated Process Planning and Scheduling (IPPS) Problem in Reconfigurable Manufacturing Environment. IFAC-PapersOnLine 2020, 53, 10755 -10760.

AMA Style

Luca Morganti, Hichem Haddou Benderbal, Lyes Benyoucef, Marco Bortolini, Francesco Gabriele Galizia. A New Process Quality-based Multi-objective Multi-part Approach for the Integrated Process Planning and Scheduling (IPPS) Problem in Reconfigurable Manufacturing Environment. IFAC-PapersOnLine. 2020; 53 (2):10755-10760.

Chicago/Turabian Style

Luca Morganti; Hichem Haddou Benderbal; Lyes Benyoucef; Marco Bortolini; Francesco Gabriele Galizia. 2020. "A New Process Quality-based Multi-objective Multi-part Approach for the Integrated Process Planning and Scheduling (IPPS) Problem in Reconfigurable Manufacturing Environment." IFAC-PapersOnLine 53, no. 2: 10755-10760.

Chapter
Published: 20 October 2019 in Springer Series in Advanced Manufacturing
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In the recent years, the adoption of reconfigurable systems represents a primary strategy to improving flexibility, elasticity and efficiency in both manufacturing and assembly. Global markets, the increasing need for customization, high-quality standards, dynamic batches and short life cycles are the key factors driving the transition from traditional to reconfigurable manufacturing systems (RMSs). Despite their automation level, such systems still require actions by human operators, e.g. material handling, WIP load/unload, tool setup, etc. These operations rise safety issues because of the human–machine interaction and cooperation. Particularly, RMSs require changes of auxiliary modules and tools, based on the manual intervention, to achieve effective system configurations enlarging the produced mix. In this field, embracing the emerging Industry 4.0 technology, a lack of procedures and reference approaches exists to supporting companies and practitioners in analysing the impact on safety and ergonomics coming from the switch from standard to RMSs. This chapter, after revising the literature, standards and reference guidelines, converges to an innovative methodological and operative framework supporting and spreading the integration of safety, ergonomics and human factors in the emerging reconfigurable systems. Deep attention is paid to best-in-class examples, from industry, to strengthen the industrial perspective and applicability.

ACS Style

M. Bortolini; L. Botti; F. G. Galizia; C. Mora. Safety, Ergonomics and Human Factors in Reconfigurable Manufacturing Systems. Springer Series in Advanced Manufacturing 2019, 123 -138.

AMA Style

M. Bortolini, L. Botti, F. G. Galizia, C. Mora. Safety, Ergonomics and Human Factors in Reconfigurable Manufacturing Systems. Springer Series in Advanced Manufacturing. 2019; ():123-138.

Chicago/Turabian Style

M. Bortolini; L. Botti; F. G. Galizia; C. Mora. 2019. "Safety, Ergonomics and Human Factors in Reconfigurable Manufacturing Systems." Springer Series in Advanced Manufacturing , no. : 123-138.

Articles
Published: 23 September 2019 in International Journal of Green Energy
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Tobacco is among the top sectors, worldwide, for revenues and aggregate turnover with a global market arena and a group of top players progressively driving the change toward high-quality standards and a strong customer and environmental care. Behind cigarettes, the tobacco supply chain includes agricultural and industrial phases, to grow and cure the tobacco leaves and to manufacture and deliver the final products. This study addresses the goal of greening the tobacco flue-curing process, aimed at drying the tobacco leaves and known as the most energy-intensive process, presenting a joint techno-economic and environmental feasibility study for Virginia tobacco type in Italy. Starting from a review of the process, the curing barn features and the required physical conditions to obtain top quality flue-cured tobacco, this study investigates the impact of using biomass instead of fossil fuels to feed the heat generators. The input data, to support the analysis, are from Italian producers selling tobacco to an international leading company that joined the present research. Results highlight that the switch to non-fossil fuels for tobacco curing leads to annual cost savings up to 13% and to global environmental savings, i.e. emitted equivalent carbon dioxide reduction, up to 95% without product quality decrease.

ACS Style

Marco Bortolini; Mauro Gamberi; Cristina Mora; Alberto Regattieri. Greening the tobacco flue-curing process using biomass energy: a feasibility study for the flue-cured Virginia type in Italy. International Journal of Green Energy 2019, 16, 1220 -1229.

