Building a virtual factory: an integrated design approach to building smart factories

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Emre Yildiz ◽  
Charles Møller
Keyword(s):  
Wind Turbine ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Integrated Design ◽  
Manufacturing Plant ◽  
Design And Development ◽  
Content Type ◽  
Virtual Factory ◽  
Integrated Design Approach ◽  
Analysis Design

Purpose The complexity of manufacturing systems, on-going production and existing constraints on the shop floor remain among the main challenges for the analysis, design and development of the models in product, process and factory domains. The potential of different virtual factory (VF) tools and approaches to support simultaneous engineering for the design, and development of these domains has been addressed in the literature. To fulfil this potential, there is a need for an approach which integrates the product, process and production systems for designing and developing VF and its validation in real-life cases. This paper aims to present an integrated design approach for VF design and development, as well as a demonstration implemented in a wind turbine manufacturing plant. Design/methodology/approach As the research calls for instrumental knowledge to discover the effects of intervention on the operations of an enterprise, design science research methodology is considered to be a well-suited methodology for exploring practical usefulness of a generic design to close the theory–practice gap. The study was planned as an exploratory research activity which encompassed the simultaneous design and development of artefacts and retrospective analysis of the design and implementation processes. The extended VF concept, architecture, a demonstration and procedures followed during the research work are presented and evaluated. Findings The artefacts (models and methods) and the VF demonstrator, which was evaluated by industry experts and scholars based on the role of the VF in improving the performance in the evaluation and reconfiguration of new or existing factories, reduce the ramp-up and design times, supporting management decisions. Preliminary results are presented and discussed. Research limitations/implications The concept VF model, its architecture and general methodology as an integrated design and development approach, can be adopted and used for VF design and development both for discrete and continuous manufacturing plants. The development and demonstration were limited, however, because real-time synchronisation, 3D laser scanning data and a commonly shared data model, to enable the integration of different VF tools, were not achievable. Originality/value The paper presents a novel VF concept and architecture, which integrates product, process and production systems. Moreover, design and development methods of the concept and its demonstration for a wind turbine manufacturing plant are presented. The paper, therefore, contributes to the information systems and manufacturing engineering field by identifying a novel concept and approach to the effective design and development of a VF and its function in the analysis, design and development of manufacturing systems.

Production models of multiple products using a single machine under quality screening and reworking policies

2019 ◽  
Vol 14 (1) ◽  
pp. 232-259 ◽  
Author(s):  
Ata Allah Taleizadeh ◽  
Mahshid Yadegari ◽  
Shib Sankar Sana
Keyword(s):  
Single Machine ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Production Costs ◽  
High Tech ◽  
Screening Process ◽  
Automatic Production ◽  
Content Type ◽  
Economic Production ◽  
Imperfect Items

Purpose The purpose of this study is to formulate two multi-product single-machine economic production quantity (EPQ) models by considering imperfect products. Two policies are assumed to deal with imperfect products: selling them at discount and applying a reworking process. Design/methodology/approach A screening process is used to identify imperfect items during and after production. Selling the imperfect items at a discount is examined in the first model and the reworking policy in the second model. In both models, demand during the production process is satisfied only by perfect items. Data collected from a case company are used to illustrate the performance of the two models. Moreover, a sensitivity analysis is carried out by varying the most important parameters of the models. Findings The case study in this research is used to demonstrate the applicability of the proposed models, i.e. the EPQ model with salvaging and reworking imperfect items. The models are applied to a high-tech un-plasticized polyvinyl chloride (UPVC) doors and windows manufacturer that produces different types of doors and windows. ROGAWIN Co. is a privately owned company that started in 2001 with fully automatic production lines. Finally, the results of applying the different ways of handling the imperfect items are discussed, along with managerial insights. Originality/value In real-world production systems, manufacturing imperfect products is unavoidable. That is why, it is important to make a proper decision about imperfect products to reduce overall production costs. Recently, applying a reworking strategy has gained the most interest when it comes to handling this problem. The principal idea of this research is to maximize the total profit of manufacturing systems by optimizing the period length under some capacity constraints. The proposed models were applied to a company of manufacturing UPVC doors and windows.

Which factors determine the success of strategic niche developments?

