Copyright CS) IFAC Management and Control of Production

and Logistics, Grenoble, France, 2000

STEP TO RUNNING FEASIBILITY STUDIES OF MANUFACTURING SYSTEMS

Luc LOSSENT, Patrick MARTIN

CRAN, FaculM des sciences, BP 239, F 54506 VANDOEUVRE LES NANCY Cedex
LGIPM, ENSAM Metz, Technopole 2000,4 rue Augustin Fresnel, F 57008 Metz Cedex 3

Abstract : Manufacturing systems engineering needs innovation, creativity and

technological research. Feasibility studies concerning this engineering field are numerous
and take place in a concurrent environment. We propose a methodology, articulated
around seven concurrent processes. It uses a iterative approach integrating all factors. Its
objectives are to formalise processes, to indicate pertinent tools and methods, to co-
ordinate partners in conducting the study, to structure and memorise technical data
following the system specifications. A realisation of a flexible production system has to
validate the methodology. Copyright @20001FAC

Keywords: feasibility study, configuration management, modelling, system design.

I. INTRODUCTION low communication...) and implies a low diffusion of

Competition leads companies to design and
develop their products in shorter and shorter delays.
Many products conception and manufacturing tools
and methods appear (Mony, 1992). Few tools and
methodologies are proposed to guide engineering in
the task of manufacturing system design. (Garro,
1992 ). This is obvious in the design cycle upstream
phases. These phases called 'feasibility" and
"Validation" (Tollenaere, 1998), go from the need
expression to preliminary project. The difficulty to
find methodologies in these phases can be explained:
- the specificity, complexity of the feasibility studies
linked to a multi-trade approach.
- multiple role of man ; customer, designer, user...
- a variable horizon for decision taking and
information flows, economic constraints
- physical simulation close to impossible ones,
- no memorizing information in creativity phases...
The respect of due time constraint do not
permit doing method in parallel with design and
manufacturing work. Competitiveness inducts
Research & Development separate teams, set up
protections for processes and technologies (patent,
tools and methods used.
Similar to product design, 70 to 80% of a
system costs are implied by des~ phases. Choices
taken after feasibility studies drives the company in
more or less simple, quick and expensive solutions.
We propose here some definitions of the
product, the manufacturing system design, including
feasibility studies in the frame of integrated
engineering, which concepts are in PRIMECAs
conference acts. (IDMME, 1998).
We present a methodology to help to
feasibility studies conducts, aiming at structuring the
steps, in SMEs domain, where we realised different
applications and this in th e context particularly
concurrent of feasibility studies. We describe an
application realised at Atelier Inter -etablissements
de Productique Lorrain : the Flexible Production
System.
2. DEFINITION
A manufacturing system is a particular product with
specifications which are taken in account during the
design processes. We compare product and system in
table I.

