scholarly journals Automation Pyramid as Constructor for a Complete Digital Twin, Case Study: A Didactic Manufacturing System

Sensors ◽  
2021 ◽  
Vol 21 (14) ◽  
pp. 4656
Author(s):  
Edwin Mauricio Martinez ◽  
Pedro Ponce ◽  
Israel Macias ◽  
Arturo Molina
Keyword(s):  
Industry 4.0 ◽  
Manufacturing System ◽  
Industrial Process ◽  
Operating Conditions ◽  
Shop Floor ◽  
Virtual Model ◽  
Digital Twin ◽  
Disruptive Technologies ◽  
Pyramid Model

Nowadays, the concept of Industry 4.0 aims to improve factories’ competitiveness. Usually, manufacturing production is guided by standards to segment and distribute its processes and implementations. However, industry 4.0 requires innovative proposals for disruptive technologies that engage the entire production process in factories, not just a partial improvement. One of these disruptive technologies is the Digital Twin (DT). This advanced virtual model runs in real-time and can predict, detect, and classify normal and abnormal operating conditions in factory processes. The Automation Pyramid (AP) is a conceptual element that enables the efficient distribution and connection of different actuators in enterprises, from the shop floor to the decision-making levels. When a DT is deployed into a manufacturing system, generally, the DT focuses on the low-level that is named field level, which includes the physical devices such as controllers, sensors, and so on. Thus, the partial automation based on the DT is accomplished, and the information between all manufacturing stages could be decremented. Hence, to achieve a complete improvement of the manufacturing system, all the automation pyramid levels must be included in the DT concept. An artificial intelligent management system could create an interconnection between them that can manage the information. As a result, this paper proposed a complete DT structure covering all automation pyramid stages using Artificial Intelligence (AI) to model each stage of the AP based on the Digital Twin concept. This work proposes a virtual model for each level of the traditional AP and the interactions among them to flow and control information efficiently. Therefore, the proposed model is a valuable tool in improving all levels of an industrial process. In addition, It is presented a case study where the DT concept for modular workstations underpins the development of technologies within the framework of the Automation Pyramid model is implemented into a didactic manufacturing system.

scholarly journals TO SUPPORT IOT COLLABORATIVE EXPRESSIVENESS ON THE SHOP FLOOR

2021 ◽  
Vol 1 ◽  
pp. 3149-3158
Author(s):  
Álvaro Aranda Muñoz ◽  
Yvonne Eriksson ◽  
Yuji Yamamoto ◽  
Ulrika Florin ◽  
Kristian Sandström
Keyword(s):  
Industry 4.0 ◽  
Shop Floor ◽  
Manufacturing Companies ◽  
Technical Aspects ◽  
Industrial Landscape ◽  
The Future ◽  
New Research ◽  
Empirical Material

AbstractThe availability of new research for IoT support and the human-centric perspective of industry 4.0 opens a gap to support operators in unleashing their creativity so they can provide improvements opportunities with IoT technology. This paper presents a case-study carried out in four Swedish manufacturing companies, where four different workshops were facilitated to support operators in the conceptualization of manufacturing improvements with IoT technologies. The empirical material gathered during these workshops has been analyzed in five different reflective sessions and discussed in light of previous research from industry 4.0, operators, and IoT support. Results indicate that operators can collaboratively create conceptual IoT solutions and that expressiveness in communicating their ideas and needs using IoT technology is more relevant than technical aspects and details of their proposed IoT solutions. This technological expressiveness is identified as a necessary skill to be cultivated on the shop floor and can potentially contribute to making a more effective and socially sustainable industrial landscape in the future.

Corporate survival in Industry 4.0 era: the enabling role of lean-digitized manufacturing

2019 ◽  
Vol 31 (1) ◽  
pp. 1-30 ◽  
Author(s):  
Morteza Ghobakhloo ◽  
Masood Fathi
Keyword(s):  
Enterprise Resource Planning ◽  
Industry 4.0 ◽  
Manufacturing System ◽  
Resource Planning ◽  
Security And Privacy ◽  
Social Implications ◽  
Future Research ◽  
Manufacturing Firm ◽  
Content Type

