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1、A web-based manufacturing service systemfor rapid product developmentHongbo Lan, Yucheng Dinga,*, Jun Hong, Hailiang Huangb, Bingheng LuaThis paper proposes a novel integrated system of rapid product development based on rapidprototyping, and develops anetworked manufacturing service system which of

2、fers bettersupport for the rapid product development in small and mediumsized enterprises by taking fulladvantage of the quickly evolving computer network and information technologies. Thearchitecture of the networked manufacturing service system is presented. Furthermore, some ofthe key issues, inc

3、ludingmodelling and planning a manufacturing chain, selecting feasiblecollaborative manufacturers, queuing a manufacturing task, using the synchronouslycollaborative work environment, and constructing a suitable running platform, are described indetail. Java-enabled solution, together with web techn

4、iques, is employed for building such anetworked service system. Finally, an actual example is provided illustrating the application ofthis service system.:Rapid product development; Rapid prototyping; Service system; Web-based application This is the era of information technology. Informationtechnol

5、ogy has influenced every realmof society, and dramatically impacted on the traditional industry.Current industries are facingthe new challenges:quick response to business opportunity has been consideredas one of themost important factors to ensurecompany competitiveness; manufacturing industry isevo

6、lvingtoward digitalization, network and globalization.In order to respond to the changeeffectively,manufacturing strategy has to be modified from timeto time in accordance with themarket situation andcustomer demand. Any change of strategy should enable manufacturers tobe better equipped themselves,

7、with capabilities to cope with demands suchas a faster responseto market changes, a shortenedlead time of production, improved quality and speed,the abilityto deliver quality products to global customers,and improved communications andtransportationsystem 1. It is an established fact that the useof

8、computers in design andmanufacturing constitutesthe most significant opportunity for substantial productivitygain inindustry. It has now been widelyaccepted that the future of manufacturing organizationswill beinformation-oriented, knowledge drivenand much of their daily operations will beautomateda

9、round the global information network that connectseveryone together 2. In order tomeet the demand ofrapid product development, various new technologiessuch as reverseengineering (RE), rapid prototyping (RP), and rapid tooling (RT) have emerged and areregardedas enabling tools with abilities to short

10、en theproduct development and manufacturing time.Forexample, it has been claimed that RP can cut newproduct development costs by up to 70%and the timeto market by 90% 3. However, these equipments aretoo expensive for the smalland medium sized enterprises(SMEs), and many techniques such as 3D CADsoli

11、d modelling,RP process planning, free-form surfacesreconstruction, etc., require the high skilled personneltocomplete. Therefore, it is especially difficultfor the SMEs to take full advantage of thesetechnologiesin the product development process. In order tooffer the support of rapid productdevelop

12、ment fornumerousSMEs,manyRPservice bureaus (SBs)whichcan not only manufacturephysical prototype and rapidtooling but also provide other engineering services,have beenestablished. By 2001, there are more than500 SBs all over the world. But not every SBcanpossess all design and manufacturing capabilit

13、iesrequired, it must employ effectively theexternalresource to better satisfy client requirements. Namely,a virtual enterprise which usuallydefined as a temporaryalliance of enterprises that come together to sharetheir skills, corecompetencies, and resource in order tobetter respond to business oppo

14、rtunities, whosecooperationis supported by computer networks 4, is tobe founded. Every SBconducts onlythe tasks of its corecompetencies, and depends on numerous partners tocarry out the remainingtasks that this SB has no such manufacturing capabilities to accomplish in time.While a newthought emphas

15、izing service quality is becoming a basic strategy by which manufacturingindustries can win global competition in the 21st century. Teleservice engineering is anemerging fieldwhichaddresses service issue for manufacturers and customers. As digitalmanufacturing technique progresses quickly, digital s

16、ervice will be integrated seamlessly intothe digital design and manufacturing system 7. The internet, incorporating computers andmultimedia, has provided tremendous potential for remote integration and collaboration inbusiness and manufacturing applications. In order to provide a production collabor

17、ativeenvironment for many SMEs and SBs to implement the networked manufacturing, it isespecially urgent for many SBs and SMEs to construct a service platform of networkedmanufacturing to speed up the product development process of the SMEs.The rest of this paper is organized as follows.Related resea

18、rch work is reviewed in Section .In Section 3, we introduce an integrated system of rapid product development based on RP.Section 4 describes the workflow and functional design of the networked manufacturing servicesystem. The configuration of system running platform is presented in Section 5. In Se

19、ction ,we discuss the design of internet application. A case study is demonstrated in Section 7. Finally,Section 8 concludes the paper.2. Related researchWith the development of computer network and information technologies, the networkedmanufacturing techniques are playing a more and more important

20、 role in manufacturingindustry. Substantial investments have been made to support the research and practice ofnetworked manufacturing (telemanufacturing or global manufacturing) from both the academiccommunity and industrial bodies all over the world in recent years. A number of strategies andframew