17
 Product
The functions as a whole to satisfy the customeT
and have the best possible profit margin
(maximum orofits)
Has a purchasing cost, implementation cost,
maintain cost, exploitation cost, recycle cost.
Has a quality
Evolves
Is realised in a quantity >= to the process, and
often in hUl!e ouantities.
In most cases it is prototyped, tested.
The future of the enterprise depends on the net benefits
from its oroducts sales and its exoloitation costs
The product is what is delivered to the customeT
Product functions are realised by duos functions
product Iproduct-process entity.
Table I : companson between product and process
We give the definition of a manufacturing
system: a «mechanical» group realising basic
functions: Transfonn, Transport, Stock, Wait and
Control, applied to one or many products evolving
with time. This ensemble is constituted by an
"Operative Part";OP and by a 'Command Part";CP.
The OP contains structures, kinematics,
activators. The CP contains sensors, calculation
elements, tacking decisions, interfaces, operators
pendant, and communication with other machines.
Man or team assures control, supervision
and maintain activities on this system. Man or team
is polyvalent. We are in the socio-technical
approach, pointed out by (Orty-Hemandez, 1995).
We are interested in manufacturing system
development, interacting with product design. The
system will have to manufacture products in middle
series which belongs to a same family, but with
numerous variations to answer to customers
demands.
By process, we understand processes (forge,
foundries, sawmills, assembly technologies...),
productive resources (machines, work systems..),
scheduling and requirement planning.
Many lectures (Hennet, 1997; Kamrani 1995)
deals of production system design but the essential
interest is in the logistical aspect (implantation,
scheduling) based on the knowledge of technical and
time datas (range, time to produce, resources) given
by the methods function.
From the mechanical man point of view, the
problem of preliminary project in manufacturing
system:
1- Consists in, from product specifications
(partials in most cases) to choose
manufacturing processes and to predefine
resources.
Process
(standard cases)
Sum of orderly means and functions to obtain (imperatively) products functions at
lowest price
PeTmitto obtain a cost, through a manufacturin g time, investments costs distributed on
~
:0 a pay back, general and development costs, and costs inducted by the type of process
g used.
c:
~Its cost is often suoerior to the oroducts one.
'"
With means adapted to products restraints
"t:l
~
v
Has to be able to evolve with the product and even to be recycled.
E'" Adapts always to the product. even bad.
0 Is realised only at few exemplars.
Cannot be prototyped (except ifit is consideTed as a catalogues product), its cost
taken in account.
The system is what stays in the enterprise, the functional analysis part which does not
get out the enterprise.
Each piece answers to functions
Process functions answers to the need issued from one (or more) duo(s) product
(unction / entitv product
2- By an integration of craft knowledge and by
using appropriate models, methods and
tools.
3- In order to answer to production objectives
(quality, reactivity, productivity ... ) and to
economical or legal restraints.
The system is fed with entering materials or
products. It evacuates materials or products with or
without added value.A system has flexibility notions:
- evolution relating to environment,
- modification on product and on production phase,
- pennit rapid fonnat exchanges.
In many studies, the system must be integrated in an
existing environment. This system appeals to one or
more process to realise one or more functions. The
manufacturing system is also called «special
machine» and does not exist in catalogue.
3. STUDY OF A MANUFACTURING SYSTEM
FEASIBILITY
We decompose a manufacturing system life cycle
into seven phases: Need expression, system research
and development, industrialisation, realisation,
installation and working order, exploitation and
break up. Other cycle of life representations
(Zanettin, 1993 ; Tichkiewitch, 1996) pennit a
visualisation in a given context.
Feasibility studies are led all the design-
realisation process long. (Principles and process
feasibility, industrialisation feasibility, realisation
feasibility ...). On the other hand, the economical
feasibility is omnipresent. Systems feasi>ility studies
also pennit to know limits of science and technology
on a given process.
We work in system feasibility working study in
research and development.
We will now present both levels of integration:
18
_ External integration is usually taken into account
by persons exterior to the requesting department.
-Internal integration consists in using all the
multi-function and multi-know-how skills
necessary for the development and the use of a
system.
These studies must integrate the knowledge
and the know-how of the various professional fields
and experts. The existing equipment, machines and
processes as well as suppliers must be integrated. All
the participants make up the project team . Time
and efficiency are saved by favoring a fast
convergence towards an optimized solution by
avoiding many modification and repetition cycles.
4. METHODOLOGY FOR FEASIBILITY
STUDIES FOR MANUFACTIJRING SYSTEMS
4.1. Introduction: We propose a methodology
for conducting a feasibility study for a system that is
broken down into several procedures (Lossent,
1997), and which includes the ideas of simultaneity,
parallelism and integration.
Information transfert. between one activity and information
system, direction according the arrow
Communication flow or decision
direction according the arrow(s)
between partners.
Call for methods or tools necessaryfor feaSibility, direction
according the arrow(s)
Methods or tools necessary to the different activities
Validation step. it leads towards decisions on choices done.
this point is related to a transition. Some decision tools and
indicators are used by the staffand the customer leading to
planning. At this stage, the process is evaluated. Point. the
mark is in a circle with its order in the process.
A rectangle represent an activity, an action or ajob. This
rectangle is preceded by a square allowing to number the
rectangle. Rounded shaped rectangle represent the
contents in communication with another
Its an Information System. a database with a mark to
distinguish them
Figure 1- Syntax
4.2. The Needs-Functions-Constraints procedures:
They have three phases carried out simultaneously
by using a distributed (Salaii, 1995), (figure 2) and a
repetitive architecture in parallel with the ones of the
product (Lossent, 1997), (figure 3). The solution
emerges from this distribution. The customer's
needs:
the expression of needs contains the customer's
requirements with the indications provided by
the specifications,
19
The first procedures consist in setting up
needs, their specifications as well as the analyses
accompanying them, and then in determining the
functional analysis conducted in parallel and the
constraints associated with these functions. The
main lines of the second procedures are looking for
principles and processes, technological solutions
making it possible to carry them out and the speci fic
constraints coming from them. Simultaneity consists
in starting the various phases of the study as soon as
possible. Problems arise in synchronizing the
activities and a solution is proposed by S. Marier
(Marier, 1995). In parallel, we have conducted
feasibility studies for the manufacturing system and
the product along the same lines as the work by
HA.Baboli (Baboli, 1995).
The simultaneity and parallelism of this work
require a large amount of communication and a
special planning in the feasibility phases. We treat
these various activities by using a syntax (figure 1).
This graphic formalism allows us to communicate
simply and clearly with our various partners and it
avoids ambiguities in interpreting the text.
< SZ__ ~
<: :::>D
---.. Used methods, used tools, 1
validation tools 1
t- ~~I~~t~o:~~i:t-CD
: Decision tool :
: Running valuation I
I Industry indicators :
\ ~
,-----------
m Action or activity )
0t...__A:C:ti:o=n=0=r=a=c:t::iV:it...:.y_ _1
Ey
the specification of needs that covers the
qualitative and quantitative information,
the analysis of needs making it possible to
define the extent of the studies.
4.3. The study offunctions : The functional analysis
shows the main functions necessary for realizing the
customer's needs. The nature of these functions
leads to breaking down the system into several sub-
systems, which are parallel.
 Team project
creation Product!
manufacturing

