Smart Manufacturing: State-of-the-Art Review in Context of Conventional and Modern Manufacturing Process Modeling, Monitoring and Control

2018 ◽  
Author(s):  
Parikshit Mehta ◽  
Prahalada Rao ◽  
Zhenhua (David) Wu ◽  
Vukica Jovanović ◽  
Olga Wodo ◽  
...  
Keyword(s):  
Process Modeling ◽  
Manufacturing Process ◽  
Industry 4.0 ◽  
Data Science ◽  
State Of The Art ◽  
Smart Manufacturing ◽  
Future Research ◽  
High Tech ◽  
Monitoring And Control ◽  
And Control

With the advances in automation technologies, data science, process modeling and process control, industries worldwide are at the precipice of what is described as the fourth industrial revolution (Industry 4.0). This term was coined in 2011 by the German federal government to define their strategy related to high tech industry [1], specifically multidisciplinary sciences involving physics-based process modeling, data science and machine learning, cyber-physical systems, and cloud computing coming together to drive operational excellence and support sustainable manufacturing. The boundaries between Information Technologies (I.T.) and Operation Technologies (O.T.) are quickly dissolving and the opportunities for taking lab-scale manufacturing science research to plant and enterprise wide deployment are better than ever before. There are still questions to be answered, such as those related to the future of manufacturing research and those related to meeting such demands with a highly skilled workforce. Furthermore, in this new environment it is important to understand how process modeling, monitoring, and control technologies will be transformed. The aim of the paper is to provide state-of-the-art review of Smart Manufacturing and Industry 4.0 within scope of process monitoring, modeling and control. This will be accomplished by giving comprehensive background review and discussing application of smart manufacturing framework to conventional (machining) and advanced (additive) manufacturing process case studies. By focusing on process modeling, monitoring, analytics, and control within the larger vision of Industry 4.0, this paper will provide a directed look at the efforts in these areas, and identify future research directions that would accelerate the pace of implementation in advanced manufacturing industry.

A Review of Manufacturing Process Control

2020 ◽  
Vol 142 (11) ◽  
Author(s):  
Robert G. Landers ◽  
Kira Barton ◽  
Santosh Devasia ◽  
Thomas Kurfess ◽  
Prabhakar Pagilla ◽  
...  
Keyword(s):  
Process Control ◽  
Manufacturing Process ◽  
Raw Materials ◽  
The Body ◽  
Smart Manufacturing ◽  
Future Research ◽  
Manufacturing Processes ◽  
Monitoring And Control ◽  
Substantial Impact ◽  
Manufacturing Process Control

Abstract Smart manufacturing concepts are being integrated into all areas of manufacturing industries, from the device level (e.g., intelligent sensors) to the efficient coordination of business units. Vital components of any manufacturing enterprise are the processes that transform raw materials into components, assemblies, and finally products. It is the manufacturing process where smart manufacturing is poised to make substantial impact through process control, i.e., the intelligent manipulation of process variables to increase operation productivity and part quality. This article discusses three areas of manufacturing process control: control-oriented modeling, sensing and monitoring, and the design and construction of controllers. The discussion will center around the following manufacturing processes: machining, grinding, forming, joining, and additive. While many other important processes exist, the discussions of control of these mechanical manufacturing processes will form a framework commonly applied to these processes and the discussion will form a framework to provide insights into the modeling, monitoring, and control of manufacturing processes more broadly. Conclusions from these discussions will be drawn, and future research directions in manufacturing process control will be provided. This article acknowledges the contributions of two of the pioneering researchers in this field, Dr. Yoram Koren and Dr. Galip Ulsoy, who have made seminal contributions in manufacturing process control and continued to build the body of knowledge over the course of many decades.

Fractal Pattern Recognition of Image Profiles for Manufacturing Process Monitoring and Control

2018 ◽  
Author(s):  
Farhad Imani ◽  
Bing Yao ◽  
Ruimin Chen ◽  
Prahalada Rao ◽  
Hui Yang
Keyword(s):  
Additive Manufacturing ◽  
Process Monitoring ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Experimental Studies ◽  
Precision Machining ◽  
Monitoring And Control ◽  
Process Monitoring And Control ◽  
Ultra Precision ◽  
And Control

Nowadays manufacturing industry faces increasing demands to customize products according to personal needs. This trend leads to a proliferation of complex product designs. To cope with this complexity, manufacturing systems are equipped with advanced sensing capabilities. However, traditional statistical process control methods are not concerned with the stream of in-process imaging data. Also, very little has been done to investigate nonlinearity, irregularity, and inhomogeneity in image stream collected from manufacturing processes. This paper presents the multifractal spectrum and lacunarity measures to characterize irregular and inhomogeneous patterns of image profiles, as well as detect the hidden dynamics of the underlying manufacturing process. Experimental studies show that the proposed method not only effectively characterizes the surface finishes for quality control of ultra-precision machining but also provides an effective model to link process parameters with fractal characteristics of in-process images acquired from additive manufacturing. This, in turn, will allow a swift response to processes changes and consequently reduce the number of defective products. The proposed fractal method has strong potentials to be applied for process monitoring and control in a variety of domains such as ultra-precision machining, additive manufacturing, and biomanufacturing.

