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.

An Implementation of Lean Technology in an in-Plant Manufacturing System, a Funiture Company

2011 ◽  
Vol 110-116 ◽  
pp. 4799-4807 ◽  
Author(s):  
Quynh Lam Ngoc Le ◽  
Ngoc Hien Do ◽  
Ki Chan Nam
Keyword(s):  
Production System ◽  
Cost Reduction ◽  
Manufacturing System ◽  
Added Value ◽  
Shop Floor ◽  
Practical Case ◽  
Toyota Production System ◽  
System A ◽  
The World

The development of the Toyota Production System (TPS) based on principles of lean technology has especially impressed numerous manufacturers around the world. It attaches remarkable importance to reducing and then eliminating waste and focusing on added-value activities. Lean technology is growing in important and scope because they help companies become more competitive and streamlined at a time when competitive and cost reduction pressures have intensified. Accordingly, a studied furniture company intends to transform its shop floor first to lean system. It is really an interesting and practical case study, so this paper presents an implementation of lean technology in an in-plant manufacturing system through a systematic way, step by step. It could be considered as a reference of an implementation of the lean technology.

scholarly journals A Comparison between Dedicated and Flexible Manufacturing Systems: Optimization and Sensitivity Analysis

2021 ◽  
Vol 40 (1) ◽  
pp. 130-139
Author(s):  
Abdul Salam Khan ◽  
Khawer Naeem ◽  
Raza Ullah Khan
Keyword(s):  
Sensitivity Analysis ◽  
Flexible Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Cost Minimization ◽  
Process Time ◽  
Future Research ◽  
Second Phase ◽  
Solution Approach ◽  
The Impact

An abrupt change requires a robust and flexible response from a manufacturing system. Dedicated Manufacturing System (DMS) has been a long practiced taxonomy for mass production and minimum varieties. In contrast, Flexible Manufacturing System (FMS) has been introduced for responding to quantity as well as variety issues. This study considers both production taxonomics by using a multi objective model of cost and time. An Integer Linear Programming (ILP) formulation is presented and subsequently validated. The analysis procedure is administered in two phases. In the first phase, comparison of production cost and process time in DMS and FMS is presented. The model is implemented by using an exact solution approach and results show that FMS is a viable option, compared to DMS, according to the criteria of cost, time, and productivity. In the second phase, sensitivity analysis is performed by using several FMS (n) and the impact of cells selection on the performance of system is studied. It is concluded that n=1 (single cell-based FMS) is more relevant for cost minimization; however, n = 6 is a suitable candidate for producing more quantity in given time horizon (process time minimization). Lastly, key findings are reported, and future research avenues are provided.

Collaborative Platform for Remote Manufacturing Systems Using Industrial Internet and Digital Twin in the COVID-19 Era

2021 ◽  
Author(s):  
Jay Lee ◽  
Xiaodong Jia ◽  
Qibo Yang ◽  
Keyi Sun ◽  
Xiang Li
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
The Real ◽  
Digital Twin ◽  
Manufacturing Efficiency ◽  
Industrial Internet ◽  
Industrial Operations ◽  
Promising Solution ◽  
Technology Group ◽  
Collaborative Platform

Abstract In the wake of COVID-19, significant influence on the manufacturing industries has been observed in the past year due to the restrictions of in-person communications and interactions. As a consequence, manufacturing efficiency has reduced remarkably all over the world. Despite the great harm to the industrial operations under the pandemic, the opportunities for remote collaborative manufacturing system also arise. Effective and efficient remote manufacturing systems for the real industries have been highly demanded. Through the integration of industrial internet and digital twin systems, the remote manufacturing system can be largely facilitated. This paper proposes a general framework for the remote manufacturing system during the COVID-19 era. The concept of the intelligent collaborative remote manufacturing system is firstly reviewed, as well as discussions of the current pandemic situation and its influence on the industries. The current commercial platforms of the systems are also presented. A case study on the lighthouse factories at the Foxconn Technology Group is finally presented for understanding the implementation of the proposed strategy. The effectiveness of the framework has been validated in the real industrial scenarios, and great economic and operational benefits have been obtained. The proposed framework offers a promising solution for the remote manufacturing system under the current pandemic.

scholarly journals Digital Twin for Monitoring Ergonomics during Manufacturing Production

2020 ◽  
Vol 10 (21) ◽  
pp. 7758
Author(s):  
Alessandro Greco ◽  
Mario Caterino ◽  
Marcello Fera ◽  
Salvatore Gerbino
Keyword(s):  
Decision Making ◽  
Decision Making Process ◽  
Methodological Framework ◽  
Production Lines ◽  
Work Activities ◽  
Digital Twin ◽  
Set Up ◽  
Operational Issues ◽  
Smart Factories

Within the era of smart factories, concerning the ergonomics related to production processes, the Digital Twin (DT) is the key to set up novel models for monitoring the performance of manual work activities, which are able to provide results in near real time and to support the decision-making process for improving the working conditions. This paper aims to propose a methodological framework that, by implementing a human DT, and supports the monitoring and the decision making regarding the ergonomics performances of manual production lines. A case study, carried out in a laboratory, is presented for demonstrating the applicability and the effectiveness of the proposed framework. The results show how it is possible to identify the operational issues of a manual workstation and how it is possible to propose and test improving solutions.

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.

Sign in / Sign up

Export Citation Format

Share Document