21、orks have been proposed. Abdel-Malek et al. 8 described a structure within which acompany can outsource several of its production and design activities via internet anddeveloped a model to aid a company in selecting among the available technological andfunctional alternatives to maximize its flexibi

22、lity. Montreuil et al. 9 presented a framework for designing and operating agile manufacturing networks, enabling tocollaboratively plan, control and manage day-to-day contingencies in a dynamic environment.Tso et al. 10 introduced the architecture of an agent-based collaborative service supportsyst

23、em, which is able to carry out service requests in a manufacturing information networkthrough some specially designed virtual agents. Cheng et al. 11 put forward an integratedframework for web-based design and manufacturing which is developed based on Java solutionand CORBA-ORG broking technologies.

24、 Offodile and Abdel-Malek 12 introduced aframework for integrating IT and manufacturing strategies using the virtual manufacturingparadigm. Huang et al. 13 presented a holonic framework for virtual enterprises and controlmechanisms of virtual enterprises under this framework. OSullivan 14 described

25、aninformation architecture and associated toolset for understanding and managing the process ofbusiness development. Akkermansa and Horstc 15 discussed managerial aspects ofinformation technology infrastructure standardisation in networked manufacturing firms andpresented a strategic framework to gu

26、ide managers in making sensible decisions regarding ITinfrastructure standardisation, based on a number of pre-existing economic and managementtheories, such as transaction cost theory, organisational design and IT maturity growth stages.Jin et al. 16 presented a research on key application technolo

27、gies and solutions, whichincludes a network safety strategy which ensures data transfer among the leaguer members;production data management based on Web/DOT (distributed object technology) and XMLcriteria which ensure data exchange in structure-variance characteristic environments; thenetwork platf

28、orm which provides the conversion service of different types of CAD files.Woerner and Woern 17 introduced a new web service based platform providing developedmethods for co-operative plant production within virtual engineering.To full realize the teleservice engineering in todays globalized manufact

29、uring industry andmeet the current market situation and customer demand, a number of global manufacturingnetworks have been established by, among others, the Society of Manufacturing Engineer 18,Lockheed Martin (AIMSNET) 19 and 3M (the 3M Innovation Global Network) 20.Todays industries are facing se

30、rious structural problems brought about by their rapiddevelopment of overseas activities under a global integrated manufacturing environment.Service and maintenance are becoming extremely important practices for companies tomaintain their manufacturing productivity and customer satisfaction in forei

31、gn regions. Due tothe inherent problems of traditional help desk support, some companies have starteddeveloping web-based online customer service support system. Foo et al. 21 described anintegrated help desk support for customer service via internet. Lee 7 discussed the conceptand framework of a te

32、leservice engineering system for the life cycle support of manufacturingequipment and products. A system for remote customer support has been created in the FCSAdemonstrator of the Globerman 21 project 22. The purpose of these systems above is toprovide effective and responsive remote support to cus

33、tomers in the use, maintenance andtroubleshooting of their equipment.University of California is studying and developing a project called the Tele-ManufacturingFacility (TMF) which is to create an automated RP capability on the Internet. TMF allows usersto easily submit jobs and have the system auto

34、matically maintain a queue. While it canautomatically check many flaws in .STL files, and in many cases, fix them 23. RP potentiallyoffers great benefits when used during the design and manufacturing process. However, RPmust be used in an effective manner if these benefits are to be fully exploited.

35、 The RP-noviceshave a lot of difficulties in getting a global view of the RP technique and in tackling wellfounded decision for investment or outsourcing of RP tasks because of the very quickappearance of new and improved processes in this field. In order to help novices select asuitable RP process,

36、 the rapid prototyping system selector has been developed by manyresearchers 24. Quickparts. com, which is a privately held manufacturing servicescompany dedicated to providing customers with an on-line E-commerce system to procurelowvolume and high-volume custom manufactured parts, has developed a

37、QuickQuote system.The QuickQuote system enables customers to get instant, customerized quotations for theproduction of their parts 28. 3D Systems Company, which is the earliest and biggest RPequipment manufacturer, has provided RP&M service for customer via Internet 29.From these literatures survey,

38、 it is clear that most of studies mainly focused on the strategyand overall architecture of networked manufacturing as well as individual function module,there is still no comprehensive and banausic networked manufacturing service system tosupport rapid product development. Built on the emerging res

39、earches and our earlier work (e.g.Refs. 30,31), a web-based manufacturing service system for rapid product development is tobe established. The development process from initial conceptual design to commercial product is an iterativeprocess which includes: product design; analysis of performance, saf

40、ety and reliability; productprototyping for experimental evaluation; and design modification. Therefore, any step of newproduct development process has a direct and strong influence on time-to-market. A goodproduct development system must enable designers or design teams to consider all aspects ofpr