2014 ◽  
Vol 14 (1) ◽  
pp. 36-51 ◽  
Author(s):  
Erwin Mlecnik
Keyword(s):  
Success Factors ◽  
Integrated Design ◽  
Enterprise Network ◽  
Content Type ◽  
Design Concepts ◽  
Architectural Innovation ◽  
Integrated Design Approach ◽  
Network Composition ◽  
Market Niche ◽  
Regional Enterprise

Purpose – The study ' s purpose is to review and discuss limitations of “strategic niche management” (SNM) success factors in relation to the experiences of an enterprise network to improve niche development for integrated design concepts. Design/methodology/approach – The emergence of a successful passive house innovation network in the Flemish Region is described. The innovation journey of the network is related to success factors detected in SNM literature regarding market niche development. Findings – The study identifies additional success factors for systemic innovation, such as involving small- and medium-sized innovators and demonstration projects and using a dedicated regional enterprise network. Research limitations/implications – The qualitative analysis specifically reflected on SNM success factors such as envisioning, learning, and network composition and formation. The study confirms the importance of these success factors by means of one detailed innovation journey. It identifies additional success factors and discusses opportunities to improve the relation of SNM literature with other seminal fields. Practical implications – Government seed money is important in providing a breakthrough in enterprise network initiatives. A focus on architectural innovation instead of technology innovation is to be preferred for stimulating integrated design concepts. Originality/value – The paper addresses the relevance and limitations of SNM success factors during the formation of enterprise networks. The study shows how an integrated design approach was used to cluster innovation opportunities and to inspire innovation development and collaboration for know-how development between multiple players.

Assessing the implementation feasibility of intelligent production systems based on cloud computing, industrial internet of things and business social networks

Kybernetes ◽  
2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jiabao Sun ◽  
Ting Yang ◽  
Zhiying Xu
Keyword(s):  
Social Networks ◽  
Cloud Computing ◽  
Internet Of Things ◽  
Resource Sharing ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Industrial Internet Of Things ◽  
Content Type ◽  
Industrial Internet ◽  
The Impact

PurposeThe increasing demands for customized services and frequent market variations have posed challenges to managing and controlling the manufacturing processes. Despite the developments in literature in this area, less consideration has been devoted to the growth of business social networks, cloud computing, industrial Internet of things and intelligent production systems. This study recognizes the primary factors and their implications for intelligent production systems' success. In summary, the role of cloud computing, business social network and the industrial Internet of things on intelligent production systems success has been tested.Design/methodology/approachIntelligent production systems are manufacturing systems capable of integrating the abilities of humans, machines and processes to lead the desired manufacturing goals. Therefore, identifying the factors affecting the success of the implementation of these systems is necessary and vital. On the other hand, cloud computing and the industrial Internet of things have been highly investigated and employed in several domains lately. Therefore, the impact of these two factors on the success of implementing intelligent production systems is examined. The study is descriptive, original and survey-based, depending on the nature of the application, its target and the data collection method. Also, the introduced model and the information collected were analyzed using SMART PLS. Validity has been investigated through AVE and divergent validity. The reliability of the study has been checked out through Cronbach alpha and composite reliability obtained at the standard level for the variables. In addition, the hypotheses were measured by the path coefficients and R2, T-Value and GOF.FindingsThe study identified three variables and 19 sub-indicators from the literature associated that impact improved smart production systems. The results showed that the proposed model could describe 69.5% of the intelligence production systems' success variance. The results indicated that business social networks, cloud computing and the industrial Internet of things affect intelligent production systems. They can provide a novel procedure for intelligent comprehensions and connections, on-demand utilization and effective resource sharing.Research limitations/implicationsStudy limitations are as below. First, this study ignores the interrelationships among the success of cloud computing, business social networks, Internet of things and smart production systems. Future studies can consider it. Second, we only focused on three variables. Future investigations may focus on other variables subjected to the contexts. Ultimately, there are fewer experimental investigations on the impact of underlying business social networks, cloud computing and the Internet of things on intelligent production systems' success.Originality/valueThe research and analysis outcomes are considered from various perspectives on the capacity of the new elements of Industry 4.0 for the manufacturing sector. It proposes a model for the integration of these elements. Also, original and appropriate guidelines are given for intelligent production systems investigators and professionals' designers in industry domains.

