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Energies 2016, 9(10), 790; doi:10.3390/en9100790

Sustainability Enhancement of a Turbine Vane Manufacturing Cell through Digital Simulation-Based Design

1
Fraunhofer Joint Laboratory of Excellence on Advanced Production Technology (Fh-J_LEAPT Naples), Department of Industrial Engineering, University of Naples Federico II, Naples 80125, Italy
2
School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast BT7 1NN, UK
3
Fraunhofer Joint Laboratory of Excellence on Advanced Production Technology (Fh-J_LEAPT Naples), Department of Chemical, Materials and Industrial Production Engineering, University of Naples Federico II, Naples 80125, Italy
*
Author to whom correspondence should be addressed.
Academic Editor: Hua Li
Received: 28 July 2016 / Revised: 31 August 2016 / Accepted: 23 September 2016 / Published: 29 September 2016
(This article belongs to the Special Issue Energy Saving Design for Manufacturing Process, Product, and System)
View Full-Text   |   Download PDF [3535 KB, uploaded 29 September 2016]   |  

Abstract

Modern manufacturing systems should satisfy emerging needs related to sustainable development. The design of sustainable manufacturing systems can be valuably supported by simulation, traditionally employed mainly for time and cost reduction. In this paper, a multi-purpose digital simulation approach is proposed to deal with sustainable manufacturing systems design through Discrete Event Simulation (DES) and 3D digital human modelling. DES models integrated with data on power consumption of the manufacturing equipment are utilized to simulate different scenarios with the aim to improve productivity as well as energy efficiency, avoiding resource and energy waste. 3D simulation based on digital human modelling is employed to assess human factors issues related to ergonomics and safety of manufacturing systems. The approach is implemented for the sustainability enhancement of a real manufacturing cell of the aerospace industry, automated by robotic deburring. Alternative scenarios are proposed and simulated, obtaining a significant improvement in terms of energy efficiency (−87%) for the new deburring cell, and a reduction of energy consumption around −69% for the coordinate measuring machine, with high potential annual energy cost savings and increased energy efficiency. Moreover, the simulation-based ergonomic assessment of human operator postures allows 25% improvement of the workcell ergonomic index. View Full-Text
Keywords: manufacturing systems; sustainable development; simulation; discrete event simulation; 3D digital human modelling; energy management; ergonomics manufacturing systems; sustainable development; simulation; discrete event simulation; 3D digital human modelling; energy management; ergonomics
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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Caggiano, A.; Marzano, A.; Teti, R. Sustainability Enhancement of a Turbine Vane Manufacturing Cell through Digital Simulation-Based Design. Energies 2016, 9, 790.

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