Purpose The purpose of this paper is to demonstrate how small manufacturing firms can leverage their Information Technology (IT) resources to develop the lean-digitized manufacturing system that offers sustained competitiveness in the Industry 4.0 era. Design/methodology/approach The study performs an in-depth five years case study of a manufacturing firm, and reports its journey from failure in the implementation of enterprise resource planning to its success in integrating IT-based technology trends of Industry 4.0 with the firm’s core capabilities and competencies while pursuing manufacturing digitization. Findings Industry 4.0 transition requires the organizational integration of many IT-based modern technologies and the digitization of entire value chains. However, Industry 4.0 transition for smaller manufacturers can begin with digitization of certain areas of operations in support of organizational core strategies. The development of lean-digitized manufacturing system is a viable business strategy for corporate survivability in the Industry 4.0 setting. Research limitations/implications Although the implementation of lean-digitized manufacturing system is costly and challenging, this manufacturing strategy offers superior corporate competitiveness in the long run. Since this finding is rather limited to the present case study, assessing the business value of lean-digitized manufacturing system in a larger scale research context would be an interesting avenue for future research. Practical implications Industry 4.0 transition for typical manufacturers should commensurate with their organizational, operational and technical particularities. Digitization of certain operations and processes, when aligned with the firm’s core strategies, capabilities and procedures, can offer superior competitiveness even in Industry 4.0 era, meaning that the strategic plan for successful Industry 4.0 transition is idiosyncratic to each particular manufacturer. Social implications Manufacturing digitization can have deep social implications as it alters inter- and intra-organizational relationships, causes unemployment among low-skilled workforce, and raises data security and privacy concerns. Manufacturers should take responsibility for their digitization process and steer it in a direction that simultaneously safeguards economic, social and environmental sustainability. Originality/value The strategic roadmap devised and employed by the case company for managing its digitization process can better reveal what manufacturing digitization, mandated by Industry 4.0, might require of typical manufacturers, and further enable them to better facilitate their digital transformation process.

A Digital Twin Concept for Manufacturing Systems

2018 ◽  
Author(s):  
Wesley Ellgass ◽  
Nathan Holt ◽  
Hector Saldana-Lemus ◽  
Julian Richmond ◽  
Ali Vatankhah Barenji ◽  
...  
Keyword(s):  
Virtual Reality ◽  
Real Time ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Virtual Space ◽  
Smart Manufacturing ◽  
Shop Floor ◽  
Digital Twin ◽  
Physical Resources ◽  
Virtual Resources

With the developments and applications of the advanced information technologies such as cloud computing, internet of thing, artificial intelligence and virtual reality, industry 4.0 and smart manufacturing era are coming. In this respect, one of the specific challenges is to achieve a connection of physical resources on the shop floor with virtual resources, for real-time response, real time process optimization, and simulation, which is merged by big data problem. In this respect, Digital Twins (DT) concept is introduced as a key technology, which includes physical resources, virtual resources, service system, and digital twin data. DT considers current condition of physical resource and prediction of future events to make a responsive decision. However, due to the complexity of building a digital equivalent in virtual space to its physical counterpart, very little applications have been developed with this purpose, especially in the industrial manufacturing area. Therefore, the types of data and technology required to build the DT for a manufacturing system are presented in this work, trying to develop a framework of DT based manufacturing system, which is supported by the virtual reality for virtualization of physical resources.

scholarly journals The Digital Chasm between an Idea and Its Implementation in Industry 4.0—The Case Study of a Polish Service Company

2021 ◽  
Vol 13 (16) ◽  
pp. 8834
Author(s):  
Katarzyna Jasińska
Keyword(s):  
Conceptual Model ◽  
Industry 4.0 ◽  
Business Case ◽  
Operating Conditions ◽  
Research Trend ◽  
Theoretical Ground ◽  
Empirical Verification ◽  
Theoretical Part ◽  
Innovation Potential

