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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.
Marco Bortolini; Maurizio Faccio; Francesco Galizia; Mauro Gamberi. Push/Pull Parts Production Policy Optimization in the ATO Environment. Applied Sciences 2021, 11, 6570 .
AMA StyleMarco 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 StyleMarco Bortolini; Maurizio Faccio; Francesco Galizia; Mauro Gamberi. 2021. "Push/Pull Parts Production Policy Optimization in the ATO Environment." Applied Sciences 11, no. 14: 6570.
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.
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 StyleFrancesca 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 StyleFrancesca 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.
The assembly of large and complex products such as cars, trucks, and white goods typically involves a huge amount of production resources such as workers, pieces of equipment, and layout areas. In this context, multi-manned workstations commonly characterize these assembly lines. The simultaneous operators’ activity in the same assembly station suggests considering compatibility/incompatibility between the different mounting positions, equipment sharing, and worker cooperation. The management of all these aspects significantly increases the balancing problem complexity due to the determination of the start/end times of each task. This paper proposes a new mixed-integer programming model to simultaneously optimize the line efficiency, the line length, and the workload smoothness. A customized procedure based on a simulated annealing algorithm is developed to effectively solve this problem. The aforementioned procedure is applied to the balancing of the real assembly line of European sports car manufacturers distinguished by 665 tasks and numerous synchronization constraints. The experimental results present remarkable performances obtained by the proposed procedure both in terms of solution quality and computation time. The proposed approach is the practical reference for efficient multi-manned assembly line design, task assignment, equipment allocation, and mounting position management in the considered industrial fields.
Francesco Pilati; Emilio Ferrari; Mauro Gamberi; Silvia Margelli. Multi-Manned Assembly Line Balancing: Workforce Synchronization for Big Data Sets through Simulated Annealing. Applied Sciences 2021, 11, 2523 .
AMA StyleFrancesco Pilati, Emilio Ferrari, Mauro Gamberi, Silvia Margelli. Multi-Manned Assembly Line Balancing: Workforce Synchronization for Big Data Sets through Simulated Annealing. Applied Sciences. 2021; 11 (6):2523.
Chicago/Turabian StyleFrancesco Pilati; Emilio Ferrari; Mauro Gamberi; Silvia Margelli. 2021. "Multi-Manned Assembly Line Balancing: Workforce Synchronization for Big Data Sets through Simulated Annealing." Applied Sciences 11, no. 6: 2523.
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.
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 StyleMarco 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 StyleMarco 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.
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.
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 StyleMarco 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 StyleMarco 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.
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.
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 StyleMarco 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 StyleMarco 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.
Non-traditional warehouses shorten the travelled paths to store and retrieve (S/R) the loads, thanks to additional aisles crossing the parallel racks. This paper provides the analytic model to best design a non-traditional warehouse for unit-load (UL) with diagonal cross-aisles and storage policy according to the class-based storage (CBS) strategy. The model minimizes the average single-command cycle time to S/R the loads, best sizing the classes, their shape, and the position/numbers of additional aisles. The focus is on both 2- and 3-CBS optimizing the number of diagonal cross-aisles to best balance the travel time reduction and the loss of storage space due to the aisles. Furthermore, benchmarking toward standard warehouses with no diagonal cross-aisles and random assignment strategy allows quantifying the positive impact of the proposed design configuration on the daily warehouse operations.
Marco Bortolini; Maurizio Faccio; Emilio Ferrari; Mauro Gamberi; Francesco Pilati. Design of diagonal cross-aisle warehouses with class-based storage assignment strategy. The International Journal of Advanced Manufacturing Technology 2018, 100, 2521 -2536.
AMA StyleMarco Bortolini, Maurizio Faccio, Emilio Ferrari, Mauro Gamberi, Francesco Pilati. Design of diagonal cross-aisle warehouses with class-based storage assignment strategy. The International Journal of Advanced Manufacturing Technology. 2018; 100 (9-12):2521-2536.