AMA Style

Marco Bortolini, Mauro Gamberi, Cristina Mora, Alberto Regattieri. Greening the tobacco flue-curing process using biomass energy: a feasibility study for the flue-cured Virginia type in Italy. International Journal of Green Energy. 2019; 16 (14):1220-1229.

Chicago/Turabian Style

Marco Bortolini; Mauro Gamberi; Cristina Mora; Alberto Regattieri. 2019. "Greening the tobacco flue-curing process using biomass energy: a feasibility study for the flue-cured Virginia type in Italy." International Journal of Green Energy 16, no. 14: 1220-1229.

Original article
Published: 21 August 2019 in The International Journal of Advanced Manufacturing Technology
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Within cellular manufacturing systems (CMSs), families of parts are assigned to manufacturing cells, composed by homogeneous sets of machines. In conventional CMSs, each cell is devoted to the production of a specific part family, reducing material handling and work-in-process. Despite their flexibility, such systems still suffer from coping with the present market challenges asking for dynamic part mix and the need of agility in manufacturing. To meet these challenges, the recent literature explores the idea of including elements of the emerging reconfigurable manufacturing paradigm in the design and management of CMSs, leading to the cellular reconfigurable manufacturing system (CRMS) concept. The aim of this paper is to propose an original linear programming optimization model for the design of CRMSs with alternative part routing and multiple time periods. The production environment consists of multiple cells equipped with reconfigurable machine tools (RMTs) made of basic and auxiliary custom modules. By changing the auxiliary modules, different operations become available on the same RMT. The proposed approach determines the part routing mix and the auxiliary module allocation best balancing the part flows among RMTs and the effort to install the modules on the machines. The approach discussion is supported by a literature case study, while a multi-scenario analysis is performed to assess the impact of different CMS configurations on the system performances, varying both the number of cells and the RMT assignment to each of them. A benchmarking concludes the paper comparing the proposed CRMS against a conventional CMS configuration. The analysis shows relevant benefits in terms of reduction of the intercellular travel time (− 58.6%) getting a global time saving of about 53.3%. Results prove that reconfigurability is an opportunity for industries to face the dynamics of global markets.

ACS Style

Marco Bortolini; Francesco Gabriele Galizia; Cristina Mora; Francesco Pilati. Reconfigurability in cellular manufacturing systems: a design model and multi-scenario analysis. The International Journal of Advanced Manufacturing Technology 2019, 104, 4387 -4397.

AMA Style

Marco Bortolini, Francesco Gabriele Galizia, Cristina Mora, Francesco Pilati. Reconfigurability in cellular manufacturing systems: a design model and multi-scenario analysis. The International Journal of Advanced Manufacturing Technology. 2019; 104 (9-12):4387-4397.

Chicago/Turabian Style

Marco Bortolini; Francesco Gabriele Galizia; Cristina Mora; Francesco Pilati. 2019. "Reconfigurability in cellular manufacturing systems: a design model and multi-scenario analysis." The International Journal of Advanced Manufacturing Technology 104, no. 9-12: 4387-4397.

Journal article
Published: 24 June 2019 in Procedia CIRP
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Mixed-model Flexible Manufacturing Systems (FMSs) and, more recently, Reconfigurable Manufacturing Systems (RMSs) are widely studied as diffuse solutions for complex production environments, targeting variable markets and highly dynamic production plans. Their design and management are challenging both in new plants and for plant-redesign actions. In this field, the literature suggests the adoption of cellular configurations as effective solutions. These configurations partition the FMS and RMS machines into manufacturing cells and assign the working parts to the cells to reduce the so-called intercellular flows, causing costs and inbound congestions. This paper advances the current literature presenting and applying an optimal linear programming cost model for the redesign of mixed-model FMS/RMS cellular production environments. The model goes beyond the widely studied partitioning of the FMSs among the cells and it best balances machine relocations and redundancies, the production area layout optimization and the intercellular flow reduction. The major industrial operative constraints are included in the model together with a reference case study to exemplify its advantages toward the standard approaches.

ACS Style

Marco Bortolini; Emilio Ferrari; Francesco Gabriele Galizia; Cristina Mora; Francesco Pilati. Optimal redesign of Cellular Flexible and Reconfigurable Manufacturing Systems. Procedia CIRP 2019, 81, 1435 -1440.

