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Books > Professional & Technical > Industrial chemistry & manufacturing technologies > General
In today's competitive global environment, manufacturers are offered with unprecedented opportunities to build hyper-efficient and highly flexible plants, towards meeting variable market demand, while at the same time supporting new production models such as make-to-order (MTO), configure-to-order (CTO) and engineer-to-order (ETO). During the last couple of years, the digital transformation of industrial processes is propelled by the emergence and rise of the fourth industrial revolution (Industry 4.0). The latter is based on the extensive deployment of Cyber-Physical Production Systems (CPPS) and Industrial Internet of Things (IIoT) technologies in the manufacturing shopfloor, as well as on the seamless and timely exchange of digital information across supply chain participants. The benefits of Industry 4.0 have been already proven in the scope of pilot and production deployments in a number of different use cases including flexibility in automation, predictive maintenance, zero defect manufacturing and more. Despite early implementations and proof-of-concepts, CPPS/IIoT deployments are still in their infancy for a number of reasons, including: * Manufacturers' poor awareness about digital manufacturing solutions and their business value potential, as well as the lack of relevant internal CPPS/IIoT knowledge. * The high costs that are associated with the deployment, maintenance and operation of CPPS systems in the manufacturing shopfloors, which are particularly challenging in the case of SME (Small Medium Enterprises) manufacturers that lack the equity capital needed to invest in Industry 4.0. * The time needed to implement CPPS/IIoT and the lack of a smooth and proven migration path from existing OT solutions. * The uncertainty over the business benefits and impacts of IIoT and CPPS technologies, including the lack of proven methods for the techno-economic evaluation of Industry 4.0 systems. * Manufacturers' increased reliance on external integrators, consultants and vendors. * The absence of a well-developed value chain needed to sustain the acceptance of these new technologies for digital automation. In order to alleviate these challenges, three European Commission funded projects (namely H2020 FAR-EDGE (http://www.far-edge.eu/), H2020 DAEDALUS (http://daedalus.iec61499.eu) and H2020 AUTOWARE (http://www.autoware-eu.org/)) have recently joined forces towards a "Digital Shopfloor Alliance". The Alliance aims at providing leading edge and standards based digital automation solutions, along with guidelines and blueprints for their effective deployment, validation and evaluation. The present book provides a comprehensive description of some of the most representative solutions that offered by these three projects, along with the ways these solutions can be combined in order to achieve multiplier effects and maximize the benefits of their use. The presented solutions include standards-based digital automation solutions, following different deployment paradigms, such as cloud and edge computing systems. Moreover, they also comprise a rich set of digital simulation solutions, which are explored in conjunction with the H2020 MAYA project (http://www.maya-euproject.com/). The latter facilitate the testing and evaluation of what-if scenarios at low risk and cost, but also without disrupting shopfloor operations. As already outlined, beyond leading edge scientific and technological development solutions, the book comprises a rich set of complementary assets that are indispensable to the successful adoption of IIoT/CPPS in the shopfloor. The book is structured in three parts as follows: * The first part of the book is devoted to digital automation platforms. Following an introduction to Industry 4.0 in general and digital automation platforms in particular, this part presents the digital automation platforms of the FAR-EDGE, AUTOWARE and DAEDALUS projects. * The second part of the book focuses on the presentation of digital simulation and digital twins' functionalities. These include information about the models that underpin digital twins, as well as the simulators that enable experimentation with these processes over these digital models. * The third part of the book provides information about complementary assets and supporting services that boost the adoption of digital automation functionalities in the Industry 4.0 era. Training services, migration services and ecosystem building services are discussed based on the results of the three projects of the Digital Shopfloor Alliance. The target audience of the book includes: * Researchers in the areas of Digital Manufacturing and more specifically in the areas of digital automation and simulation, who wish to be updated about latest Industry 4.0 developments in these areas. * Manufacturers, with an interest in the next generation of digital automation solutions based on Cyber-Physical systems. * Practitioners and providers of Industrial IoT solutions, which are interested in the implementation of use cases in automation, simulation and supply chain management. * Managers wishing to understand technologies and solutions that underpin Industry 4.0, along with representative applications in the shopfloor and across the supply chain.