Chicago/Turabian StyleMarco Bortolini; Maurizio Faccio; Emilio Ferrari; Mauro Gamberi; Francesco Pilati. 2018. "Design of diagonal cross-aisle warehouses with class-based storage assignment strategy." The International Journal of Advanced Manufacturing Technology 100, no. 9-12: 2521-2536.
Since 1913, the Harris’ model is adopted within intermittent production systems to size the batches to produce and purchase. For each product, the model sets the so-called Economic Order Quantity (EOQ) as the quantity optimally trading-off the cost of orders and the average stock cost. Traditionally, the EOQ from the Harris’ model is a milestone for make-to-stock (MTS) production systems. In addition, existing extensions of the base model are in the direction of including multiple actors of the supply chain, i.e. joint economic lot size, and tailored product management policies, i.e. consignment stock. A basic hypothesis behind the lot size models is that the production line productivity is higher than the average market demand so that a dynamic equilibrium becomes feasible. Nevertheless, in the case of permanent or temporary high product request, the productivity of a single production line can be insufficient. This case makes of interest the adoption of multi-line production systems. Such systems are made of parallel production lines able to produce the same product at the same final qualitative standards so that the output is a unique batch of identical products. This paper investigates MTS multi-line systems presenting two formulations of the EOQ model for the case of identical lines (1) and the case of lines with different productivity and setup cost (2). Finally, an application of the model is done with data taken from a leading company operating in the beverage packaging sector.
Marco Bortolini; Silvia Errani; Mauro Gamberi; Francesco Pilati; Alberto Regattieri. Beyond the Harris’ Model to Optimally Define Lot Sizes in a Make-to-Stock Multi-line Production System. EngOpt 2018 Proceedings of the 6th International Conference on Engineering Optimization 2018, 1316 -1327.
AMA StyleMarco Bortolini, Silvia Errani, Mauro Gamberi, Francesco Pilati, Alberto Regattieri. Beyond the Harris’ Model to Optimally Define Lot Sizes in a Make-to-Stock Multi-line Production System. EngOpt 2018 Proceedings of the 6th International Conference on Engineering Optimization. 2018; ():1316-1327.
Chicago/Turabian StyleMarco Bortolini; Silvia Errani; Mauro Gamberi; Francesco Pilati; Alberto Regattieri. 2018. "Beyond the Harris’ Model to Optimally Define Lot Sizes in a Make-to-Stock Multi-line Production System." EngOpt 2018 Proceedings of the 6th International Conference on Engineering Optimization , no. : 1316-1327.
Smart and distributed energy micro-production is the new pattern for the electric energy supply, joining high service level and sustainability issues. Within such a context, the renewables, i.e. solar photovoltaic (PV), micro-wind, etc., play an increasing role as part of the source mix because of their capillary presence and the decrease of the required initial technology investments. On the contrary, the renewable intermittence is the key weakness to overcome to make a turning point to their final spread. To this purpose, hybrid energy systems join the plus of having renewable modules to the plus of having backup traditional units activated in the case of lack of energy. This study presents and applies to an Italian rural context a linear programming model to best design and manage a local off-grid renewable smart energy system. The power system may include PV and micro-wind technologies together with a battery bank and diesel generator as the backup system. Starting from the expected average load profile, the environmental conditions and the technical features of the energy modules, the model selects the most suitable energy sources, optimizes the power rates of each unit and manages the energy flows within the system. The final goal to achieve is to minimize the levelized cost of the produced electricity (LCOE) making such a system competitive respect to fully fossil fuel based energy systems. The aforementioned case study exemplifies the model application focusing on a remote scientific center requiring electric energy for its daily research activities. The area where the center is located is badly connected to the national grid and, actually, a fossil fuel generator is used, only, to provide electricity. An as-is vs. to-be differential analysis assesses the effect of introducing a dedicated renewable smart energy system finding its economic feasibility over a 15 year lifetime. Evidences show the convenience of exploiting the solar source, while little convenience is for micro-wind installation because of low available wind power and the increasing system complexity. Globally, the LCOE is close to 0.14 €/kWh making competitive the hybrid energy solution, close to the evident environmental benefit.