An integrated design approach for class-based block stacked warehouse

Facilities ◽  
2019 ◽  
Vol 37 (13/14) ◽  
pp. 919-941
Author(s):  
Rakesh Venkitasubramony ◽  
Gajendra Kumar Adil
Keyword(s):  
Material Handling ◽  
Integrated Design ◽  
Operating Conditions ◽  
Cost Ratio ◽  
Single Class ◽  
Content Type ◽  
Handling Cost ◽  
Integrated Design Approach ◽  
Space Cost ◽  
Number Of Classes

Purpose This paper aims to develop an approach to design a warehouse that uses class-based storage policy in a way that minimizes both space cost and material handling cost. Design/methodology/approach The authors argue for and develop an optimization model for joint determination of lane depth, lateral width and product partitions for minimizing the sum of handling and space costs. In doing so, the assumption of perfect sharing is also relaxed. Using computational experiments, the authors characterize the operating conditions based on pick density and cost ratio. The authors further outline an approach to decide the conditions under which it is advantageous to implement multiple classes. Findings More classes are preferred when both the pick density and cost ratio are higher and vice versa. Factors such as demand skewness, lane depth and stacking height affect the space-sharing dynamics. Practical implications The paper gives the practical insights on when the conditions under which it is advisable to partition a warehouse into a certain number of classes instead of maintaining and when to maintain as a single-class block. It also gives a method to estimate the space-sharing factor, given a combination of operating parameters. Originality/value Very few studies have seen class-based storage policy in the context of block stacked warehouse layout. Further, block stacking designs have mostly been approached with the objective of minimizing just the space cost. This study contributes to the literature by developing an integrated model, which has the practical utility.

A model for reliability analysis of multi-state manufacturing systems

2014 ◽  
Vol 31 (8) ◽  
pp. 938-949 ◽  
Author(s):  
Seyed Ahmad Niknam ◽  
Rapinder Sawhney
Keyword(s):  
Reliability Analysis ◽  
System Reliability ◽  
Design Methodology ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Production Systems ◽  
Case Scenario ◽  
Worst Case ◽  
Content Type ◽  
Proposed Model

Purpose – The purpose of this paper is to investigate the reliability analysis of a multi-state manufacturing system with different performance levels. In, fact, reliability assessment of manufacturing systems gives a reasonable demonstration of system performance. Design/methodology/approach – This research utilizes a multi-state system reliability analysis to develop a new metric for evaluating production systems. Findings – The proposed model provides a sensible measure to assess the system situation against the best-case scenario of a production line. Originality/value – The proposed model incorporates not only failures that stop production but also deals with partial failures where the system continues to operate at reduced performance rates. The analyses are represented in a best-case vs worst-case situation. Each of these cases provides insight for managers with respect to planning operation and maintenance activities.

Process Planning and Decentralised Process Control for Cybertronic Production Systems

2015 ◽  
Vol 794 ◽  
pp. 486-493 ◽  
Author(s):  
Christian Weidig ◽  
Chantal Steimer ◽  
Jan Christian Aurich
Keyword(s):  
Process Planning ◽  
Development Process ◽  
Production Systems ◽  
Integrated Design ◽  
Design Phase ◽  
Production Planning And Control ◽  
Design And Development ◽  
Collaborative Activity ◽  
Planning And Control ◽  
And Control

Cybertronic systems which augment mechatronic basis systems by means of communication, collaboration and intelligence are proposed to be utilised to develop next generation production systems. A model-based development process is proposed to enable integrated design and development of the product and the production system. This paper will highlight the importance of process planning as collaborative activity within the integrated design and development process. A concept will be introduced how process planning can be conducted for cybertronic production systems, considering decentralised production planning and control already during the design phase.

The impact of reconfigurability on the operational performance of manufacturing systems

2019 ◽  
Vol 31 (1) ◽  
pp. 145-168 ◽  
Author(s):  
Isabela Maganha ◽  
Cristovao Silva ◽  
Luis Miguel D. F. Ferreira
Keyword(s):  
Manufacturing Systems ◽  
Production Systems ◽  
Operational Performance ◽  
Future Research ◽  
Reconfigurable Manufacturing ◽  
Manufacturing Companies ◽  
Clustering Methods ◽  
Content Type ◽  
Core Characteristics ◽  
The Impact