41、oduct design, manufacturing, selling and recycling at the early stage of a design cycle. So thatdesign iteration and changes can be made easily and effectively. The more fluent the feedbackis, the higher possibility success of the system has. Design for manufacturing (DFM) andconcurrent engineering

42、(CE) require that product and process design be developedsimultaneously rather than sequentially 32.The integrated system of rapid product development is composed of three modules: digitalprototype, physical prototype and rapid tooling and functional part manufacturing system. Theproduct development

43、 starts from the creation of a 3D model using a 3D CAD software package.Atthat stage the product geometry is defined and its aesthetic and dimensional characteristicsare verified. The main function of digital prototype is to perform 3D CAD modelling. Theproduct and its components are directly design

44、ed on a 3D CAD system (e.g. Pro/Engineer,Unigraphics, CATIA, IDEAS, etc.) during the creative design process. If a physical part isavailable, the model can be constructed by the reverse engineering (RE) technique. RE is amethodology for constructing CAD models of physical parts by digitizing an exis

45、ting part,creating a digital model and then using it to manufacturing components 33. RE can reduce thedevelopment cycle when redesigns become necessary for improved product performance.Pre-existing parts with features for improved performance can be readily incorporated into thedesired part design.

46、When a designer creates a new design using mock-up, it is also necessary toconstruct the CAD model of the mock-up for further use of the design data in analysis andmanufacturing. The three primary steps in RE process are part digitization, features extraction,and 3D CAD modelling. Part digitization

47、is accomplished by a variety of contact or non-contactdigitizers. There are various commercial systems available for part digitization. There systemsrange from coordinate measuring machine (CMM),laser scanners to ultrasonic digitizers. Theycan be classified into two broad categories: contact and non

48、-contact. Laser triangulation scanner(LTS), magnetic resonance images (MRI), and computer tomography (CT) are commonly usednon-contact devices. Contact digitizers mainly have CMM and cross-sectional imagingmeasurement (CIM). Feature extraction is normally achieved by segmenting the digitized dataand

49、 capturing surface features such as edges. Part modelling is fulfilled through fitting a varietyof surface to the segmented data points 34. In order to reduce the iterations ofdesign-prototypetest cycles, increase the product process and manufacturing reliability, it isnecessary to guide in optimiza

50、tion of the product design and manufacturing process throughCAE.The CAD model can be directly converted to the physical prototype using a RP technique. RPis a new forming process which fabricates physical parts layer by layer under computer controldirectly from 3D CAD models in a very short time. In

51、 contrast to traditional machining methods,the majority of rapid prototyping systems tend to fabricate parts based on additivemanufacturing process, rather than subtraction or removal of material. Therefore, this type offabrication is unconstrained by the limitations inherent in conventional machini

52、ng approaches35. RP potentially offers great benefits when used during the design and manufacturingprocess. It can help shorten time-to-market, improve quality and reduce cost. Over the last 10years, RP machines have been widely used in industry. The RP methods commercially availableinclude Stereoli

53、thgraphy (SL), Selective Laser Sintering (SLS), Fused DepositionManufacturing (FDM), Laminated Object Manufacturing (LOM), Ballistic ParticleManufacturing (BMP), and Three Dimensional Printing (3D printing) 36, etc.RTis a technique that transforms the RP patterns into functional parts, especially me

54、tal parts.Furthermore, the integration of both RP and RT in development strategy promotes theimplementation of concurrent engineering in companies. Numerous processes have beendeveloped for producing dies fromRP system. The RT methods can generally be dividedintodirect and indirect tooling categorie

55、s, and also soft (firm) and hard tooling subgroups. IndirectRT requires some kinds of master patterns, which can be made by conventional methods (e.g.HSM), or more commonly by an RP process such as SL or SLS. Direct RT, as the namesuggests, involves manufacturing a tool cavity directly on the RP sys

56、tem, hence eliminating theintermediatestep of generating a pattern 37. On the basis of abovetechniques, a novel integrated system ofrapid product development is to be established. Its detailed structure is shown in Fig. 1.4. The workflow and function designThe workflow of the service system of netwo

57、rkedmanufacturing is shown in Fig. 2. The firststep is to log in to the website of SB. Users have to enter their names and passwords. Thosewithout registration or authorization can also enter into the system, but they are limited toviewing the information that is open to the public such as typical c

58、ases in this systempassword entered by the user will be verified by the system. After entering the SB websitesuccessfully, the system will check the security level of users, and determine which modulesthey can access or employ. According to authentication for the system, all usersa re to bedivided i

59、nto four categories: general users (without registration), potential clients, real clients,and system administrator. Received job requests from clients, the SB will perform firstlyprocess planning which fulfills the task decomposition and selects the most suitable processmethods. It is necessary for

60、 users to get the preliminary product quote and manufacturing timefrom the SB before the follow-up process continues. If such results may be accepted initially,The SB will negotiate further with users by Video-conferencing system. Once come to termeach other, a contract is to be confirmed, and the u