Marco Bortolini; Mauro Gamberi; Francesco Pilati; Alberto Regattieri. Design and Management of Renewable Smart Energy Systems: An Optimization Model and Italian Case Study. EngOpt 2018 Proceedings of the 6th International Conference on Engineering Optimization 2018, 1340 -1352.
AMA StyleMarco Bortolini, Mauro Gamberi, Francesco Pilati, Alberto Regattieri. Design and Management of Renewable Smart Energy Systems: An Optimization Model and Italian Case Study. EngOpt 2018 Proceedings of the 6th International Conference on Engineering Optimization. 2018; ():1340-1352.
Chicago/Turabian StyleMarco Bortolini; Mauro Gamberi; Francesco Pilati; Alberto Regattieri. 2018. "Design and Management of Renewable Smart Energy Systems: An Optimization Model and Italian Case Study." EngOpt 2018 Proceedings of the 6th International Conference on Engineering Optimization , no. : 1340-1352.
The current research aims to present an inclusive review of latest research works performed with the aim of improving the efficiency of the hybrid renewable energy systems (HRESs) by employing diverse ranges of the optimization techniques, which aid the designers to achieve the minimum expected total cost, while satisfying the power demand and the reliability. For this purpose, a detailed analysis of the different classification drivers considering the design factors such as the optimization goals, utilized optimization methods, grid type as well as the investigated technology has been conducted. Initial results have indicated that among all optimization goals, load demand parameters including loss of power supply probability (LPSP) and loss of load probability (LLP), cost, sizing (configuration), energy production, and environmental emissions are the most frequent design variables which have been cited the most. Another result of this paper indicates that almost 70% of the research projects have been dedicated towards the optimization of the off-grid applications of the HRESs. Furthermore, it has been demonstrated that, integration of the PV, wind and battery is the most frequent configuration. In the next stage of the paper, a review concerning the sizing methods is also carried out to outline the most common techniques which are used to configure the components of the HRESs. In this regard, an analysis covering the optimized indicators such as the cost drivers, energy index parameters, load indicators, battery’s state of charge, PV generator area, design parameters such as the LPSP, and the wind power generation to load ratio, is also performed.
Maurizio Faccio; Mauro Gamberi; Marco Bortolini; Mojtaba Nedaei. State-of-art review of the optimization methods to design the configuration of hybrid renewable energy systems (HRESs). Frontiers in Energy 2018, 12, 591 -622.
AMA StyleMaurizio Faccio, Mauro Gamberi, Marco Bortolini, Mojtaba Nedaei. State-of-art review of the optimization methods to design the configuration of hybrid renewable energy systems (HRESs). Frontiers in Energy. 2018; 12 (4):591-622.
Chicago/Turabian StyleMaurizio Faccio; Mauro Gamberi; Marco Bortolini; Mojtaba Nedaei. 2018. "State-of-art review of the optimization methods to design the configuration of hybrid renewable energy systems (HRESs)." Frontiers in Energy 12, no. 4: 591-622.
Purpose The purpose of this paper is to investigate the autoclave-pump pressured water distribution system. Pressured water is used in many manufacturing processes, as a raw material or as a service fluid for different applications. Design/methodology/approach The performances and the total installation costs of such systems are strongly related to its design and to its decision variables definition. The authors first identify the independent variables (i.e. the decision variables) and the dependent variables of the system and, second, propose a techno-economic mathematical method able to determine its minimum installation cost with an integrated approach. Findings The trade-off between the autoclave installation costs versus the pump installation costs is demonstrated. A sensitive analysis of the cost of the system as function of its decision variables has been performed to propose a practical graphical analysis tools to proper design the integrated pump-autoclave pressured water distribution system. Originality/value Many previous researches focus only on the pump system optimization or in the tank system optimization without an integrated approach. The wide utilization in industry of the autoclave-pump pressured water distribution system together with the lack of similar contributions in this area enforces the value of this research.