Environmental Management System ISO 14001:2004 provides the information and practical know-how required to facilitate a smooth adoption and incorporation of the latest revisions and enhancements put forth by the International Organization for Standardization. This unique work shows how to adopt or transition to the documentation procedures required for an Environmental Management System (EMS) using the 14001:2004 series of standards. These globally accepted procedures help eliminate waste and improve efficiency, while providing the means to achieve both local and international compliance. This tool supplies step-by-step guidance on how to develop and implement an EMS that, with little effort, can be instantly applied to any process-related industry or organization interested in environmental compliance, whether it is regulated or not. A complete, single-source reference, written in simple and precise language, the book puts the answers to complex and thorny issues at your fingertips. It includes samples of policy statements, objectives, targets, and programs that can be amended or adopted without wasting time re-inventing the wheel. The CD-ROM includes customizable Standard Operating Procedures (SOPs) that can be downloaded, edited, printed, and easily tailored to incorporate changes and add organizational requirements. The SOPs exclusively refer to the documents specially required for compliance; however other formats are included to ensure that the soft copy can be easily used worldwide in a diverse range of industries and organizations. The book helps minimize documentation and avoid the nightmare faced by management representatives at the time of certification. An effective time saver when you are in the process of writing and organizing documentation for certification and further improvement purposes, this book and CD-ROM package helps you easily translate the revised ISO 14001:1
Wood adhesives are of tremendous industrial importance, as more than two-thirds of wood products in the world today are completely or partially bonded together using a variety of adhesives. Adhesive bonding offers many advantages over other joining methods for wood components, and there has been a great deal of R& D activity in devising new wood adhesives or improving the existing ones. The modern mantra in all industrial sectors is: "think green, go green," which has attracted much attention in the wood adhesive industry. Therefore, there is also a lot of research activity in synthesizing environmentally benign and human-friendly wood adhesives. This book is divided into four parts: Part 1: Fundamental Adhesion Aspects in Wood Bonding; Part 2: Synthetic Adhesives; Part 3: Environment-friendly adhesives; and Part 4: Wood Welding and General Paper. It addresses many different types of wood adhesives, as well as bonding (welding) of wood components without adhesives, a more recent development. The information contained in this book is valuable for individuals engaged in all aspects of wood adhesion and adhesives and, hopefully, will inspire new ideas in wood adhesives, a topic of vital industrial importance.
Tribosystem Analysis: A Practical Approach to the Diagnosis of Wear Problems provides a systematic framework for conducting root cause analyses and categorizing various types of wear. Designed specifically for engineers without formal training in tribology, this book: Describes a number of direct and indirect methods for detecting and quantifying wear problems Surveys different microscopy techniques, including those for light optics, electron optics, and acoustic imaging Discusses the selection of wear and friction test methods, both standard and custom, identifying possible pitfalls for misuse Presents practical examples involving complex materials and environments, such as those with variable loads and operating conditions Uses universally accepted terminology to create consistency along with the potential to recognize similar problems and apply comparable solutions Complete with checklists to ensure the right questions are asked during diagnosis, Tribosystem Analysis: A Practical Approach to the Diagnosis of Wear Problems offers pragmatic guidance for defining wear problems in the context of the materials and their surroundings.
