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Architectural Holarchy of The Next Generation Manufacturing System

The document discusses the architectural holarchy of next generation manufacturing systems. It proposes seeing manufacturing systems as modular cyber-physical systems whose architecture permanently accords to manufactured product requirements. The function, procedure, topology and holarchy model of the system are presented, along with its main features.

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0% found this document useful (0 votes)
43 views6 pages

Architectural Holarchy of The Next Generation Manufacturing System

The document discusses the architectural holarchy of next generation manufacturing systems. It proposes seeing manufacturing systems as modular cyber-physical systems whose architecture permanently accords to manufactured product requirements. The function, procedure, topology and holarchy model of the system are presented, along with its main features.

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孫ウィーユ
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© © All Rights Reserved
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International Journal of Modeling and Optimization, Vol. 12, No.

1, February 2022

Architectural Holarchy of the Next Generation


Manufacturing System
Gabriel Frumuşanu and Alexandru Epureanu

are appropriate for supporting the manufacturing activity.


Abstract—Nowadays, the global energy network can generate More specific, the manufacturing system consists in a
and transmit, between any two points belonging to it, high combination of manufacturing equipment and humans bound
quantity of energy. During recent years, a global information by a common material and information flow, Fig. 1. Design
network, able to process, store, and transmit huge amounts of and manufacturing interfaces should also be considered, since
information, has been developed as well. These networks manufacturing always begins with a design such a drawing,
entirely cover the industrial space, already giving the
opportunity to make permanently available, in any of its points,
sketch, CAD file or any other way of communicating the
at any time, as much as needed, both energy and information. features and characteristics of the product that is to be
On the other hand, the mass customization trend has led to the manufactured [4].
pronounced increase of “manufacturing to order” (MTO) PERFORMANCE
production, taking place in a higher and higher number of small
& medium enterprises. At this level, a given manufacturing
system cannot be quickly and appropriately configured to a Production Production Production
given product, due to production high variability in range. As Product Production control equipment processes
design (for planning (feedback, (including (removal,
consequence, the manufacturing system is, quite always, more production) (programming) adaptive machine forming,
or less unadjusted to the manufactured product, its optimizing) tools) etc.)
performance being significantly affected. Starting from here,
the challenge is to make a conceptual rebuilding of the
manufacturing system, aiming to increase its degree of COSTS AND CAPABILITES
appropriateness to products, by taking advantage from the
opportunities brought by the existence of global energy & Needs (product requirements)
information networks. This paper approach is to see the next Ready for use products
generation manufacturing system as holonic modular cyber- Creativity (product concepts)
physical system. System architecture permanently accords to Fig. 1. The manufacturing system [4].
the manufactured product requirements. The function,
procedure, topology and holarchy model of the system are
In economic approach, the manufacturing system is seen as
presented. The main features of the system are also revealed.
a system in which raw materials are processed from one form
Index Terms—Manufacturing system, manufacturing holon, into another, known as a product, gaining a higher or added
architectural topology, architectural holarchy, modular cyber- value in the process and thus creating wealth in the form of a
physical system. profit, [3]. This is illustrated in Fig. 2.

I. INTRODUCTION
In general approach, the supply chain means a system of
organizations, people, activities, information, and resources
involved in moving a product or service from supplier to
customer. Supply chain activities involve the transformation
of natural resources, raw materials, and components into a Fig. 2. Basic model of manufacturing system adding value [3].
finished product that is delivered to the end customer [1]. One
of the most important activities in products supply chain is Four distinct strategies within manufacturing can be
manufacturing, because it has a decisive impact onto entire revealed [3]:
supply chain performance. Manufacturing has various • Make to stock (MTS) strategy, when product-focused
definitions. According to [2], manufacturing is the production manufacturing systems produce large quantities of few
of goods through the use of labor, machines, tools, and standard products, for which there is a predictable
chemical or biological processing or formulation. At the same demand pattern,
time manufacturing can be defined as the making of products
• Assemble to order (ATO) strategy, when producing
from raw materials using various processes, equipment,
products with many options from relatively few major
operations and manpower according to a detailed plan [3].
sub-assemblies and parts after having received customer
In broad sense, the manufacturing system may be defined
orders. This entails manufacturing the above sub-
as an ensemble of facilities and assets, selected such as they
assemblies and parts and holding them in stock until a

Manuscript received May 13, 2021; revised August 23, 2021.


