• Journal of the Korean Society for Precision Engineering
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• v.17 no.1
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• pp.171-178
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• 2000

In this study, an indirect method to estimate the setup runout of a ball-end mill from cutting force signal is proposed. This runout makes cutting forces of each tooth of the milling cutter unequal. By transforming the cutting force model from time domain to frequency domain through time-convolution theorem, the magnitude and phase angle of runout can be explicitly expressed with material constants, cutting conditions, and force signal. The static setup runout can be obtained by extrapolating estimated effective runout, which is independent of feedrate but decreases linearly with increase in axial depth of cut. The setup runout estimated by slot cutting experiments, shows good agreement with the measured one.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.34 no.2
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• pp.103-111
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• 2011

The reduction of setup time is very important in a lot production system. A punch press is a typical system of lot production. This paper describes a case study to reduce setup time of a punch press manufacturing system. Especially, this case study reduced the time of die exchange in the case that the standardization of die height is impossible realistically because of diversity on die height and heavy expenses. This study adopts a supplementary die and supplementary blocks to make the use of auto-clamping device possible. The paper also gives a sequencing algorithm to reduce the number of exchange of the supplementary die.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.1066-1069
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• 2004

Recently the monitoring system of tool setup in high speed precision machining tool is required for manufacturing products that have highly complex and small shape, high precision and high function. It is very important to reduce time to setup tool in order to improve the machining precision and productivity and to protect the breakage of cutting tool as the shape of product is smaller and more complex. Generally, the combination of errors that geometrical clamping error of fixing tool at the spindle of machining center and the asynchronized error of driving mechanism causes that the run-out of tool reaches to 3∼20 times of the thickness of cutting chip. And also the run-out is occurred by the misalignment between axis of tool shank and axis of spindle and spindle bearing in high speed rotation. Generally, high speed machining is considered when the rotating speed is more than 8,000 rpm. At that time, the life time of tool is reduced to about 50％ and the roughness of machining surface is worse as the run-out is increased to 10 micron. The life time of tool could be increased by making monitoring of tool-setting easy, quick and precise in high speed machining center. This means the consumption of tool is much more reduced. And also it reduces the manufacturing cost and increases the productivity by reducing the tool-setup time of operator. In this study, in order to establish the concept of tool-setting monitoring the measuring method of the geometrical error of tool system is studied when the spindle is stopped. And also the measuring method of run-out, dynamic error of tool system, is studied when the spindle is rotated in 8,000 ∼ 60,000 rpm. The dynamic phenomena of tool-setup is analyzed by implementing the monitoring system of rotating tool system and the noncontact measuring system of micro displacement in high speed.

• Journal of Korean Institute of Industrial Engineers
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• v.12 no.2
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• pp.33-44
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• 1986

This research is concerned with group scheduling problems in multi-stage manufacturing system with dependent setup time. The objective of the research is to develop and evaluate a heuristic algorithm for determining group sequence and job sequence within each group to minimize total tardiness in multi-stage manufacturing systems with sequence dependent group setup time. The group scheduling heuristic algorithm is developed and evaluated by comparisons with twenty-seven problems with the known optimum solutions and 144,000 random schedules of a large variety problems. The results indicate that the proposed heuristic algorithm gets the same optimum solutions for the problems and also provides the good solutions in comparison with the random schedules of the large variety problems. A numerical example is given to illustrate the heuristic algorithm.

• Journal of the Korean Operations Research and Management Science Society
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• v.26 no.2
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• pp.69-83
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• 2001

The problem of minimizing total tardiness on a batch processing machine with incompatible job families when there are sequence independent setup times between families is studied where all jobs of the same family have identical processing times and jobs of different families cannot be processed together. A batch processing machine can process a number of jobs, within a maximal batch size, simultaneously as a batch. The processing time required of each batch is equal to the one of jobs. A dynamic programming algorithm which gives the optimal solution, and several heuristics are presented. Performance of simple dispatching rules based on due dates are compared, and the best of them is used as an initial solution for the decomposition algorithm, which is shown to give good schedules in relatively short computational time.