Maurizio Faccio; Mauro Gamberi; Mojtaba Nedaei; Francesco Pilati. Technical and economic modelling and evaluation of a water distribution system equipped with an autoclave for industrial production applications. Journal of Engineering, Design and Technology 2018, 16, 342 -359.
AMA StyleMaurizio Faccio, Mauro Gamberi, Mojtaba Nedaei, Francesco Pilati. Technical and economic modelling and evaluation of a water distribution system equipped with an autoclave for industrial production applications. Journal of Engineering, Design and Technology. 2018; 16 (3):342-359.
Chicago/Turabian StyleMaurizio Faccio; Mauro Gamberi; Mojtaba Nedaei; Francesco Pilati. 2018. "Technical and economic modelling and evaluation of a water distribution system equipped with an autoclave for industrial production applications." Journal of Engineering, Design and Technology 16, no. 3: 342-359.
The impact of packaging waste on the environment is becoming unsustainable, which has necessitated a turning point in material recycling and reuse. Such a concept is highly relevant in the humanitarian supply chain due to the huge mass of packaging items that are provided to countries hit by disasters, with these bad conditions making it almost impossible to adopt a rational management of waste streams. The goal of this study is to provide an approach and feasible solutions to reduce the environmental influence of waste produced by packaging and at the same time, to help people affected by disasters. Starting from the analysis of the available materials, several solutions of packaging reuse and recycling are developed and several prototypes are realized and tested in collaboration with the United Nations Humanitarian Response Depots-Lab (UNHRD-Lab), which starts from the basic packaging materials used to supply first-aid to people, including cardboard, pallets, woods, and plastics. This paper addresses the above ideas and presents the design process, results and some quality tests. The experimental evidence encourages future on-field validation in refugee camps.
Alberto Regattieri; Mauro Gamberi; Marco Bortolini; Francesco Piana. Innovative Solutions for Reusing Packaging Waste Materials in Humanitarian Logistics. Sustainability 2018, 10, 1587 .
AMA StyleAlberto Regattieri, Mauro Gamberi, Marco Bortolini, Francesco Piana. Innovative Solutions for Reusing Packaging Waste Materials in Humanitarian Logistics. Sustainability. 2018; 10 (5):1587.
Chicago/Turabian StyleAlberto Regattieri; Mauro Gamberi; Marco Bortolini; Francesco Piana. 2018. "Innovative Solutions for Reusing Packaging Waste Materials in Humanitarian Logistics." Sustainability 10, no. 5: 1587.
Organic waste (OW) management tackles the problem of sanitation and hygiene in developing countries and humanitarian camps where unmanaged waste often causes severe health problems and premature death. OW still has a usable energy content, allowing biogas production, potentially contributing to satisfy the local needs, e.g., cooking, lighting and heating. Digesters are the devices converting OW into biogas under anaerobic conditions. They are simple and effective solutions for the OW management in rural areas, humanitarian camps and remote developing regions, producing energy and fertilizers for local farming as residual. This paper describes the design and lab-test of a domestic OW management system integrating a waterless toilet with a small-scale digester producing safe biogas for local micro-consumption. Starting from people’s needs and an extensive review of the current state-of-art technology, the proposed system’s key innovation and strength is the combination of effectiveness and a very simple construction, set up and use, fitting with the rural conditions and raw materials available within the emerging countries. A small-scale prototype is assembled and lab-tested assessing the quantity—i.e., productivity—and quality—i.e., composition and methane content—of the produced biogas. The measured productivity in terms of specific biogas production (SBP) is of about 0.15 m3/kgSV and a methane content of about 74% in mass match the energy needs of domestic users, encouraging the spread of such systems in developing regions and rural areas.
