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The purpose of this paper is to present a Design for Additive Manufacturing (DfAM) methodology that connects several methods, from geometrical design to post-process selection, into a common optimisation framework.

A design methodology is formulated and tested in a case study. The outcome of the case study is analysed by comparing the obtained results with alternative designs achieved by using other design methods. The design process in the case study and the potential of the method to be used in different settings are also discussed. Finally, the work is concluded by stating the main contribution of the paper and highlighting where further research is needed.

The proposed method is implemented in a novel framework which is applied to a physical component in the case study. The component is a structural aircraft part that was designed to minimise weight while respecting several static and fatigue structural load cases. An addition goal is to minimise the manufacturing cost. Designs optimised for manufacturing by two different AM machines (EOS M400 and Arcam Q20+), with and without post-processing (centrifugal finishing) are considered. The designs achieved in this study show a significant reduction in both weight and cost compared to one AM manufactured geometry designed using more conventional methods and one design milled in aluminium.

The method in this paper allows for the holistic design and optimisation of components while considering manufacturability, cost and component functionality. Within the same framework, designs optimised for different setups of AM machines and post-processing can be automatically evaluated without any additional manual work.

The purpose of this paper is to investigate the status of lean manufacturing in Indian automotive sector, component manufacturing industries in terms of lean adoption, benefits, motivation, and challenges of implementing lean manufacturing practices.

The research objectives were achieved by conducting a qualitative multicase study approach. Fourteen Indian automotive component manufacturing small and medium-sized enterprises (SMEs) were chosen based on their different product offerings as well as differing approaches to the introduction and implementation of lean initiatives. Data were collected through in-depth, semistructured interviews supported by shop-floor observations.

The findings from the present study suggest that some of the participating automotive component manufacturing SMEs have a relatively good understanding of lean concepts and philosophy. However, there is room for further improvement for most SMEs. Major top five lean practices being implemented were found to be cellular manufacturing, total productive maintenance, 5S, work standardization, and quality management practices. Also, leadership and organizational culture were found to be crucial factors for the success of lean manufacturing.

The fact that the data collected for the research study is based on subjective business evidence obtained from company representatives comprises the main limitation of the present study. So, the results should be considered with caution, as far as the lean adoption in Indian automotive component manufacturing sector is concerned.

Based on the present study, suggestions can be made regarding the successful adoption of lean principles, not only for the participating SMEs but also for the whole of the automotive component manufacturing sector. More specifically, by determining the strength and weakness of automotive component manufacturing SME's effort to adopt lean, suitable managerial initiatives can be undertaken by these companies as well as the whole sector to fully adopt lean and derive the respective benefits.

This paper explores the status of lean adoption in Indian automotive component manufacturing SMEs. Considering the unique characteristics of the automotive component manufacturing industry, the present research would be helpful for making strategies to implement lean in automotive component manufacturing industry setups.

This paper aims to deploy Lean Six Sigma (LSS) framework to facilitate defect reduction and enhance bottom line results of an automotive component manufacturing organization.

LSS is a business process improvement strategy widely used in the manufacturing field for enhancing manufacturing organization performance. The integration of Lean and Six Sigma will enable the attainment of defects reduction by eliminating non-value-adding activities from production line. LSS framework has been developed with the integration of define–measure–analysis–improve–control (DMAIC) tools and techniques.

The finding of this study is that the LSS framework has been successfully implemented in automotive component manufacturing organization, and non-value-adding activities and defects from assembly line have been reduced. The proposed LSS framework applies lean tools within Six Sigma DMAIC approach to facilitate waste elimination and defect reduction. The developed framework with linkage of DMAIC tools and techniques reduces defects and non-value-adding activities with enhanced bottom line results. The implementation of proposed LSS framework shows effective improvement in key metrics.

The developed framework has been test implemented in an automotive component manufacturing organization. In future, more number of studies could be conducted. Further, advanced lean tools and techniques could be included in the framework for increasing the effectiveness of production line.

The proposed LSS framework with linkage of DMAIC tools and techniques has been successfully implemented in an assembly line of automotive component manufacturing organization. This method is presently applied for an automotive component manufacturing organization; in future, the approach could be applied in different industrial sectors with addition of new tools and techniques for improving its effectiveness.

LSS framework has been designed and test implemented in an assembly line of an automotive component manufacturing organization. Hence, the inferences are practical and key results of the study.