Industrial automation has gone from simple pre-programmed machine instructions to complex general manufacturing, rules-based automation procedures. Unlike other books on industrial automation, this book focuses in on "Manufacturing Operations Systems" (MOPS) in general. It describes their development, implementation and successful management. The book especially addresses the all-important human-machine interface: computer-based manufacturing procedures that are understandable to both computers and humans. Consequently, a language for writing procedures is discussed. It is a language based on Chinese grammar, which is the simplest of all complex human languages. Finally, the design of procedures is discussed as a hierarchy of complexity, along with exception handling at each level. Readers with basic experience using non-procedural automation can greatly benefit from the productivity gains possible from procedural-based automation. They will learn how to create procedural language that is as close to natural language as possible. The reader also will benefit from * A brief overview and history of Manufacturing Operations (MOPS) * Coverage of manufacturing units and regulatory and sequential control * Discussion of Data recording from MOPs and tasks * An overview of Automating Manufacturing Tasks with DCS, PLC, and PCS * Guidelines for setting up an Automated MOPS (AMOPS) project * Guidelines for validating an AMOPS for regulated industries * Examples of applications for both continuous and batch manufacturing
In Optimization of Industrial Unit Processes, the term "optimization" means the maximizing of productivity and safety while minimizing operating costs. In a fully optimized plant, efficiency and productivity are continuously maximized while levels, temperatures, pressures, or flows float within their allowable limits. This control philosophy differs from earlier approaches - where levels and temperatures were controlled at constant values, and plant productivity was only an accidental, uncontrolled consequence of those controlled variables. With this approach, the sides of a multivariable control envelope are the various constraints while inside the envelope the process is continuously moved to maximize efficiency and productivity. Because one must understand a process before one can control it (let alone optimize it), Optimization of Industrial Unit Processes discusses the "personality" and characteristics of each process in term of its time constants, gains, and other unique features. This book provides information for engineers who design or operate industrial plants and who seek to increase the profitability of their plants. It recognizes that all industrial processes involve operations such as material transportation, heat transfer, and reactions. Therefore each plant consists of a combination of basic unit operations and can be optimized by maximizing the efficiency, and minimizing the operating cost, of the individual unit operations from which it is composed. Optimization of Industrial Unit Processes discusses real world processes - where pipes leak, sensors plug, and pumps cavitate - offering practical solutions to real problems. Each control system described in the book works, illustrating the state of the art in controlling a particular unit operation. This second edition reflects the continual improvement and evolution of control systems as well as anticipates future advances. Bela G. Liptak speaks on Post-Oil Energy Technology on the AT&T Tech Channel.
The revised and updated new edition of the popular optimization book for engineers The thoroughly revised and updated fifth edition of Engineering Optimization: Theory and Practice offers engineers a guide to the important optimization methods that are commonly used in a wide range of industries. The author-a noted expert on the topic-presents both the classical and most recent optimizations approaches. The book introduces the basic methods and includes information on more advanced principles and applications. The fifth edition presents four new chapters: Solution of Optimization Problems Using MATLAB; Metaheuristic Optimization Methods; Multi-Objective Optimization Methods; and Practical Implementation of Optimization. All of the book's topics are designed to be self-contained units with the concepts described in detail with derivations presented. The author puts the emphasis on computational aspects of optimization and includes design examples and problems representing different areas of engineering. Comprehensive in scope, the book contains solved examples, review questions and problems. This important book: Offers an updated edition of the classic work on optimization Includes approaches that are appropriate for all branches of engineering Contains numerous practical design and engineering examples Offers more than 140 illustrative examples, 500 plus references in the literature of engineering optimization, and more than 500 review questions and answers Demonstrates the use of MATLAB for solving different types of optimization problems using different techniques Written for students across all engineering disciplines, the revised edition of Engineering Optimization: Theory and Practice is the comprehensive book that covers the new and recent methods of optimization and reviews the principles and applications.
This book is about Sulph(on)ation Technology in its technical entirety, aiming at superiority in final product quality, raw material utilisation, sustained plant reliability and safety, minimisation of liquid effluent and gaseous emissions; it is about the total quality of the operation. It will be of value to engineers and chemists who are, or will be, involved in the practical daily operation of sulphonation plants or R&D activities. The book can also be used as a tool for the teacher in preparing fmal year projects in a chemical engineering curriculum. The book covers sulphonation of alkylbenzenes, primary alcohols, alcohol ethers, alpha-olefIns and fatty acid methyl esters, with a strong emphasis on the sulphur-based S /air sulphonation technology. The first part deals with raw material specifications, hazards, storage, handling and physical properties. In the following section the process chemistry is discussed, indicating main chemical reactions, undesired parallel and consecutive reactions, exothermal heat effects and all other process chemistry data that are relevant for process selection and equipment design. The section about the actual process equipment from the various plant equipment suppliers (Ballestra, Chemithon, Mazzoni, Meccaniche Modeme and Lion Corp.) takes into account the chemical reaction engineering aspects derived from the sulphonation technology processing chemistry. Product quality, product storage and handling, product safety and physical properties are the contents of the next section. The effluent handling and exhaust gas treatment of the SOiair sulphonation technology are further discussed in detail.