Digitization in Industry 4.0 is a key trend in a modern company’s development. However, business practice shows that digitization can be associated not only with the prospect of development but with numerous limitations that a company may struggle with. The goal of this manuscript is to verify the existence and identify of the management gaps that lead to formation of digitization problems in companies under the conditions of Industry 4.0. Management gap is understood here as a set of discontinuities, identified within management functions, which result in specific problems in the implementation of digitization projects. In general, this aspect is omitted in the literature on the subject, which focuses on benefits of implementing Industry 4.0 technology. The chosen goal of the manuscript is part of the research trend related to the identification of general digitization problems and to a company’s development, taking into account the use of technological solutions, as well as to the scope of research on the problems of implementing ICT projects. The development of an enterprise is understood as the ability to improve an organization both in the face of internal challenges and the environmental with maintaining innovation potential. The research structure is based on the construction of a conceptual model of management gaps and its empirical verification. In the theoretical part, the chosen research method is analysis of literature from the last 20 years and in the practical part analysis of a business case supplemented with an in-depth interview conducted among the management of the analyzed company. In the theoretical part, the article defines basic concepts related to Industry 4.0 and digitization of companies. It presents the place and role of digitization and its impact on the blurring of boundaries of traditional management layers. Based on these considerations, a conceptual model is developed defining management gaps within which problems of digitization of enterprises are indicated. The practical part of the article presents an empirical verification of the existence of the formulated management gaps on the basis of a business case analysis. The case study describes a mass, geographically dispersed implementation of the application for 34,000 users, which is the result of the implementation of the digitization strategy. Conclusions were formulated in the last part of the manuscript. On the theoretical ground, the analysis confirms that the process of digitization in an enterprise under the conditions of Industry 4.0 is related to blurring the boundaries of operational, tactical and strategic management. The premises of the said blur are identifiable and appear in each of the above-mentioned layers. On the practical ground, the existence of reasons for blurring the boundaries of management is related to the need to adapt the organization to the new operating conditions related to Industry 4.0. The strategic activities should be targeted at determining the directions of company improvement, which should precede the efforts to implement advanced solutions in the field of Industry 4.0. This approach allows providing a sustainable company development with the possibility of creating short-term effects and maintaining a long-term growth perspective.

scholarly journals Industrial consumers’ electricity market participation options: a case study of an industrial cooling process in Denmark

2021 ◽  
Vol 4 (S2) ◽  
Author(s):  
Nicolas Fatras ◽  
Zheng Ma ◽  
Bo Nørregaard Jørgensen
Keyword(s):  
Electricity Markets ◽  
Electricity Market ◽  
Market Price ◽  
Industrial Process ◽  
Operating Conditions ◽  
Comparative Approach ◽  
Market Participation ◽  
Cooling Process ◽  
Process Flexibility

AbstractIn a deregulated market context, industrial consumers often have multiple market participation options available to bid their flexible consumption in electricity markets and thereby reduce their electricity bill. Yet most participation strategies for demand response are developed in a fixed and predefined set of submarkets. Meanwhile, little literature has compared multiple market options for market participants. Therefore, this paper proposes a comparative approach between available market options to evaluate savings from different market participation options. More specifically, this study implements an optimisation program in Python to investigate the impacts of changes in an industrial process’ flexibility on savings with different market participation options. The optimisation program is tested with a case study of an industrial cooling process in three Danish submarkets (day-ahead, intraday, and regulating power markets). The market participation options are formed by different combinations of these three submarkets, and the type and amount of process flexibility are varied by changing time and load constraints in the optimisation program. The results show that bidding in market options with multiple submarkets yields higher savings than single-market bidding, but that increases in available flexibility impact savings in each market option differently. Increased flexibility will only bring additional savings if it allows to take further advantage of price variations in a market option. Additionally, increases in savings with flexibility depend on the considered type of flexibility. These changes in relative savings between market options at each flexibility level imply that the optimal market option is not a static choice for a process with variable operating conditions. The optimal market option for an industrial consumer depends not only on market price signals, but also on the type and amount of available flexibility.

scholarly journals Development of a Smart Cyber-Physical Manufacturing System in the Industry 4.0 Context

2019 ◽  
Vol 9 (16) ◽  
pp. 3325 ◽  
Author(s):  
Tran ◽  
Park ◽  
Nguyen ◽  
Hoang
Keyword(s):  
Radio Frequency Identification ◽  
Mass Production ◽  
Industry 4.0 ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Shop Floor ◽  
Self Healing ◽  
Manufacturing Environment ◽  
Information And Communication ◽  
Ict Infrastructure

The complexity and dynamic of the manufacturing environment are growing due to the changes of manufacturing demand from mass production to mass customization that require variable product types, small lot sizes, and a short lead-time to market. Currently, the automatic manufacturing systems are suitable for mass production. To cope with the changes of the manufacturing environment, the paper proposes the model and technologies for developing a smart cyber-physical manufacturing system (Smart-CPMS). The transformation of the actual manufacturing systems to the Smart-CPMS is considered as the next generation of manufacturing development in Industry 4.0. The Smart-CPMS has advanced characteristics inspired from biology such as self-organization, self-diagnosis, and self-healing. These characteristics ensure that the Smart-CPMS is able to adapt with continuously changing manufacturing requirements. The model of Smart-CPMS is inherited from the organization of living systems in biology and nature. Consequently, in the Smart-CPMS, each resource on the shop floor such as machines, robots, transporters, and so on, is an autonomous entity, namely a cyber-physical system (CPS) which is equipped with cognitive capabilities such as perception, reasoning, learning, and cooperation. The Smart-CPMS adapts to the changes of manufacturing environment by the interaction among CPSs without external intervention. The CPS implementation uses the cognitive agent technology. Internet of things (IoT) with wireless networks, radio frequency identification (RFID), and sensor networks are used as information and communication technology (ICT) infrastructure for carrying out the Smart-CPMS.