The purpose of this paper is to present the model-driven decision support system (DSS) for small and medium manufacturing enterprises (SMMEs) that actively participates in collaborative activities and manages the planned obsolescence in production. In dealing with the complexity of such demand and supply scenario, the optimisation models are also developed to evaluate the performance of operations practices.

The model-driven DSS for SMMEs, which uses the optimisation models for managing and coordinating planned obsolescence, is developed to determine the optimal manufacturing plan and minimise operating costs. A case application with the planned obsolescence and production scenario is also provided to demonstrate the approach and practical insights of DSS.

Assessing planned obsolescence in production is a challenge for manufacturing managers. A DSS for SMMEs can enable the computerised support in decision making and understand the planned obsolescence scenarios. The causal relationship of different time-varying component obsolescence and availability in production are also examined, which may have an impact on the overall operating costs for producing manufactured products.

DSS can resolve and handle the complexity of production and planned obsolescence scenarios in manufacturing industry. The optimisation models used in the DSS excludes the variability in component wear-out life and technology cycle. In the future study, the optimisation models in DSS will be extended by taking into the uncertainty of different component wear-out life and technology cycle considerations.

This paper demonstrates the flexibility of DSS that facilitates the optimisation models for collaborative manufacturing in planned obsolescence and achieves cost effectiveness.

The purpose of this study is to explore the applications of 3D printing in space sectors. The authors have highlighted the potential research gap that can be explored in the current field of study. Three-dimensional (3D) printing is an additive manufacturing technique that uses metallic powder, ceramic or polymers to build simple/complex parts. The parts produced possess good strength, low weight and excellent mechanical properties and are cost-effective. Therefore, efforts have been made to make the adoption of 3D printing successful in space so that complex parts can be manufactured in space. This saves a considerable amount of both time and carrying cost. Thereof the challenges and opportunities that the space sector holds for additive manufacturing is worth reviewing to provide a better insight into further developments and prospects for this technology.

The potentiality of 3D printing for the manufacturing of various components under space conditions has been explained. Here, the authors have reviewed the details of manufactured parts used for zero-gravity missions, subjected to onboard international space station conditions and with those manufactured on earth. Followed by the major opportunities in 3D printing in space which include component repair, material characterization, process improvement and process development along with the new designs. The challenges like space conditions, availability of power in space, the infrastructure requirements and the quality control or testing of the items that are being built in space are explained along with their possible mitigation strategies.

These components are well comparable with those prepared on earth which enables a massive cost saving. Other than the onboard manufacturing process, numerous other components as well as a complete robot/satellite for outer space applications were manufactured by additive manufacturing. Moreover, these components can be recycled onboard to produce feedstock for the next materials. The parts produced in space are bought back and compared with those built on earth. There is a difference in their nature, i.e. the flight specimen showed a brittle nature, and the ground specimen showed a denser nature.

This review discusses the advancements of 3D printing in space and provides numerous examples of the applications of 3D printing in space and space applications. This paper is solely dedicated to 3D printing in space. It provides a breakthrough in the literature as a limited amount of literature is available on this topic. This paper aims at highlighting all the challenges that additive manufacturing faces in the space sector and also the future opportunities that await development.

This paper aims to develop build strategies for rapid manufacturing of components of varying complexity with the help of illustration.

The build strategies are developed using a hybrid layered manufacturing (HLM) setup. HLM, an automatic layered manufacturing process for metallic objects, combines the best features of two well-known and economical processes, viz., arc weld-deposition and milling. Depending on the geometric complexity of the object, the deposition and/or finish machining may involve fixed (3-axis) or variable axis (5-axis) kinematics.

Fixed axis (3-axis) kinematics is sufficient to produce components free of undercuts and overhanging features. Manufacture of components with undercuts can be categorized into three methods, viz., those that exploit the inherent overhanging ability, those that involve blinding of the undercuts in the material deposition stage and those that involve variable axis kinematics for aligning the overhang with the deposition direction.

Although developed using the HLM setup, these generic concepts can be used in a variety of metal deposition processes.

This paper describes the methodology for realizing undercut features of varying complexity and also chalks out the procedure for their manufacture with the help of case studies for each approach.