The authors are with the Manufacturing Engineering Department,
Dunărea de Jos University of Galaţi, Romania (e-mails:
[email protected], [email protected]).

DOI: 10.7763/IJMO.2022.V12.793 15
International Journal of Modeling and Optimization, Vol. 12, No. 1, February 2022

customer order arrives. The specific product that advantages of an FMS [7], [15] is its high flexibility in
customer requires is then assembled from appropriate managing manufacturing resources like time and effort in
sub-assemblies and parts, order to manufacture a new product. Among FMS drawbacks,
• Make to order (MTO) strategy, when product they should be noticed the high initial set-up cost, the
manufacture follows customer specifications. substantial pre-planning, the requirement of skilled labour,
Manufacture does not commence until the customer and the complicated maintenance.
order is received. The reconfigurable manufacturing system (RMS) is
• Engineer to order (ETO) strategy, which is an extension designed for rapid change in structure, as well as in hardware
of MTO strategy, with the engineering design of the and software components, in order to quickly adjust its
product based on the customer specifications. production capacity and functionality within a part family in
In what concerns the global manufacturing trends, product response to sudden changes in market or regulatory
complexity and variety continue to increase, product life- requirements [16-20]. The RMS possesses six core
cycle are becoming shorter, markets have become characteristics: scalability (design for capacity changes),
multinational and global competition has been increasing convertibility (design for functionality changes),
rapidly, market conditions fluctuate widely and customers are diagnosability (design for easy diagnostics), customization
consistently demanding high-quality, low-cost products and (flexibility limited to part family), modularity (modular
on-time delivery [5]. components), and integrability (interfaces for rapid
Under these circumstances, during recent years, a new integration) [16].
marketing and manufacturing technique that combines the Despite bringing manufacturing in MTO strategy closer to
flexibility and personalization of custom-made products with manufacturing in MTS strategy from the point of view
the low unit costs associated with mass production occurred, concerning the manufacturing system accordance to product,
namely mass customization [6]. Mass customization is both FMS and RMS still show limitations in this matter:
directly related to MTO/ETO manufacturing strategies. - The modules composing FMS and RMS are each
In principle, the choice between the main strategies, MTS specific to a given operation / part-type, hence they are
and MTO, is decisively influenced by the frequency of actually used only for limited time intervals (20 – 30% of
changing the product, which involves modifications of the system working time),
manufacturing system. From this point of view, MTS strategy - The FMS / RMS adequation to a given product is often
has the advantage of enabling a very good fitting of the hard to be accomplished due to insufficient information
manufacturing system to the product, while in MTO strategy concerning its previous cases of manufacturing, there is not
it is much more difficult to obtain this fitting, this leading to enough experience accumulated.
a performance loss. To be more specific, we should notice So, there still remain a notable challenge: a more efficient
that the product change has certain (significant) costs, adaptation of the manufacturing system when changing the
because it requires to change both the process (hence the product while working in MTO strategy of manufacturing.
process planning, which is not necessarily complicated), and This paper aims to present a conceptual rebuilding of the
the manufacturing system. The accordance of the manufacturing system, aiming to increase its degree of
manufacturing system to new products may be a difficult task, appropriateness to products, by taking advantage from the
especially when is needed to be performed frequently. opportunities brought by the existence of global energy &
During recent years, manufacturing into MTO strategy is information networks. This paper approach is to see the
more and more important due to increasing request for manufacturing system as holonic modular cyber-physical
customized products, personalized solutions, turnkey system, composed by modules of general manufacturing use,
solutions, and integrated solutions, which call for such a whilst system architecture changes according to the
strategy. This led to the need of increasing the efficiency in manufactured product requirements.
adapting the manufacturing system to product change. The Next section introduces the manufacturing function,
answer to this need is the development of modular-type procedure and environment, according to this paper approach.
manufacturing systems: the flexible manufacturing system The third section deals with the proposed model of
(FMS) and the reconfigurable manufacturing system (RMS). architectural holarchy for the next generation manufacturing
A flexible manufacturing system (FMS) is a manufacturing system. The fourth section presents the system operation,
system in which there is some amount of flexibility that while the last section is for conclusion.
allows the system to react in case of changes, whether
predicted or unpredicted [7]-[9]. This flexibility is generally
considered to fall into two categories, which both contain II. FUNCTIONS, PROCEDURE AND ENVIRONMENT
numerous subcategories [10]-[12]. The first category is This paper further actually proposes a conceptual
referred as Routing flexibility, which covers the system's architectural model of next generation manufacturing system.
ability to be changed to produce new product types, and By architectural model of a certain system, we understand
ability to change the order of operations executed on a part
here the picture of system constitutive elements together with
[13], [14]. The second category is called Machine flexibility,
the functional relations among them. In manufacturing
which consists of the ability to use multiple machines to
perform the same operation on a part, as well as the system's system case, the architectural model will be introduced as
ability to absorb large-scale changes, such as in volume, topology of system elements – further referred as holons –
capacity, or capability. Most FMS consist of three main together with the diagram of the relations established among
systems: 1) Work machines, which are often automated CNC them during system operation.
machines, connected by 2) Material handling system, to A. System Function
optimize parts flow, and 3) Central control computer, which
Manufacturing means obtaining products by actions of
controls material movements and machine flow. The main