Alberto Regattieri; Marco Bortolini; Emilio Ferrari; Mauro Gamberi; Francesco Piana. Biogas Micro-Production from Human Organic Waste—A Research Proposal. Sustainability 2018, 10, 330 .
AMA StyleAlberto Regattieri, Marco Bortolini, Emilio Ferrari, Mauro Gamberi, Francesco Piana. Biogas Micro-Production from Human Organic Waste—A Research Proposal. Sustainability. 2018; 10 (2):330.
Chicago/Turabian StyleAlberto Regattieri; Marco Bortolini; Emilio Ferrari; Mauro Gamberi; Francesco Piana. 2018. "Biogas Micro-Production from Human Organic Waste—A Research Proposal." Sustainability 10, no. 2: 330.
Francesco Pilati; Marco Bortolini; Mauro Gamberi; Maurizio Faccio. Macro and micro-logistic aspects in defining the parts-feeding policy in mixed-model assembly systems. International Journal of Services and Operations Management 2018, 31, 1 .
AMA StyleFrancesco Pilati, Marco Bortolini, Mauro Gamberi, Maurizio Faccio. Macro and micro-logistic aspects in defining the parts-feeding policy in mixed-model assembly systems. International Journal of Services and Operations Management. 2018; 31 (4):1.
Chicago/Turabian StyleFrancesco Pilati; Marco Bortolini; Mauro Gamberi; Maurizio Faccio. 2018. "Macro and micro-logistic aspects in defining the parts-feeding policy in mixed-model assembly systems." International Journal of Services and Operations Management 31, no. 4: 1.
The cost of quality represents a relevant item in total manufacturing costs. The learning process is incorporated into contemporary models because of its impact on unitary production costs through both autonomous (learning by doing) and induced (learning by means of proactive actions) learning processes. A learning model with time-varying learning rate is proposed in order to establish the relationship between quality improvements and training hours to allocate to suppliers. The performance indicator adopted is the rate of non-conforming units, rather than the more traditional process variance. This enables definition of a novel total cost function, which can be minimised for the best allocation of training hours to suppliers during a single learning cycle. A novel criterion also emerges for the evaluation of suppliers in terms of investment opportunity. Finally, a case study was carried out in order to verify the applicability of this model to real industrial settings.
Francesco Lolli; Rita Gamberini; Mauro Gamberi; Marco Bortolini. The training of suppliers: a linear model for optimising the allocation of available hours. International Journal of Industrial and Systems Engineering 2018, 28, 135 .
AMA StyleFrancesco Lolli, Rita Gamberini, Mauro Gamberi, Marco Bortolini. The training of suppliers: a linear model for optimising the allocation of available hours. International Journal of Industrial and Systems Engineering. 2018; 28 (2):135.
Chicago/Turabian StyleFrancesco Lolli; Rita Gamberini; Mauro Gamberi; Marco Bortolini. 2018. "The training of suppliers: a linear model for optimising the allocation of available hours." International Journal of Industrial and Systems Engineering 28, no. 2: 135.
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Marco Bortolini; Rita Gamberini; Mauro Gamberi; Francesco Lolli. The training of suppliers: a linear model for optimising the allocation of available hours. International Journal of Industrial and Systems Engineering 2018, 28, 135 .
AMA StyleMarco Bortolini, Rita Gamberini, Mauro Gamberi, Francesco Lolli. The training of suppliers: a linear model for optimising the allocation of available hours. International Journal of Industrial and Systems Engineering. 2018; 28 (2):135.
Chicago/Turabian StyleMarco Bortolini; Rita Gamberini; Mauro Gamberi; Francesco Lolli. 2018. "The training of suppliers: a linear model for optimising the allocation of available hours." International Journal of Industrial and Systems Engineering 28, no. 2: 135.