AMA Style

Marco Bortolini, Emilio Ferrari, Francesco Gabriele Galizia, Cristina Mora, Francesco Pilati. Optimal redesign of Cellular Flexible and Reconfigurable Manufacturing Systems. Procedia CIRP. 2019; 81 ():1435-1440.

Chicago/Turabian Style

Marco Bortolini; Emilio Ferrari; Francesco Gabriele Galizia; Cristina Mora; Francesco Pilati. 2019. "Optimal redesign of Cellular Flexible and Reconfigurable Manufacturing Systems." Procedia CIRP 81, no. : 1435-1440.

Journal article
Published: 24 June 2019 in Procedia CIRP
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The management of the production and procurement of the assembled parts in an assembly to order (ATO) environment is a challenging problem. Due to the high variety and high inventory space utilization of the sheet metal plate parts, many companies choose to include in their production the cutting, blending, welding and if necessary, painting processes, reducing the lead time and consequently the stocks levels. The related trade-off between the setup times and the inventory space utilization is clear. This paper aims to propose a bi-objective optimization model to properly set the MTO/MTS policy to adopt. A case study is reported to test the model and to demonstrate the practical implication of this research.

ACS Style

M. Bortolini; M. Faccio; M. Gamberi; Francesco Pilati. MTO/MTS policy optimization for sheet metal plate parts in an ATO environment. Procedia CIRP 2019, 81, 1046 -1051.

AMA Style

M. Bortolini, M. Faccio, M. Gamberi, Francesco Pilati. MTO/MTS policy optimization for sheet metal plate parts in an ATO environment. Procedia CIRP. 2019; 81 ():1046-1051.

Chicago/Turabian Style

M. Bortolini; M. Faccio; M. Gamberi; Francesco Pilati. 2019. "MTO/MTS policy optimization for sheet metal plate parts in an ATO environment." Procedia CIRP 81, no. : 1046-1051.

Journal article
Published: 29 May 2019 in Procedia Manufacturing
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This research proposes an approach to design and to manage Cellular Reconfigurable Manufacturing Systems (CRMSs) from a multi-product and multi-period perspective. The production environment consists of multiple cells of machines equipped with Reconfigurable Machine Tools (RMTs) made of basic and auxiliary custom modules to perform specific tasks. The approach acts into two steps; the former is the machine cell design phase, assigning machines to cells, the latter is the cell loading phase, assigning modules to each machine and cell. The goal is to guarantee the economic sustainability of the manufacturing system by exploring how to best balance the part flow among machines already equipped with the required modules and the effort to install the necessary modules on the machine on which the part is located.

ACS Style

Marco Bortolini; Francesco Gabriele Galizia; Cristina Mora. Dynamic design and management of reconfigurable manufacturing systems. Procedia Manufacturing 2019, 33, 67 -74.

AMA Style

Marco Bortolini, Francesco Gabriele Galizia, Cristina Mora. Dynamic design and management of reconfigurable manufacturing systems. Procedia Manufacturing. 2019; 33 ():67-74.

Chicago/Turabian Style

Marco Bortolini; Francesco Gabriele Galizia; Cristina Mora. 2019. "Dynamic design and management of reconfigurable manufacturing systems." Procedia Manufacturing 33, no. : 67-74.

Journal article
Published: 29 May 2019 in Procedia Manufacturing
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Nowadays, dynamic products life cycles and increase in the number of product variants have led to reduction in demand per variant. This modern trend is in contrast with the high production volume of manufacturing processes such as injection molding, since they are commonly employed for mass production due to their long changeover time. Traditional rigid molds do not seem to be able to cope with the current industrial and market challenges. Flexible and reconfigurable molding processes, such as the discrete pin tooling systems and changeable molds, appear to be a promising choice for achieving manufacturing economic sustainability. They represent an effective way to save resources and reduce labor costs and setup times. This paper explores the evolution of molds used in manufacturing, from the old models to the current reconfigurable ones through a state-of-the-art analysis of academic research and solutions implemented by industry. Conclusions and insights are presented.

ACS Style

Francesco Gabriele Galizia; Waguih Elmaraghy; Hoda Elmaraghy; Marco Bortolini; Cristina Mora. The evolution of molds in manufacturing: from rigid to flexible. Procedia Manufacturing 2019, 33, 319 -326.