Purpose The purpose of this paper is to investigate the current level of reconfigurability implementation and its impact on manufacturing systems’ operational performance empirically. Design/methodology/approach This study is based on a questionnaire survey. Statistical analysis procedures were adopted to accomplish its objectives, namely, clustering methods based on cluster centroids. An ANOVA analysis was used to test for cluster differences among the variables. Findings The results show that the manufacturing companies surveyed can be divided into three clusters, with different levels of reconfigurability implemented. The implementation of the core characteristics of reconfigurability depends on the product’s complexity and demand variability, in terms of volume and product mix, as these have an impact on the operational performance, in terms of quality, delivery and flexibility. Research limitations/implications The data for this survey were collected from manufacturing companies based in Portugal. Therefore, the replication of this questionnaire in other countries is recommended for future research to confirm its findings. Practical implications The questionnaire developed could be used by managers to assess the level of reconfigurability of their production systems and for internal/external benchmarking. The findings may help managers to decide which core characteristics should be implemented in their manufacturing systems. Originality/value The majority of the research addressing performance issues in reconfigurable manufacturing systems has been applied to case studies. This research reports an empirical investigation using a questionnaire-based methodology to provide generalisable empirical evidence.

A methodology for the reconfiguration process in manufacturing systems

2014 ◽  
Vol 25 (6) ◽  
pp. 891-915 ◽  
Author(s):  
Ibrahim H. Garbie
Keyword(s):  
System Design ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Production Systems ◽  
Systems Design ◽  
Production Volume ◽  
Plant Layout ◽  
Content Type ◽  
Handling System

Purpose – The purpose of this paper is to propose a “Reconfiguration Methodology” in manufacturing systems that they can become more economically sustainable and can operate efficiency and effectively. This methodology will allow customized flexibility and capacity not only in producing a variety of products (parts) and with changing market demands, but also in changing and reengineering the system itself. Design/methodology/approach – Reconfigurable manufacturing system (RMS) is a philosophy or strategy which was introduced during the last decade to achieve agility in manufacturing systems. Until now, the RMS philosophy was based changing activities such routing, planning, programming of machines, controlling, scheduling, and physical layout or materials handling system. But the RMS concept can be based on the needed reconfiguration level (NRL), operational status of production systems, and new circumstances (NC). The NRL measure is based on the agility level of the manufacturing systems which is based on technology, people, management, and manufacturing strategies. The components of the manufacturing system design (MSD) consist of production system design, plant layout system, and material handling system. Operational status of production systems includes machine capability (flexibility) and capacity (reliability), production volume or demand, and material handling equipment in addition to the plant layout. The NC are also consisting of new product, developing the existing ones, and changing in demand. Findings – Reconfiguration manufacturing systems from one period to another period is highly desired and is considered as a novel manufacturing philosophy and/or strategy toward creating new sustainable manufacturing systems. A new reconfiguration methodology for the manufacturing systems will be analyzed and proposed. Two Case studies will be introduced. Originality/value – The suggestion of a new methodology of reconfiguration including the NRL (configurability index) and the operational status of manufacturing systems with respect to any circumstance is highly considered. The reconfiguration methodology also provides a framework for sustainability in the manufacturing area which mainly focussed on manufacturing systems design.

scholarly journals Increasing Resilience of Production Systems by Integrated Design

2021 ◽  
Vol 11 (18) ◽  
pp. 8457
Author(s):  
Steffen Ihlenfeldt ◽  
Tim Wunderlich ◽  
Marian Süße ◽  
Arvid Hellmich ◽  
Christer-Clifford Schenke ◽  
...  
Keyword(s):  
Supply Chain ◽  
Production Planning ◽  
Business Process ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Discrete Event ◽  
Integrated Design ◽  
Process Models ◽  
Automation Systems ◽  
Business Process Execution

The paper presents a framework for considering resilience as an integrated aspect in the design of manufacturing systems. The framework comprises methods for the assessment of resilience, supply chain and production planning, flexible execution and control as well as modular and skill-based methods for automation systems. A basic classification of risk categories and their impacts on manufacturing environments is given so that a concept of reconfigurable and robust production systems can be derived. Based on this, main characteristics and concepts of resilience are applied to manufacturing systems. As a lever of increased resilience on business and supply chain level, options for synchronized production planning are presented in a discrete event simulation. Furthermore, a concept to increase resilience on the level of business process execution is investigated, allowing manufacturing tasks to be rescheduled during runtime using a declarative approach to amend conventional business process models.

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