Digital Twin of manufacturing systems: a case study on increasing the efficiency of reconfiguration

2020 ◽  
Vol 68 (6) ◽  
pp. 435-444 ◽  
Author(s):  
Behrang Ashtari Talkhestani ◽  
Michael Weyrich
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
Added Value ◽  
Future Research ◽  
System Availability ◽  
Qualitative And Quantitative ◽  
Digital Twin ◽  
System A ◽  
Set Up

AbstractThe added value of a Digital Twin for reconfiguring manufacturing systems promises an increase in system availability, a reduction in set-up and conversion times and enables the manufacturing of customer-specific products. To evaluate this claim, this paper selects an architecture of the Digital Twin and realizes it on the basis of an application scenario for a cyber-physical manufacturing system. A case study is used to test the reconfiguration of a manufacturing system by comparing two different methods, one without and one with use of the Digital Twin. In this paper, the process steps of both reconfigurations are described and discussed in detail and a qualitative and quantitative evaluation of the reconfiguration results is presented. Finally, this paper gives an outlook on future research on intelligent automation of manufacturing systems using the Digital Twin.

scholarly journals A Digital Twin Approach for the Improvement of an Autonomous Mobile Robots (AMR’s) Operating Environment—A Case Study

Sensors ◽  
2021 ◽  
Vol 21 (23) ◽  
pp. 7830
Author(s):  
Paweł Stączek ◽  
Jakub Pizoń ◽  
Wojciech Danilczuk ◽  
Arkadiusz Gola
Keyword(s):  
Real Life ◽  
Autonomous Mobile Robots ◽  
Shop Floor ◽  
Operating Environment ◽  
Digital Twin ◽  
Digital Twins ◽  
Management Processes ◽  
Physical Testing ◽  
Test Scenarios

The contemporary market creates a demand for continuous improvement of production, service, and management processes. Increasingly advanced IT technologies help designers to meet this demand, as they allow them to abandon classic design and design-testing methods in favor of techniques that do not require the use of real-life systems and thus significantly reduce the costs and time of implementing new solutions. This is particularly important when re-engineering production and logistics processes in existing production companies, where physical testing is often infeasible as it would require suspension of production for the testing period. In this article, we showed how the Digital Twin technology can be used to test the operating environment of an autonomous mobile robot (AMR). In particular, the concept of the Digital Twin was used to assess the correctness of the design assumptions adopted for the early phase of the implementation of an AMR vehicle in a company’s production hall. This was done by testing and improving the case of a selected intralogistics task in a potentially “problematic” part of the shop floor with narrow communication routes. Three test scenarios were analyzed. The results confirmed that the use of digital twins could accelerate the implementation of automated intralogistics systems and reduce its costs.

scholarly journals The Benefits in Coupling Exergy Analysis and Life Cycle Assessment in the Context of Sustainable Manufacturing for Industry 4.0: A Real Industrial Case

2021 ◽  
Vol 39 (1) ◽  
pp. 12-22
Author(s):  
Valeria Selicati ◽  
Nicola Cardinale
Keyword(s):  
Life Cycle ◽  
Industry 4.0 ◽  
Manufacturing System ◽  
Sustainable Manufacturing ◽  
Life Cycle Thinking ◽  
Monitoring And Control ◽  
System Failures ◽  
Cost Of Energy ◽  
And Control

The continuously rising cost of energy and its impact on environmental policy are the primary boost for industry to stay global competitive in terms of maximizing productivity and raising operational costs. The prevailing goal in the height of industry 4.0 is to inspect and optimize manufacturing processes. The challenge is to consider thermodynamics as simulation and modelling solution that enables improve energy production and help efforts to shift towards a smart factory. The aim of this paper is to demonstrate that using thermodynamic models as Exergy and Life Cycle thinking provides major benefits since it allows evaluation results more reliable and aims to develop a retrofitting approach that enhances the process to avoid system failures efficiently. Any practitioner may pick suitable sensing networks in line with Industry 4.0, in order to develop a monitoring and control infrastructure and improve any manufacturing system, getting it smarter. In this article, an explanatory case study on the production process of an Italian SME will be presented and discussed.

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