------0
.'Needs validation \
• Indicators: •
'·Product
:evolution I
I·Communication :""2~-----~1
:.Safety •
•-Cost :
I.MTBF
'--- --, 3 1~------41

Figure 2- The iterative and distributed process Figure 3- The expression ofproduction flux system
needs

These sub-systems require several professions and
this is the birth of a second parallelism. A
profession corresponds to a sub-system or a
function and maybe even several departments or
subcontractors/suppliers. During this phase,
competition can be added to increase the
performances of each team by emulating creativity.
(figure 4) The functions are the interpretation of
needs. We work on the "tranformation" between
figure 4 (principle and basic syntax) and figure 5
(tree application of software development). The
figure 5 proposal is a software development with a
"configuration" management software. This
development allows to manage technical data. We
create many views of a system (need view, function
view, function constraints view, technical
constraints view, principle view... ). Such as impact
view between function(s) and technological
solutions and constraints.
4.5. The Generation of constraints (figures 6,7):
The constraints characterized by the specifications
of each function are associated with this same
function. For example, the function "Mechanically
assemble the various parts of the product" becomes
a constraint as soon as the specifications introduce
tolerances on the positioning, speed and physical
characteristics of the products. These are functional
,~--0
I function 4 Function derme •.•.....•. s:z. ;;:..
I validation .;'F~=====-II
: impact I 5 Function locating
• indicator I 5 1
n--13'
I . Transport
, fun ':-V
5.2 Direction drive
I cl10n 5.3 Assembl
I indicator
I perfonn.
I ..
\ _m~lca~~ 'lp:;~...l..l:~,==:::':"J I
constraints, which must be listed and represented
clearly. As in the case of functions, the constraints
come from the expressed needs.
4.6. The procedures of looking for principles or
processes (figure 8) : These activities are, as
before, distributed and repetitive. Having
established the links between the constraints,
looking for the principle or process makes it
possible to solve them. The team will come up with
X solutions that will answer the problems and
transform them into technological solutions taking
the specific constraints into account. In some cases,
the technical solutions require testing with their
specific constraints in order to provide information
on the principles or the processes. This research
takes place as long as one or several feasible,
acceptable solutions are not proposed or the
allotted budget / time for the feasibility study have
not been reached. The "goal reached" condition is
in general an association of several typical criteria:
costs, complexity,... or a weighting between the
various criteria. It is important to determine what
is the limiting factor in the research in order to
know if, after modification or elimination of a
criteria, there is a new feasible solution. The "path"
covered in order to constitute a reusable history
must be noted.
Function: production I
transport mechanical power piece postionl
Assembly
:=====:
control
~'--:::::L:::::::;----'
Power pilot
,--------
I Communications : Specifications L
rr supplier ]
i. _~~i~a~o~ __' ] documentationsJ
Trad e competence: I ' - - - - - J
documentations documentations I-
SADT, FAST,
function analysis

Figure 4- Study ofthe production flux system needs Figure 5 : Principle oftree tranformation

20
 In order to validate the users' needs III
exploitation, the feasibility procedure was extended
by a prototype and the parallel design of a product
circulating in this production installation.