AMA Style

Francesco Gabriele Galizia, Waguih Elmaraghy, Hoda Elmaraghy, Marco Bortolini, Cristina Mora. The evolution of molds in manufacturing: from rigid to flexible. Procedia Manufacturing. 2019; 33 ():319-326.

Chicago/Turabian Style

Francesco Gabriele Galizia; Waguih Elmaraghy; Hoda Elmaraghy; Marco Bortolini; Cristina Mora. 2019. "The evolution of molds in manufacturing: from rigid to flexible." Procedia Manufacturing 33, no. : 319-326.

Articles
Published: 12 April 2019 in International Journal of Production Research
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Product platforms represent an effective strategy implemented by manufacturers to cope with dynamic market demands, decrease lead-time and delay products differentiation. A decision support system (DSS) for product platforms design and selection in high-variety manufacturing is presented. It applies median-joining phylogenetic networks (MJPN) for the platforms design and phylogenetic tree decomposition for platforms selection by determining the product family phylogenetic network and defines the platforms at various levels of assembly corresponding to different trade-offs between number of platforms (variety) and number of assembly/disassembly tasks (customisation effort). Product platforms are reconfigured and customised to derive final product variants. The phylogenetic tree is decomposed in multiple levels, from the native platforms to the final variants. New Platforms Reconfiguration Index (PRI) and Platforms Customisation Index (PCI) were developed as metrics to evaluate the platforms customisation effort. A case study of a large family of plastic valves is used to demonstrate the DSS application. It shows reduction of 60% in platforms variety and increases in platform customisation assembly/disassembly tasks by only 20% leading to significant production and inventory efficiencies and cost savings. This methodology supports companies in the design and selection of best product platforms for high-variety to reduce cost and delivery time.

ACS Style

Francesco Gabriele Galizia; Hoda Elmaraghy; Marco Bortolini; Cristina Mora. Product platforms design, selection and customisation in high-variety manufacturing. International Journal of Production Research 2019, 58, 893 -911.

AMA Style

Francesco Gabriele Galizia, Hoda Elmaraghy, Marco Bortolini, Cristina Mora. Product platforms design, selection and customisation in high-variety manufacturing. International Journal of Production Research. 2019; 58 (3):893-911.

Chicago/Turabian Style

Francesco Gabriele Galizia; Hoda Elmaraghy; Marco Bortolini; Cristina Mora. 2019. "Product platforms design, selection and customisation in high-variety manufacturing." International Journal of Production Research 58, no. 3: 893-911.

Journal article
Published: 01 January 2019 in International Journal of Advanced Operations Management
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In modern business, industrial companies embrace lean philosophy to increase their efficiency moving toward the so-called continuous improvement of industrial processes. In parallel, according to the international regulations and stakeholder pressures, rising attention is toward sustainable environmental, i.e., green, practices. A relevant scientific area addresses the topic of matching lean management (LM) and green management (GM) principles within logistics, from a quantitative and optimised perspective. This paper follows this stream and proposes a bi-objective model optimising stock efficiency and environmental sustainability in the design of direct distribution logistic networks. The former goal belongs to LM, the latter belongs to GM. The model application to an Italian case study showcases its benefit reducing the average stock without a relevant increase of the emissions due to frequent replenishments. A cost analysis of the results completes this paper to include the economic dimension within the study boundaries.

ACS Style

Marco Bortolini; Francesco Gabriele Galizia; Mauro Gamberi; Cristina Mora; Francesco Pilati. Enhancing stock efficiency and environmental sustainability goals in direct distribution logistic networks. International Journal of Advanced Operations Management 2019, 11, 1 .

AMA Style

Marco Bortolini, Francesco Gabriele Galizia, Mauro Gamberi, Cristina Mora, Francesco Pilati. Enhancing stock efficiency and environmental sustainability goals in direct distribution logistic networks. International Journal of Advanced Operations Management. 2019; 11 (1/2):1.

Chicago/Turabian Style

Marco Bortolini; Francesco Gabriele Galizia; Mauro Gamberi; Cristina Mora; Francesco Pilati. 2019. "Enhancing stock efficiency and environmental sustainability goals in direct distribution logistic networks." International Journal of Advanced Operations Management 11, no. 1/2: 1.