The handling activities within mixed-model assembly systems deal with two different logistic levels of the production environment. The micro-logistic level includes movements of parts across each assembly station due to pick to assembly activities. The macro-logistic level includes movements of parts within the supermarket and to deliver the stock-keeping units to the assembly stations. The most frequently adopted part-feeding policies, i.e., kanban system and kitting system, strongly influences both logistic levels with opposite effects. The former continuously refills the assembly stations; the latter prepares and delivers kits of components for each product. Moving from kanban to kitting system the time spent at the macro-logistic level increases. On the contrary, the time spent in part handling at the micro-logistic level decreases when moving from kanban to kitting system. Effective trade-offs are encouraged. This paper analyses the two introduced part-feeding policies, including hybrid possibilities, through an operative total handling time comparison model. The findings from five industrial cases belonging to different sectors and a global simulation analysis are discussed. Conclusions about the impact of some of the most important logistic variables of the production system to the whole performances drive the industrial practitioners in the part-feeding policy selection.
Maurizio Faccio; Mauro Gamberi; Marco Bortolini; Francesco Pilati. Macro and micro-logistic aspects in defining the parts-feeding policy in mixed-model assembly systems. International Journal of Services and Operations Management 2018, 31, 433 .
AMA StyleMaurizio Faccio, Mauro Gamberi, Marco Bortolini, Francesco Pilati. Macro and micro-logistic aspects in defining the parts-feeding policy in mixed-model assembly systems. International Journal of Services and Operations Management. 2018; 31 (4):433.
Chicago/Turabian StyleMaurizio Faccio; Mauro Gamberi; Marco Bortolini; Francesco Pilati. 2018. "Macro and micro-logistic aspects in defining the parts-feeding policy in mixed-model assembly systems." International Journal of Services and Operations Management 31, no. 4: 433.
Safeguard the operator health is nowadays a hot topic for most of the companies whose production process relies on manual manufacturing and assembly activities. European legislations, national regulations and international standards force the companies to assess the risk of musculoskeletal disorders of operators while they are performing manual tasks. Furthermore, international corporates typically require their partners to adopt and implement particular indices and procedures to assess the ergonomic risks specific of their industrial sector. The expertise and time required by the ergonomic assessment activity compels the companies to huge financial, human and technological investments. An original Motion Analysis System (MAS) is developed to facilitate the evaluation of most of the ergonomic indices traditionally adopted by manufacturing firms. The MAS exploits a network of marker-less depth cameras to track and record the operator movements and postures during the performed tasks. The big volume of data provided by this motion capture technology is employed by the MAS to automatically and quantitatively assesses the risk of musculoskeletal disorders over the entire task duration and for each body part. The developed hardware/software architecture is tested and validated with a real industrial case study of a car manufacturer which adopts the European Assembly Worksheet (EAWS) to assess the ergonomic risk of its assembly line operators. The results suggest how the MAS is a powerful architecture compared to other motion capture solutions. Indeed, this technology accurately assesses the operator movements and his joint absolute position in the assembly station 3D layout. Finally, the MAS automatically and quantitatively fill out the different EAWS sections, traditionally evaluated through time- and resource-consuming activities.
Marco Bortolini; Mauro Gamberi; Francesco Pilati; Alberto Regattieri. Automatic assessment of the ergonomic risk for manual manufacturing and assembly activities through optical motion capture technology. Procedia CIRP 2018, 72, 81 -86.
AMA StyleMarco Bortolini, Mauro Gamberi, Francesco Pilati, Alberto Regattieri. Automatic assessment of the ergonomic risk for manual manufacturing and assembly activities through optical motion capture technology. Procedia CIRP. 2018; 72 ():81-86.
Chicago/Turabian StyleMarco Bortolini; Mauro Gamberi; Francesco Pilati; Alberto Regattieri. 2018. "Automatic assessment of the ergonomic risk for manual manufacturing and assembly activities through optical motion capture technology." Procedia CIRP 72, no. : 81-86.