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International Journal of Modeling and Optimization, Vol. 12, No. 1, February 2022

transforming some raw materials. The transforming actions comprised as the totality of the assets needed for obtain the
lay on natural phenomena (physical, chemical or biological), product, disposed inside an organizationally structured space.
artificially provoked. Each such action requires both energy This environment is surrounded by physical space, cyber
(in order to enable the transformation to take place) and space, social environment, and commercial environment. All
information (in order to control the transformation such as the the assets needed in order to carry out the manufacturing
resulted product has the followed parameters). Both energy process are coming from these spaces and environments.
and information must have given forms and appropriate
values of their features.

Fig. 4. Manufacturing procedure.

CYBER SPACE
Cyber offer
Fig. 3. Manufacturing system function.

COMMERCIAL ENVIRONMENT
SOCIAL ENVIRONMENT

MANUFACTURING
Manufacturing system function F associates to a given task
Modules & New
T, seen as argument, an expected result R, seen as function information knowledge
Human resources

Products orders
output, F(T) = R (Fig. 3). The task is to change product initial
Personnel Next generation Order
state Si into product final state Sf, through a manufacturing
process. The product in its final state is the result. Function manufacturing
execution involves two component activities, taking place Knowhow system
Product
concomitantly: making and learning. Making refers to
Modules & New
actually transforming the product, while learning – to energy knowledge
ascertaining the transformation results. Before execution,
ENVIRONMENT
four issues must be established, namely: what, which refers
to the task definition, who – to the assets needed for task
accomplishment (humans included), how – to the procedure
following to be applied, and when – to the precedence Physical offer
conditions. PHYSICAL SPACE
Fig. 5. Manufacturing environment.
B. System Procedure
Firstly, it should be noticed that the product suffers The commercial environment is the source of products
successive state changes, starting from the initial, order- demands, through orders coming from the market. Product
description state, until it reaches its final state, namely the means, generally speaking, a commercial object, defined by
real-object state (Fig. 4). The chain of product state changes attributes of utility, currently described through an order. In
derives from the manufacturing process chain of stages: our approach the manufacturing system should be configured
design – planning – processing. The mentioned stages are according to manufactured product requirements.
accomplished by personnel from dedicated categories In the physical space we find the global energy network,
(product designer, process planner and machine operator, which can generate and transmit, between any two points
respectively), working on workstations that can be grouped belonging to it, high quantities of energy, but also a wide
in clusters specific to each stage. range of manufacturing modules, able to convert this energy
to required form & features values. Hence, energy is bought
C. System Environment and manufacturing modules are hired from here to compose
Manufacturing takes place in a specific environment and run the manufacturing system.
(Fig. 5). In our vision, manufacturing environment should be