Journal article
Published: 01 January 2019 in Procedia Manufacturing
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This paper aims to present a methodology and multi-scenario application for the techno-economic assessment of the wind turbine layout in a wind farm. The considered decisional variables deal with the number of wind turbines to install, their self-distance and their distance toward the primary grid line. In addition, the wind speed profile and the site boundary environmental conditions are within the methodology. The levelized cost of energy (LCOE) and the net present value (NPV) are estimated as the key results and decisional indicators to compare multiple scenarios within two relevant locations in the Middle East (a case study of Abadan site in Iran) and the Mediterranean region (a case study of Swatar site in Malta). Finally, for each site, an effective layout of the wind farm is selected. Numerical results lead to the optimum layout with the lowest cost of energy. Swatar site has the highest potential of wind for the energy production. The LCOE for this site is estimated to be 4.01 c€/kWh for a wind farm with a size of 10 MW and 5.76 c€/kWh for a wind farm with size of 25 MW. Overall, it is shown that the wind power fosters sustainable development in both case studies and the proposed structures and layouts increase the performances of the wind farms, considerably.

ACS Style

Marco Bortolini; Maurizio Faccio; Emilio Ferrari; Mauro Gamberi; Mojtaba Nedaei. Techno-Economic Design of Wind Farms: A Methodology and Multi-Scenario Application. Procedia Manufacturing 2019, 39, 1270 -1278.

AMA Style

Marco Bortolini, Maurizio Faccio, Emilio Ferrari, Mauro Gamberi, Mojtaba Nedaei. Techno-Economic Design of Wind Farms: A Methodology and Multi-Scenario Application. Procedia Manufacturing. 2019; 39 ():1270-1278.

Chicago/Turabian Style

Marco Bortolini; Maurizio Faccio; Emilio Ferrari; Mauro Gamberi; Mojtaba Nedaei. 2019. "Techno-Economic Design of Wind Farms: A Methodology and Multi-Scenario Application." Procedia Manufacturing 39, no. : 1270-1278.

Journal article
Published: 25 October 2018 in Computers & Industrial Engineering
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Nowadays the Smart Factories operating within the Industry 4.0 revolution, require more and more reliable, fast and automatic tools for production analysis and improvement. Manufacturing companies, in which the human labour has a crucial role, need instruments able to manage complex production systems in terms of resource utilization, product mix, component allocation and material handling optimization. In this context, this work presents an original hardware/software architecture, Motion Analysis System (MAS), aimed at the human body digitalization and analysis during the execution of manufacturing/assembly tasks within the common industrial workstation. MAS is based on the integration of the Motion Capture (MOCAP) technology with an ad hoc software developed for productive and ergonomic analysis of the operator during his work. MAS hardware integrates a network of depth cameras initially developed for gaming (Microsoft Kinect v2™, conceived for markerless MOCAP) and now used for industrial analysis, while an original software infrastructure is programmed to automatically and quantitatively provide productive information (human task analysis in terms of time execution and used space within the workplace, movements of hands and locations visited by the operator) and ergonomic information (full body analysis implementing all the internationally adopted indexes OWAS, REBA, NIOSH and EAWS). This double perspective makes MAS a unique and valuable tool for industrial managers oriented to the workplace analysis and design (in terms of productivity) without neglecting the operator health. This proposed contribution ends with a real industrial application analysing a water pump assembly station: the system setup is discussed and the key results obtained adopting MAS are presented and analysed.

ACS Style

Marco Bortolini; Maurizio Faccio; Mauro Gamberi; Francesco Pilati. Motion Analysis System (MAS) for production and ergonomics assessment in the manufacturing processes. Computers & Industrial Engineering 2018, 139, 105485 .

AMA Style

Marco Bortolini, Maurizio Faccio, Mauro Gamberi, Francesco Pilati. Motion Analysis System (MAS) for production and ergonomics assessment in the manufacturing processes. Computers & Industrial Engineering. 2018; 139 ():105485.

Chicago/Turabian Style

Marco Bortolini; Maurizio Faccio; Mauro Gamberi; Francesco Pilati. 2018. "Motion Analysis System (MAS) for production and ergonomics assessment in the manufacturing processes." Computers & Industrial Engineering 139, no. : 105485.