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INTJADVMANUFTECHNOL200525551559DOI101007/S0017000318433ORIGINALARTICLESHMASOODBABBASESHAYANAKARAANINVESTIGATIONINTODESIGNANDMANUFACTURINGOFMECHANICALCONVEYORSSYSTEMSFORFOODPROCESSINGRECEIVED29MARCH2003/ACCEPTED21JUNE2003/PUBLISHEDONLINE23JUNE2004SPRINGERVERLAGLONDONLIMITED2004ABSTRACTTHISPAPERPRESENTSTHERESULTSOFARESEARCHINVESTIGATIONUNDERTAKENTODEVELOPMETHODOLOGIESANDTECHNIQUESTHATWILLREDUCETHECOSTANDTIMEOFTHEDESIGN,MANUFACTURINGANDASSEMBLYOFMECHANICALCONVEYORSYSTEMSUSEDINTHEFOODANDBEVERAGEINDUSTRYTHEIMPROVEDMETHODOLOGYFORDESIGNANDPRODUCTIONOFCONVEYORCOMPONENTSISBASEDONTHEMINIMISATIONOFMATERIALS,PARTSANDCOSTS,USINGTHERULESOFDESIGNFORMANUFACTUREANDDESIGNFORASSEMBLYRESULTSOBTAINEDONATESTCONVEYORSYSTEMVERIFYTHEBENETSOFUSINGTHEIMPROVEDTECHNIQUESTHEOVERALLMATERIALCOSTWASREDUCEDBY19ANDTHEOVERALLASSEMBLYCOSTWASREDUCEDBY20COMPAREDTOCONVENTIONALMETHODSKEYWORDSASSEMBLYCOSTREDUCTIONDESIGNDFADFMMECHANICALCONVEYOR1INTRODUCTIONCONVEYORSYSTEMSUSEDINTHEFOODANDBEVERAGEINDUSTRYAREHIGHLYAUTOMATEDCUSTOMMADESTRUCTURESCONSISTINGOFALARGENUMBEROFPARTSANDDESIGNEDTOCARRYPRODUCTSSUCHASFOODCARTONS,DRINKBOTTLESANDCANSINFASTPRODUCTIONANDASSEMBLYLINESMOSTOFTHEPROCESSINGANDPACKAGINGOFFOODANDDRINKINVOLVECONTINUOUSOPERATIONSWHERECARTONS,BOTTLESORCANSAREREQUIREDTOMOVEATACONTROLLEDSPEEDFORLLINGORASSEMBLYOPERATIONSTHEIROPERATIONSREQUIREHIGHLYEFCIENTANDRELIABLEMECHANICALCONVEYORS,WHICHRANGEFROMOVERHEADTYPESTOOORMOUNTEDTYPESOFCHAIN,ROLLERORBELTDRIVENCONVEYORSYSTEMSINRECENTYEARS,IMMENSEPRESSUREFROMCLIENTSFORLOWCOSTBUTEFCIENTMECHANICALCONVEYORSYSTEMSHASPUSHEDCONVEYORMANUFACTURERSTOREVIEWTHEIRCURRENTDESIGNANDASSEMBLYMETHODSANDLOOKATANALTERNATIVEMEANSTOMANUFACTUREMOREECONOMICALANDRELIABLECONVEYORSFORTHEIRCLIENTSATPRESENT,SHMASOODUBABBASESHAYANAKARAINDUSTRIALRESEARCHINSTITUTESWINBURNE,SWINBURNEUNIVERSITYOFTECHNOLOGY,HAWTHORN,MELBOURNE3122,AUSTRALIAEMAILSMASOODSWINEDUAUMOSTMATERIALHANDLINGDEVICES,BOTHHARDWAREANDSOFTWARE,AREHIGHLYSPECIALISED,INEXIBLEANDCOSTLYTOCONGURE,INSTALLANDMAINTAIN1CONVEYORSAREXEDINTERMSOFTHEIRLOCATIONSANDTHECONVEYORBELTSACCORDINGTOTHEIRSYNCHRONISEDSPEEDS,MAKINGANYCHANGEOVEROFTHECONVEYORSYSTEMVERYDIFCULTANDEXPENSIVEINTODAYSRADICALLYCHANGINGINDUSTRIALMARKETS,THEREISANEEDTOIMPLEMENTANEWMANUFACTURINGSTRATEGY,ANEWSYSTEMOPERATIONALCONCEPTANDANEWSYSTEMCONTROLSOFTWAREANDHARDWAREDEVELOPMENTCONCEPT,THATCANBEAPPLIEDTOTHEDESIGNOFANEWGENERATIONOFOPEN,EXIBLEMATERIALHANDLINGSYSTEMS2HOANDRANKY3PROPOSEDANEWMODULARANDRECONGURABLE2DAND3DCONVEYORSYSTEM,WHICHENCOMPASSESANOPENRECONGURABLESOFTWAREARCHITECTUREBASEDONTHECIMOSAOPENSYSTEMARCHITECTUREMODELITISNOTEDTHATTHERESEARCHINTHEAREAOFIMPROVEMENTOFCONVEYORSYSTEMSUSEDINBEVERAGEINDUSTRYISVERYLIMITEDMOSTOFTHEPUBLISHEDRESEARCHISDIRECTEDTOWARDSIMPROVINGTHEOPERATIONSOFCONVEYORSYSTEMSANDINTEGRATIONOFSYSTEMTOHIGHLYSOPHISTICATEDSOFTWAREANDHARDWARETHISPAPERPRESENTSARESEARCHINVESTIGATIONAIMEDATIMPROVINGTHECURRENTTECHNIQUESANDPRACTICESUSEDINTHEDESIGN,MANUFACTURINGANDASSEMBLYOFOORMOUNTEDTYPECHAINDRIVENMECHANICALCONVEYORSINORDERTOREDUCETHEMANUFACTURINGLEADTIMEANDCOSTFORSUCHCONVEYORSAPPLYINGTHECONCEPTOFCONCURRENTENGINEERINGANDTHEPRINCIPLESOFDESIGNFORMANUFACTURINGANDDESIGNFORASSEMBLY4,5,SEVERALCRITICALCONVEYORPARTSWEREINVESTIGATEDFORTHEIRFUNCTIONALITY,MATERIALSUITABILITY,STRENGTHCRITERION,COSTANDEASEOFASSEMBLYINTHEOVERALLCONVEYORSYSTEMTHECRITICALPARTSWEREMODIEDANDREDESIGNEDWITHNEWSHAPEANDGEOMETRY,ANDSOMEWITHNEWMATERIALSTHEIMPROVEDDESIGNMETHODSANDTHEFUNCTIONALITYOFNEWCONVEYORPARTSWEREVERIEDANDTESTEDONANEWTESTCONVEYORSYSTEMDESIGNED,MANUFACTUREDANDASSEMBLEDUSINGTHENEWIMPROVEDPARTS2DESIGNFORMANUFACTURINGANDASSEMBLYDFMAINRECENTYEARS,RESEARCHINTHEAREAOFDESIGNFORMANUFACTURINGANDASSEMBLYHASBECOMEVERYUSEFULFORINDUSTRIESTHATARECON552SIDERINGIMPROVINGTHEIRFACILITIESANDMANUFACTURINGMETHODOLOGYHOWEVER,THEREHASNOTBEENENOUGHWORKDONEINTHEAREAOFDESIGNFORCONVEYORCOMPONENTS,ESPECIALLYRELATEDTOTHEISSUEOFINCREASINGNUMBERSOFDRAWINGDATAANDREENGINEERINGOFTHEPROCESSOFCONVEYORDESIGNBASEDONTRADITIONALMETHODSEMPHASISESTANDARDISATIONUSETHESIMPLESTPOSSIBLEOPERATIONSUSEOPERATIONSOFKNOWNCAPABILITYMINIMISESETUPSANDINTERVENTIONSUNDERTAKEENGINEERINGCHANGESINBATCHESAVASTAMOUNTOFPAPERSHAVEBEENPUBLISHEDTHATHAVEINVESTIGATEDISSUESRELATEDTODFMAANDAPPLIEDTOVARIOUSMETHODOLOGIESTOACHIEVERESULTSTHATPROVEDECONOMICAL,EFCIENTANDCOSTEFFECTIVEFORTHECOMPANIESUNDERINVESTIGATIONTHEMAINCLASSICATIONSOFDFMAKNOWLEDGECANBEIDENTIEDAS1GENERALGUIDELINES,2COMPANYSPECICBESTPRACTICEOR3PROCESSANDORRESOURCESPECICCONSTRAINTSGENERALGUIDELINESREFERTOGENERALLYAPPLICABLERULESOFTHUMB,RELATINGTOAMANUFACTURINGDOMAINOFWHICHTHEDESIGNERSHOULDBEAWARETHEFOLLOWINGLISTHASBEENCOMPILEDFORDFMGUIDELINES6THESEDESIGNGUIDELINESSHOULDBETHOUGHTOFAS“OPTIMALSUGGESTIONS”THEYTYPICALLYWILLRESULTINAHIGHQUALITY,LOWCOST,ANDMANUFACTURABLEDESIGNOCCASIONALLYCOMPROMISESMUSTBEMADE,OFCOURSEINTHESECASES,IFAGUIDELINEGOESAGAINSTAMARKETINGORPERFORMANCEREQUIREMENT,THENEXTBESTALTERNATIVESHOULDBESELECTED7COMPANYSPECICBESTPRACTICEREFERSTOTHEINHOUSEDESIGNRULESACOMPANYDEVELOPS,USUALLYOVERALONGPERIODOFTIME,ANDWHICHTHEDESIGNERISEX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