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International Journal of Modeling and Optimization, Vol. 12, No. 1, February 2022

In the cyber space there is the global information network, execution of T0 is accomplished by the functional part F1 of
able to process, store, and transmit huge amounts of the holon 1, while the rest of T task – by the offspring holons.
information of any kind. Similar to energy, the information, The task configuring process may successively repeat,
which is taken from the global network, also requires to be while new generations of holons will be created until, at a
converted by dedicated modules, in order to become usable given time, the initial task T is completely accomplished and
by the manufacturing system. Hereby, the cyber space the result R is delivered. For simplicity, in Fig. 6 we
provides the information needed to control the manufacturing considered only a single offspring holon, 2, which receives
system. from holon 1 the T1 task.
The social environment is approached as a pool of human So, we can state that the general manufacturing holon is
resources, having diverse skills and qualifications, and which composed by two parts: the functional part, accomplishing T0
potentially could be needed as personnel to serve the task, and the structural part, meaning all offspring holons,
manufacturing system. which simultaneously or successively execute the rest of T,
Before starting to manufacture a certain product, the until the result R is delivered.
manufacturing environment is an empty space. Dedicated
B. Functional Dimension of the Architectural Holarchy
assets, specific to the product, are then selected and
temporarily brought in this space by hiring and put together The manufacturing system function (see Fig. 3) retrieves
as manufacturing system. After delivering the required to any holon from system structure. The function F is
quantity of products, the assets are returned and the supported by a set of work-modules. Each of them means an
manufacturing space rebecomes empty, until a new product ensemble of components of general use, able to support a
will be manufactured. process function f (of manufacturing use), comprised as
A given manufacturing system is created by associating to causal relation relating a set of process variables.
a certain order a combination of issues coming from the
physical space, the cyber space, and the social environment,
comprised as available assets. Once again, the next
generation manufacturing system must be understood as an
occasional, temporary structure. 1st order 2nd order 3rd order Order
It should be noticed that the manufacturing system not only (Work-loop) (Work-station) (Work-center)
receives inputs from the surrounding spaces and
environments, but also delivers, as result of its functioning, - Manufacturing holon - Functional relation
new knowledge (to both physical and cyber spaces),
knowhow (to social environment) and, of course, products (to Fig. 7. Functional topology.
commercial environment).
The functional configuration means to configure the
manufacturing system function F, such as it can be supported
III. ARCHITECTURAL HOLARCHY by a certain set of manufacturing modules, having each a
given function f. At first, the set of F1, F2, … functional parts,
A. Manufacturing Holon which describe F, result by its configuring. Then,
manufacturing modules are selected in order to support the
functional parts from above. Each such module supports its
manufacturing function fk.
On one hand, the complexity of holon function depends on
the complexity of its task. On the other hand, holon function
results by composing the component modules functions. The
manufacturing holon complexity is reflected by its order, in
connection with the number of functional parts resulted after
its functional configuring. This further determines the
number of fk module manufacturing functions needed to be
composed for describing these functional parts.
For sample, relation (1) corresponds to a first order holon,
having a single functional part, supported by three modules.
Relation (2) corresponds to a second order holon, with two
functional parts supported by four modules, while (3)
Fig. 6. Manufacturing holon. characterizes a third order holon, with three functional parts
and five modules.
Let us consider a generic manufacturing holon (Fig. 6),
whose task T is to transform the product from an initial state 𝐹 = {𝐹1 } = 𝑓1 ∘ 𝑓2 ∘ 𝑓3 (1)
Si up to a final state Sf. This is accomplished in two stages.
During first stage, the holon 1 configures the received task, 𝐹 𝑓
which is transformed into the task T0, following to be 𝐹 = { 1 } = 𝑓1 ∘ 𝑓2 ∘ { 3 } (2)
𝐹2 𝑓4
executed by itself, and the task T1 that is released. The
variables of the tasks resulted by configuring are different to 𝐹1 𝑓2
the ones of T task. The released task further generates 𝐹 = {𝐹2 } = 𝑓1 ∘ { 𝑓 } (3)
offspring holons, which remain inside holon 1 pocket. The 𝑓3 ∘ { 4 }
𝐹3 𝑓5