Efforts to decrease the water use within industry are mandatory to pursue product and process sustainability. Particularly, the European Union (EU) is at the top level for water consumption in industry, while some sectors, such as the food and beverage (F&B), are highly water-intensive with hundreds of liters per hour of consumed and, then, drained water. This article provides a systematic overview of the most innovative insights coming from an EU Eco-Innovation project dealing with greening the F&B industry through the design, prototyping, technical, economic, and environmental assessment of a wastewater closed-loop recovery and purification system. The system, tailored for a standard mid-size F&B company using 2–3 billion L/year of raw water, collects, purifies and recirculates the key produced wastewater streams with an overall recovery efficiency of about 56%. The proposed purification technology comes from the most efficient combination of membrane-based filtration methods, reverse osmosis (RO), and ultraviolet modules. Evidence from the technical design, full-scale on-site technology prototyping, net-present-value (NPV) analysis and system life-cycle-assessment (LCA) are presented concluding about the convenience of adopting the proposed solution to reduce costs and impacts on the environment.
Marco Bortolini; Mauro Gamberi; Cristina Mora; Francesco Pilati; Alberto Regattieri. Design, Prototyping, and Assessment of a Wastewater Closed-Loop Recovery and Purification System. Sustainability 2017, 9, 1938 .
AMA StyleMarco Bortolini, Mauro Gamberi, Cristina Mora, Francesco Pilati, Alberto Regattieri. Design, Prototyping, and Assessment of a Wastewater Closed-Loop Recovery and Purification System. Sustainability. 2017; 9 (11):1938.
Chicago/Turabian StyleMarco Bortolini; Mauro Gamberi; Cristina Mora; Francesco Pilati; Alberto Regattieri. 2017. "Design, Prototyping, and Assessment of a Wastewater Closed-Loop Recovery and Purification System." Sustainability 9, no. 11: 1938.
Aim of the assembly line balancing problem (ALBP) is the efficient and effective assignment of assembly tasks to stations in one-piece-flow production systems. Although this problem has been studied for decades, few contributions consider the component picking at assembly station level. Yet, this activity has relevant and practical implications for ALBPs in the industrial context. This paper proposes an innovative multi-objective optimization model for the ALBP to assign the assembly tasks to stations by distinguishing the assembly activities involved in task execution and component picking. Thus, a function is proposed to relate the time required for component picking with the component storage location at assembly station level and the component features, namely dimensions, weight and handiness. The aim of the developed model for the ALBP is the simultaneous minimization of the assembly line takt time and ergonomic risk, both determined by the task execution and component picking activities. Furthermore, the proposed model not only defines the optimal task assignment to stations, but it also determines the optimal storage location of each component between the locations available at the different assembly stations. The multi-objective optimization model is validated with an industrial case study dealing with a kitchen appliance assembly line. The final assembly line balancing configuration proposed is distinguished by remarkable performance for both takt time and ergonomic risk objective functions. Such a balancing leads to 36% ergonomic risk reduction with just 2% takt time increase compared to the correspondent single-objective configurations. These outstanding results are determined by a proper component disposition in the different station storage locations defined by the model
Marco Bortolini; Maurizio Faccio; Mauro Gamberi; Francesco Pilati. Multi-objective assembly line balancing considering component picking and ergonomic risk. Computers & Industrial Engineering 2017, 112, 348 -367.
AMA StyleMarco Bortolini, Maurizio Faccio, Mauro Gamberi, Francesco Pilati. Multi-objective assembly line balancing considering component picking and ergonomic risk. Computers & Industrial Engineering. 2017; 112 ():348-367.
Chicago/Turabian StyleMarco Bortolini; Maurizio Faccio; Mauro Gamberi; Francesco Pilati. 2017. "Multi-objective assembly line balancing considering component picking and ergonomic risk." Computers & Industrial Engineering 112, no. : 348-367.