This paper aims to review recent research in design for additive manufacturing (DfAM), including additive manufacturing (AM) terminology, trends, methods, classification of DfAM methods and software. The focus is on the design engineer’s role in the DfAM process and includes which design methods and tools exist to aid the design process. This includes methods, guidelines and software to achieve design optimization and in further steps to increase the level of design automation for metal AM techniques. The research has a special interest in structural optimization and the coupling between topology optimization and AM.

The method used in the review consists of six rounds in which literature was sequentially collected, sorted and removed. Full presentation of the method used could be found in the paper.

Existing DfAM research has been divided into three main groups – component, part and process design – and based on the review of existing DfAM methods, a proposal for a DfAM process has been compiled. Design support suitable for use by design engineers is linked to each step in the compiled DfAM process. Finally, the review suggests a possible new DfAM process that allows a higher degree of design automation than today’s process. Furthermore, research areas that need to be further developed to achieve this framework are pointed out.

The review maps existing research in design for additive manufacturing and compiles a proposed design method. For each step in the proposed method, existing methods and software are coupled. This type of overall methodology with connecting methods and software did not exist before. The work also contributes with a discussion regarding future design process and automation.

The purpose of this paper is to present an update of and the latest results from work on a project aimed at monitoring electronic products during the whole life cycle with embedded wireless components.

Business processes of the electronic manufacturing supply chain were analysed. A business case and the system opportunities for life cycle monitoring, based on embedded wireless components system were developed. Radio frequency identification (RFID) assembly technology was adapted for the integration of components into a multi‐layer printed circuit board (PCB).

By storing product‐related information into electronic products, tracing of components, monitoring of processes, operations and costs, environmentally optimised recycling can be enhanced.

The research undertaken so far relates to the embedding of RFID tags into PCBs. Wireless components with more processing power will be used in the next project phase.

The paper details how wireless components can be embedded into multi‐layer PCBs and how a business case for a life cycle monitoring system can be established.

This paper aims to investigate a stereo vision-based hybrid (additive and subtractive) manufacturing process using direct laser metal deposition, computer numerical control (CNC) machining and in-process scanning to repair metallic components automatically. The focus of this work was to realize automated alignment and adaptive tool path generation that can repair metallic components after a single setup.

Stereo vision was used to detect the defect area for automated alignment. After the defect is located, a laser displacement sensor is used to scan the defect area before and after laser metal deposition. The scan is then processed by an adaptive algorithm to generate a tool path for repairing the defect.

The hybrid manufacturing processes for repairing metallic component combine the advantages of free-form fabrication from additive manufacturing with the high-accuracy offered by CNC machining. A Ti-6Al-4V component with a manufacturing defect was repaired by the proposed process. Compared to previous research on repairing worn components, introducing stereo vision and laser scanning dramatically simplifies the manual labor required to extract and reconstruct the defect area’s geometry.

This paper demonstrates an automated metallic component repair process by integrating stereo vision and a laser displacement sensor into a hybrid manufacturing system. Experimental results and microstructure analysis shows that the defect area could be repaired feasibly and efficiently with acceptable heat affected zone using the proposed approach.

The purpose of this paper is to assess the process of prefabricated construction (PC) and analyze the impacts of rework risk to identify the core tasks for which the rework risk has severe impacts.

The methods consist of a literature review, expert interviews, a questionnaire survey and a rework risk function. The expert interviews and questionnaire survey were administered to experts in the entire process of PC from the dimensions of rework frequency, rework cost and rework time. Descriptive and inferential statistics were employed to analyze the data. The rework risk function was based on the loss expectancy method.

There are 13 core tasks that have higher impacts than the average level. The core tasks in the design stage account for 100% of the tasks in the stage, those in the manufacturing stage account for 20% and those in the construction stage account for 23.1%. Compared with the other stages, the design stage is characterized by significantly more frequent rework, higher rework costs and longer rework time. The manufacturing stage is characterized by significantly higher rework costs than the construction stage. The manufacturing stage and construction stage are co-reliant, and both are impacted by the design stage.

The findings provide stakeholders with a clear understanding of the core tasks of the PC process and represent a method for identifying core tasks. Stakeholders can learn from this to focus on the core tasks to reduce rework risk and manage the process with the priority of PC rework management based on the following order: design > manufacturing > construction. The approach is suitable for core task identification in other areas.

This research provides insight into rework risk management and provides a novel analysis method for rework risk and PC management from the perspective of the construction process. The findings are valuable for supporting stakeholders in making effective construction plans to reduce the impacts of rework risk in PC and provide a reference for future research on process optimization.