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International Journal of Modeling and Optimization, Vol. 12, No. 1, February 2022

D. Architectural Holarchy
C. Structural Dimension of the Architectural Holarchy The two dimensions of the architectural holarchy are
presented in Fig. 9. Each architectural holon is intended to
The structural dimension reveals the content of the
accomplish a manufacturing task, seen as manufacturing
manufacturing holon structural part. This dimension results
process component, and, at the same time, it must provide the
by configuring the task T, configuring that leads to T0 task
tooling for this. As consequence, the manufacturing holons
and a certain number of released tasks.
from all configuring levels, as well as the system in its
wholeness, have dual character – hard (concerning the
functional part) and soft (concerning the structural part).
Starting from here, it should be noticed that between the
manufacturing holons there is actually a crossed holarchy,
involving both functional and structural relations.

IV. SYSTEM OPERATION


Manufacturing system operation consists in the operation
of the component holons. No matter of their position in the
architectural holarchy of the system to which they belong, the
manufacturing holon operation supposes to cyclically run
manufacturing work-cycles by covering, for every such cycle,
several successive steps (Fig. 10).

Fig. 8. Structural dimension.

The Fig. 8 illustrates the structural dimension. The task T


is communicated to Holon 1, of first generation, product state
being S1. Holon 1 configures T, as result, the product being
brought in state S2, while two new tasks issued after this are
transmitted to Holons 2 and 3, from second generation. Each
of these holons configures its received task, the product
reaching the state S3. Both Holons 2 and 3 generate further
tasks for Holons 4 and 5, respective Holons 6, 7 and 8, all five
from third generation. After the last generation of holons
accomplish their task, product state becomes the final one, Sf,
Fig. 10. Holon work-cycle.
and the manufacturing process is ended.
The first step is piloting, which means to establish,
depending on the results r of previous cycle, the task variables
vector c for the current cycle. The piloting module, denoted
by α, delivers the piloting variables through p vector.
The second step is analysis (for workstations from design
and planning stages), respective programming (for
workstations from processing stage). The dedicated module
is β and the result of its operating is the setting vector, q.
The third step is modelling (for workstations from design
stage), simulation (for workstations from planning stage),
respective processing (for workstations from processing
stage). The module in charge to perform this step is ϕ, with
the help of module γ, which drives ϕ. The γ module receives
the vector q from module β and provides the output vector, s.
The γ module enables the communication with both physical
space and commercial environment.
The fourth and last step is synthesis (for workstations from
design and planning stages) respective measuring (for the
workstations from processing stage). The specific module is
δ and it delivers the results vector r, which, at its turn, is
Fig. 9. The two dimensions of architectural holarchy. considered for the next, work-cycle.

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International Journal of Modeling and Optimization, Vol. 12, No. 1, February 2022

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is supposed to be monitored, evaluated and recorded. Hereby, Copyright © 2022 by the authors. This is an open access article distributed
one can speak about a heritage consisting in both new task under the Creative Commons Attribution License which permits unrestricted
information and newly aggregated modules, which represent use, distribution, and reproduction in any medium, provided the original
work is properly cited (CC BY 4.0).
the forms through which the system becomes increasingly
adapted to the manufactured product. Gabriel Frumuşanu was born in Galaţi, Romania,
28/09/1964. A bachelor (1988), the PhD (1999),
habilitation (2016) in industrial engineering at
CONFLICT OF INTERESTS
“Dunărea de Jos” University of Galaţi, Romania.
The authors declare no conflict of interests. He is currently professor at “Dunărea de Jos”
University of Galaţi, Romania, and the head of the
Manufacturing Engineering Department. He
AUTHORS CONTRIBUTION published over 200 scientific articles, some of them
in prestigious journals (The International Journal of
Alexandru Epureanu developed the paper main concepts,
Advanced Manufacturing Technology, Indian Journal of Engineering and
while Gabriel Frumuşanu did the rest of the work. Material Sciences, International Journal of Mechanics, Materials and
Manufacturing). He owns 5 patents. He participated at numerous
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