This second edition of An Introduction to Predictive Maintenance
helps plant, process, maintenance and reliability managers and
engineers to develop and implement a comprehensive maintenance
management program, providing proven strategies for regularly
monitoring critical process equipment and systems, predicting
machine failures, and scheduling maintenance accordingly.
The field of materials science and engineering is rapidly evolving into a science of its own. While traditional literature in this area often concentrates primarily on property and structure, the Materials Processing Handbook provides a much needed examination from the materials processing perspective. This unique focus reflects the changing complexity of new and emerging materials such as cutting-edge semiconductors, smart materials, and materials based on spintronics. This highly comprehensive work also presents groundbreaking coverage of the processes applied to a myriad of solid materials including ceramics, polymers, metals, composites, and semiconductors. Organized into six sections, this work examines processes that convert one phase into another, processes that change only the microstructure within a solid phase, shape changes that modify the microstructure and properties of materials, joining processes, and the basics of processes integration. Rich in data, yet accessible across several fields, this volume provides technicians and students with a one-stop resource on proven and promising new developments in materials processing.
Conventional synthetic materials, like metals, ceramics or glass, are usually isotropic substances, and their suitability for structural applications is achieved by morphological design and combination in the macroscopic scale. However, in modem engineering this is often not acceptable. As an alternative, the use of non-homogeneous, anisotropic materials, with significant stiffness and strength only in the directions these mechanical properties are really needed, can lead to enormous material (and weight) savings. This is the case of multiphase systems called composite materials. In these composites, different material parts are added and arranged geometrically, under clearly designed and controlled conditions. Usually, a structure of fibers provides strength and stiffness and a matrix helds them together, whilst providing the geometric form. Carbon fibers are among the high-performance fibers employed in these advanced structural composites, which are profoundly changing many of today's high technology industries. New research and development challenges in this area include upgrading the manufacturing process of fibers and composites, in order to improve characteristics and reduce costs, and modifying the interfacial properties between fibers and matrix, to guarantee better mechanical properties. The interdisciplinary nature of this "new frontier" is obvious, involving chemistry, materials science, chemical and mechanical engineering. Other topics, which more often are treated separately, are also important for the understanding of the processes of fiber production. Carbon filaments is one such topic, as the study of their mechanisms of nucleation and growth is clearly quite relevant to the production of vapour-grown carbon fibers.
Written to help the student chemist clarify the career areas and technical problems which are to be considered when chemical reactions are carried out on a large scale. Covers the research and development of consumer products based on chemical processes. Topics covered include the chemical industry and large-scale chemical manufacturing, inorganic and fermentation processes, the conversion of petroleum into purified chemical substances, and the environmental impact of these and other processes.
There are some very good books available that explain the Lean Manufacturing theory and touch on implementing its techniques. However, you cannot learn "how to be" lean from merely reading the theory. And to be successful in the real-work environment you need a clear comprehension of how lean techniques work, rather than just a remote understanding of what they are. You need to know what does and does not work in different situations. And you need the benefit of practical experience in their implementation.
An expert in his field, Jerry Arnold provides invaluable lessons learned from decades of trial and error as a die maker, die designer, and die engineer. Written in an easy-to-read manner and heavily illustrated, Die Makers Handbook is the only book of its kind expressly intended to help avoid the pitfalls associated with stamping designs, die designs, and stamping die function. This compact and practical reference has been edited by a half-dozen die makers with nearly 200 years of combined experience. The Die Makers Handbook is a must-have for your toolbox, desk, or briefcase. Developed from more than 30 years of practical shop-learned information. Chock full of all the stamping design pitfalls you don't need. Includes a full chapter on exotic measuring methods, providing unique aids and hard-to-find-data. Devotes an entire chapter of illustrated step-by-step process for designing progressive dies. Especially designed for apprentices, young journeymen, and students of die design.