• Journal of Korean Institute of Industrial Engineers
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• v.11 no.2
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• pp.75-85
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• 1985

The application of GT results in the mass production effect to multi-product, small lot-sized production. Group scheduling, which is operations scheduling based on the GT concept, is analyzed in a multistage manufacturing system. But the research has been limited in independent setup time models. A heuristic algorithm has been developed to minimize the mean flow time when setup times are dependent to sequence of group in multistage. For evaluation of the heuristic algorithm, the solution of heuristic algorithm is compared with that of random scheduling. The result of comparison indicates that the proposed heuristic algorithm provides good solutions with relatively fewer computational effort.

• Journal of Korean Institute of Industrial Engineers
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• v.19 no.4
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• pp.125-135
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• 1993

An Unrelated Parallel Processing with Weighted jobs and Setup times scheduling prolem is studied. We consider a parallel processing in which a group of processors(machines) perform a single operation on jobs of a number of different job types. The processing time of each job depends on both the job and the machine, and each job has a weight. In addition each machine requires significant setup time between processing jobs of different job types. The performance measure is to minimize total weighted flow time in order to meet the job importance and to minimize in-process inventory. We present a 0-1 Mixed Integer Programming model as an optimizing algorithm. We also present a simple heuristic algorithm. Computational results for the optimal and the heuristic algorithm are reported and the results show that the simple heuristic is quite effective and efficient.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.23 no.60
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• pp.73-81
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• 2000

The testing processes for VLSI finished devices are considerably complex because they require different types of ATE to be linked together. Due to the interaction effect between two or more linked ATEs, it is difficult to trace down the cause of the unexpected longer ATE setup time and random yields, which frequently occur in the VLSI circuit-testing laboratory. The goal of this paper is to develop and demonstrate the methodology designed to eliminate the possible interaction factors that might affect the random yields and/or unexpected longer setup time as well as increase the productivity. The statistical method such as design of experiment or multivariate analysis cannot be applied to the final testing floor here directly due to the environmental constraints. Expanded product data information (PDI) is constructed by combining product data information and ATE control information. An architecture utilizing expanded PDI is designed, which enables the engineer to conduct statistical approach investigation and reduce the setup time, as well as increase yield.

• Korean Management Science Review
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• v.13 no.1
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• pp.13-27
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• 1996

This paper considers the sequencing problem in mixed model assembly lines with hybrid workstation types and sequence-dependent setup times. Computation time is often a critical factor in choosing a method of determining the sequence. We develop a mathematical formulation of the problem to minimize the overall length of a line, and present a tabu search technique which can provide a near optimal solution in real time. The proposed technique is compared with a genetic algorithm and a branch-and-bound method. Experimental results are reported to demonstrate the efficiency of the technique.

• Journal of Korean Institute of Industrial Engineers
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• v.33 no.2
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• pp.246-253
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• 2007

All of the machines in a production line can be classified into bottleneck and non-bottleneck machines. A bottleneck is a resource whose capacity limits the throughput of the whole production facility. This paper addresses a batch sizing problem at the bottleneck machine. Traditionally, most batch sizing decisions have been made based on the EOQ (economic order quantity) model where setup and inventory costs are considered while throughput rate is assumed to be given. However, since batch size affects the capacity of the bottleneck machine, the throughput rate may not be constant. As the batch size increases, the frequency of the setup decreases. The saved setup time can be transferred to processing time, which results in higher throughput. But, the larger batch size may also result in longer lead time and larger WIP inventory level. This paper presents an alternative method to determine batch size at the bottleneck machine in a manufacturing line. A linear search algorithm is introduced to find optimal throughput rate and batch size at the same time. Numerical examples are provided to see how the proposed method works and to investigate the effects of some parameters.