scholarly journals Epoxy tooling: Technologies, developments, sustainability and future interest to industry 4.0

2021 ◽  
pp. 096739112110598
Author(s):  
Gorka Díez-Barcenilla ◽  
José L Gómez-Alonso ◽  
Koldo Gondra ◽  
Ester Zuza
Keyword(s):  
Industry 4.0 ◽  
Ad Hoc ◽  
Cost Effective ◽  
Smart Manufacturing ◽  
Future Research ◽  
Cooling Channels ◽  
Waste Reuse ◽  
Tool Performance ◽  
Rapid Manufacture ◽  
The Cost

The technology of epoxy tooling, at present under continuous development, is used for the rapid manufacture of cost-effective tools for small batch production. It is a valid alternative with no need for expensive investment in metallic moulds for the development of new products. Current investigations are focused on improvements to the production system, improved tool performance, the cost reduction of moulds and tool manufacturing sustainability. In this paper, both the advantages and the disadvantages of epoxy tooling in injection moulding, wax injection, metal stamping and hot embossing are compared with conventional techniques. Following a brief introduction of rapid tooling technologies, the latest advances of epoxy tooling and their implementation in different manufacturing processes are all analysed. These developments refer to the production of new ad-hoc epoxy composites, increased productivity using conformal cooling channels, the reduction of the tooling manufacturing costs through waste reuse and the emerging industry 4.0 technologies for smart manufacturing and tooling. The main objective is to identify both the challenges facing epoxy tooling techniques and future research directions.

Smart Manufacturing and Industry 4.0: A Preliminary Approach in Structuring a Conceptual Framework

2021 ◽  
Vol 18 ◽  
pp. 27-36
Author(s):  
Eleni Didaskalou ◽  
Petros Manesiotis ◽  
Dimitrios Georgakellos
Keyword(s):  
Conceptual Framework ◽  
Concept Mapping ◽  
Industry 4.0 ◽  
Concept Maps ◽  
Production Systems ◽  
Software Tool ◽  
Smart Manufacturing ◽  
Future Research ◽  
Key Concepts ◽  
Comprehensive Framework

Engineering concepts usually, are complex concepts, thus many times are difficult for infusing into curriculums or to be comprehensive for practitioners. A concept that still now is not fully understandable is that of Industry 4.0, an approach that increases the complexity of production systems. Nowadays production systems are facing new challenges, as physical productions systems and internet technologies are directly linked, hence increasing the complexity but also the productivity of the systems. The paper introduces an approach of visualizing the concept of smart manufacturing in the context of Industry 4.0, as the term is not clearly specified, although has attracted attention both academicians and businesses. Concept mapping is a method of capturing and visualizing complex ideas. Concept maps are graphical tools for organizing, representing and communicating complex ideas by breaking them into more key concepts. As Industry 4.0 is a factor that can boost innovation and competitiveness of business, all parties involved in shaping the strategy of an organization, should perceive the issues to be covered. Furthermore, learners must be prepared to meet these challenges and knowledgebuilding activities may enhance their process of learning. The paper makes an interesting and valuable contribution, by identifying key concepts within the subject of smart manufacturing and Industry 4.0, using the method of concept mapping. Taking into consideration these concepts a conceptual framework will be introduced, by using the software tool CmapTools. The map can be used as a basis for future research in constructing a more comprehensive framework and identifying the concepts that describe smart manufacturing in the context of Industry 4.0, in a more thorough manner.

scholarly journals Towards smart biomanufacturing: a perspective on recent developments in industrial measurement and monitoring technologies for bio-based production processes

2020 ◽  
Vol 47 (11) ◽  
pp. 947-964 ◽  
Author(s):  
Carina L. Gargalo ◽  
Isuru Udugama ◽  
Katrin Pontius ◽  
Pau C. Lopez ◽  
Rasmus F. Nielsen ◽  
...  
Keyword(s):  
Industrial Revolution ◽  
Control Strategies ◽  
Smart Manufacturing ◽  
Monitoring And Control ◽  
Large Sets ◽  
Production Processes ◽  
Recent Developments ◽  
Monitoring Technologies ◽  
And Control ◽  
Industrial Measurement

AbstractThe biomanufacturing industry has now the opportunity to upgrade its production processes to be in harmony with the latest industrial revolution. Technology creates capabilities that enable smart manufacturing while still complying with unfolding regulations. However, many biomanufacturing companies, especially in the biopharma sector, still have a long way to go to fully benefit from smart manufacturing as they first need to transition their current operations to an information-driven future. One of the most significant obstacles towards the implementation of smart biomanufacturing is the collection of large sets of relevant data. Therefore, in this work, we both summarize the advances that have been made to date with regards to the monitoring and control of bioprocesses, and highlight some of the key technologies that have the potential to contribute to gathering big data. Empowering the current biomanufacturing industry to transition to Industry 4.0 operations allows for improved productivity through information-driven automation, not only by developing infrastructure, but also by introducing more advanced monitoring and control strategies.

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