There has been a great deal of progress in additive manufacturing (AM) during the past two decades and recent developments have been highlighted by many researchers. However, until now, there has been a limit to what is available for beginners in a step-by-step format, showcasing the different commercial AM technologies for field application. This book helps fill that gap. Additive Manufacturing: Applications and Innovations presents case studies of commonly used AM technologies with basic numerical problems for better understanding. It also includes hybrid processes and 4D printing applications, which currently are not offered in other AM books. Features Offers solved and unsolved problems in additive manufacturing Provides an understanding for additive manufacturing per international standards Includes case studies for better understanding of the individual processes Presents a review of specific technology highlights Introduces future research directions, mainly in 4D printing applications
This text provides a concise methodology for developing a comprehensive industrial program to handle major emergencies such as fires, chemical and oil spills, gas leaks, and explosions. Included is expert guidance on techniques used by many of the largest multinational industrial concerns.
Broad coverage of digital product creation, from design to manufacture and process optimization This book addresses the need to provide up-to-date coverage of current CAD/CAM usage and implementation. It covers, in one source, the entire design-to-manufacture process, reflecting the industry trend to further integrate CAD and CAM into a single, unified process. It also updates the computer aided design theory and methods in modern manufacturing systems and examines the most advanced computer-aided tools used in digital manufacturing. Computer Aided Design and Manufacturing consists of three parts. The first part on Computer Aided Design (CAD) offers the chapters on Geometric Modelling; Knowledge Based Engineering; Platforming Technology; Reverse Engineering; and Motion Simulation. The second part on Computer Aided Manufacturing (CAM) covers Group Technology and Cellular Manufacturing; Computer Aided Fixture Design; Computer Aided Manufacturing; Simulation of Manufacturing Processes; and Computer Aided Design of Tools, Dies and Molds (TDM). The final part includes the chapters on Digital Manufacturing; Additive Manufacturing; and Design for Sustainability. The book is also featured for being uniquely structured to classify and align engineering disciplines and computer aided technologies from the perspective of the design needs in whole product life cycles, utilizing a comprehensive Solidworks package (add-ins, toolbox, and library) to showcase the most critical functionalities of modern computer aided tools, and presenting real-world design projects and case studies so that readers can gain CAD and CAM problem-solving skills upon the CAD/CAM theory. Computer Aided Design and Manufacturing is an ideal textbook for undergraduate and graduate students in mechanical engineering, manufacturing engineering, and industrial engineering. It can also be used as a technical reference for researchers and engineers in mechanical and manufacturing engineering or computer-aided technologies.
Sustainable Manufacturing Systems Learn more about energy efficiency in traditional and advanced manufacturing settings with this leading and authoritative resource Sustainable Manufacturing Systems: An Energy Perspective delivers a comprehensive analysis of energy efficiency in sustainable manufacturing. The book presents manufacturing modeling methods and energy efficiency evaluation and improvement methods for different manufacturing systems. It allows industry professionals to understand the methodologies and techniques being embraced around the world that lead to advanced energy management. The book offers readers a comprehensive and systematic theoretical foundation for novel manufacturing system modeling, analysis, and control. It concludes with a summary of the insights and applications contained within and a discussion of future research issues that have yet to be grappled with. Sustainable Manufacturing Systems answers the questions that energy customers, managers, decision makers, and researchers have been asking about sustainable manufacturing. The book's release coincides with recent and profound advances in smart grid applications and will serve as a practical tool to assist industrial engineers in furthering the green revolution. Readers will also benefit from: A thorough introduction to energy efficiency in manufacturing systems, including the current state of research and research methodologies An exploration of the development of manufacturing methodologies, including mathematical modeling for manufacturing systems and energy efficiency characterization in manufacturing systems An analysis of the applications of various methodologies, including electricity demand response for manufacturing systems and energy control and optimization for manufacturing systems utilizing combined heat and power systems A discussion of energy efficiency in advanced manufacturing systems, like stereolithography additive manufacturing and cellulosic biofuel manufacturing systems Perfect for researchers, undergraduate students, and graduate students in engineering disciplines, especially for those majoring in industrial, mechanical, electrical, and environmental engineering, Sustainable Manufacturing Systems will also earn a place in the libraries of management and business students interested in manufacturing system cost performance and energy management.