Function: to osition I Technological

constraints: friction
,I
reliability

I precision Guiding jack ~

Technological
constraints: radial effort
,I
-----,
'Validation: Associated
Figure 6- The generation ofconstraints f'1\_----,
customers s~cifications

Associated
It is built by attaching the documents including the documentations

information necessary for the various validations,

decisions and choices. J constraints
simulation

This tree makes it possible to follow the feasibility Figure 7- Functions and technical constraints tree
studies and to visualize at any given time the status
of the activities carried out in parallel.
P la Del.
d e l I ID. le II I

COD I I r 11 i n I.
100 Is

Figure 8- The iterative principle ofthe process

5. ASSESSMENT OF APPLYING THE FLEXIBLE
PRODUCTION SYSTEM (figure 9)
The integration aspect of the order in the physical
part is particular to this study and adapted to the
needs specified above. We have 13 objects wo are
parameters of configuration management system.
The safety of the users is taken into account
in the presentation of control elements and in
exploiting the operating part.
The various additions of the methodology
are materialized in :
- a savings of time with respect to a sequential
procedure; a savings assessed at 20%. - setting up
feasible prototype solutions reused on a
I Nud • • 51'Rd .. d, ("951!SA'''
~"S::7 __.l-_ _---=:::::::====::::=
"----J - , tccbnolo ieal
complementary installation whose feasibility
realization cost is null.
- setting up prototype solutions without
disturbing production.
- the possibility of reusing the procedures
on other projects,
- the use of the tree structure realized for
exploitation, system maintenance through a
system of configuration and document
management.
the communication realized throughout the
project for convincing, converging, deciding
and having this installation used by the various
partners.
'OSP"C'!' • 'unc"op.1COpfl"'''! I'PPf1p'rsl 5gt"t,pp, If
....:...F.:.:,:.:.-,-'b:.:i-,-":,:·,,,-Y..:../rU~P=:::d'¥';:i;=;':;:0:::::;:=;:;:::::;::;:::;:;:;:;:T;;:;=,-------/
constraints

SJ~CI ~PI

1,0
.- ---- .
--- ---
"'""""""-P-z"c::c--o S ZP I

~~Sl
• O. D
researc~r~
~

~L
r:P:":r":'",0:":,:'7,::-;-:-(1

L~1
~~_~ ~_ Software
SO IWI e tom
Soft_,re Ilsemblv
so twarc M Ilerlll tonllrlinls
---------------------------- :sz'__

Figure 9- Technological data and system configuration in feasibility and design

21
The 13 objects: B=need, F=function, FC=function constraints, S=solution, P=principle, MC=rnaterial
constraint, MA=material assembly, LC=software constrain, LA=software assembly
6. CONCLUSION
This methodology is an aid in running feasibility
studies. It makes it possible to visualize all the
procedures for studying a manufacturing system,
shows interdependencies and highlights the
functions requiring a feasibility study.
Upstream from the detailed design, showing the
impact of functional and technological constraints
on the considered solutions makes it possible to
anticipate future problems and to make the adequate
decisions. Thus, in a feasibility study on the dynamic
transfer of solid wood between two machines,
modifying the functional constraints allowed us to
design the adequate principles and technologies for
the considered schedules, within the provisional
budget and with an intrinsic reliability. Determining
the various constraints thus makes it possible to
dimension the project in resources and to help the
designer in planning the project, a difficult task in a
context of uncertainty and creativity.
These past or ongoing applications show
that, with respect to needs, functions and constraints,
formalizing the various simultaneous steps and the
tree structure of the links are difficult in the
absence of computer assistance. Application of the
flexible production system as well as others in the
agri-food and in the iron and steelmaking industry
has allowed us to quantify the interests of this
methodology by setting up performance indicators.
The use of a simple syntax associated with graphs
has favored the use of the methodology in small and
medium-sized businesses (Lossent, 1997, Martin,
1999).
7. PROSPECTS
We are currently developing a computer application
making it possible to formalize the methodology of
entering needs up to the choice of feasible solutions
by proposing a communication between the various
actors and the seven necessary steps. We are
working with a software editor in order to spread the
methodology to projects requiring feasibility studies
or preliminary studies for small and medium -sized
businesses.
We are completing this work towards the
downstream phases of the preliminary study and
notably with the links for making decisions and
memorizing information making these decisions
possible.
Links must be developed with numeric, machine
behavior, flux simulation and validation tools.
This approach was completed by work done
in small industries making it possible to formalize
information management using Merise, in order to
ensure application of the project and to evolve
22
towards product data management systems (Martin,
1999).
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Baboli HA., D. Brun Picard, Proposition d'une
methodologie de conception integree de
systeme flexible de fabrication, Actes du
congres international de genie industriel, la
Productivite dans un monde sans frontieres,
Montreal, p. 437 446, 1995.
Garro 0., Conception delements physiques de
systemes de production. Application aux
machines-outits a architecture parallele,
these de Hmiversite de Nancy I, 1992.
Hennet J.c. , Concepts et outits pour les systemes de
production, Cepadues editions, 1997.
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Kamrani A. K., Planning Design and Analysis of
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Poincare, Nancy I, octobre 1997.
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