This new volume explores recent research on advanced technologies and methods in production engineering, emphasizing effective overall process control and enhanced optimization. The authors include real-life case studies on advanced machining methods, traditional manufacturing technologies, advanced composite materials, processing with hybrid manufacturing techniques, various joining processes and their applications, micro-structure analysis, and more.
Contains a balanced discussion of homogeneous catalytic reactions that are used in industry, featuring every documented example employed in a current commercial process, or that have a broad application in the organic synthesis laboratory. Incorporates synthesis with chiral catalysts in chapters on hydrogenation, CO chemistry and olefin oxidation. New additions include Tennessee Eastman's coal-based acetic anhydride plant and IFP's Dimersol process for dimerizing propylene as well as major changes in the areas on pharmaceuticals, flavors, fragrances, agricultural and electronic chemicals.
Computational Methods and Production Engineering: Research and Development is an original book publishing refereed, high quality articles with a special emphasis on research and development in production engineering and production organization for modern industry. Innovation and the relationship between computational methods and production engineering are presented. Contents include: Finite Element method (FEM) modeling/simulation; Artificial neural networks (ANNs); Genetic algorithms; Evolutionary computation; Fuzzy logic; neuro-fuzzy systems; Particle swarm optimization (PSO); Tabu search and simulation annealing; and optimization techniques for complex systems. As computational methods currently have several applications, including modeling manufacturing processes, monitoring and control, parameters optimization and computer-aided process planning, this book is an ideal resource for practitioners.
Advanced Gear Manufacturing and Finishing offers detailed coverage of advanced manufacturing technologies used in the production of gears, including new methods such as spark erosion machining, abrasive water jet machining, additive layer manufacturing, laser shaping, and sustainable manufacturing of gears. The industry in this area is constantly producing new settings where gears must endure ever increasing stresses, strains, and temperatures. Advanced methods in manufacturing, finishing, and surface property enhancement have emerged in recent years to meet these challenges. This unique book takes a critical look at the state-of-the-art research into these new methods, and the latest improvements to classic technologies in both gear manufacturing and finishing. This book is essential reading for researchers and engineers working in the fields of powertrain manufacturing, gear technology, and advanced manufacturing technologies.
Many companies have adopted the approach of Material Requirements Planning (MRP) and Manufacturing Resource Planning (MRP II). Despite the improvements and broadening of the MRP framework, MRP II systems still perform poorly in certain manufacturing environments. Help is at hand. This book proposes new ideas to improve the planning activities at the strategic, tactical and execution layers in manufacturing organisations. It takes into account the diverse nature of manufacturing environments. The book presents an almost unique combination of theory tested in practice, enhancing traditional manufacturing planning approaches. It is essential reading for managers and practitioners in the field, and is also suitable as an advanced text for students in industrial engineering, manufacturing and management.
Hello, I'm Jake, a retired production planner. I've been talking to my coffee mate Ben about the factory where I have spent the better part of my life. Believe me, I have seen things go well and even more go very wrong. I'm outside the gate now, but the grapevine is keeping me up to date. Which is why I know that the factory is heading into oblivion, as management does not seem to understand commonsense principles and they are testing the patience of their main customer. But wait, things look like they might change when new management is brought in. This new plant manager might change things around, and thanks to my old friends we can keep on top of things. Do you want to hear my story? The concepts imbedded in the factory's journey capture the leading practices in progressive and proactive management. The commonsense concepts embody the philosophy of collaboration, shared fate, mutual respect, and leveraging the intellectual capital that exists in each and every factory. This book is for you if you want your factory to survive and thrive!
This volume encompasses state-of-the-art developments in AI-based reactive scheduling for real-time operation management in manufacturing shop floors. It is a collection of papers from the Second International Workshop of the IFIP Working Group 5.7 which brought together researchers from management information systems and knowledge engineering to expand the focus on applying new knowledge-based techniques. |
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