scholarly journals Improvement of Factory Planning by Automated Generation of a Digital Twin

2020 ◽  
Author(s):  
Markus Sommer ◽  
Josip Stjepandić ◽  
Sebastian Stobrawa ◽  
Moritz von Soden
Keyword(s):  
Object Recognition ◽  
Production Systems ◽  
Cost Savings ◽  
Cost Effective ◽  
Shop Floor ◽  
Simulation Methods ◽  
Manufacturing Companies ◽  
Factory Planning ◽  
Automated Generation ◽  
Digital Twin

The simulation of processes in production systems is a powerful tool for factory planning. The application of simulation methods within the Digital Factory is becoming increasingly relevant as developments in the field of digitalization lead to more comprehensive, efficient, embedded and cost-effective simulation methods. Especially the integration within a Digital Twin, allows these advantages to be achieved for simulations. Here, the Digital Twin can be utilized for prospective planning, analysis of existing systems or process-oriented monitoring. In all cases, the Digital Twin offers manufacturing companies room for improvement in production and logistics processes leading to cost savings. However, many companies do not apply the technology, because the generation of a Digital Twin is cost-, time- and resource-intensive and IT expertise is required. This paper presents an approach for generating a Digital Twin in the built environment automatically and for utilization in factory planning. The obstacles will be overcome by using a scan of the shop floor, subsequent object recognition, and predefined frameworks for factory planning within the Digital Twin. Here, the effort for scanning the production hall is additional, while the subsequent object recognition, the generation of the CAD model and the simulation model, as well as the factory planning can be to a great extent automated and therefore carried out with a minimum of effort. Therefore, considerable cost savings can be expected here, which more than offset the additional effort for scanning.

scholarly journals Automated Generation of a Digital Twin of a Manufacturing System by Using Scan and Convolutional Neural Networks

2020 ◽  
Author(s):  
Markus Sommer ◽  
Josip Stjepandić ◽  
Sebastian Stobrawa ◽  
Moritz von Soden
Keyword(s):  
Neural Networks ◽  
Object Recognition ◽  
Convolutional Neural Networks ◽  
Shop Floor ◽  
Process Chain ◽  
Automated Generation ◽  
Entire Process ◽  
Digital Twin ◽  
Production Processes ◽  
Novel Approach

The simulation of production processes using a Digital Twin is a promising means for prospective planning, analysis of existing systems or process-parallel monitoring. However, many companies, especially small and medium-sized enterprises, do not apply the technology, because the generation of a Digital Twin is cost-, time- and resource-intensive and IT expertise is required. This obstacle can be removed by a novel approach to generate a Digital Twin using fast scans of the shop floor and subsequent object recognition in the point cloud. We describe how parameters and data should be acquired in order to generate a Digital Twin automatically. An overview of the entire process chain is given. A particular attention is given to the automatic object recognition and its integration into Digital Twin.

Productivity Increase through Industrialization of Overhead in Cyber-Physical Production Systems

2013 ◽  
Vol 769 ◽  
pp. 359-366
Author(s):  
Till Potente ◽  
Thomas Jasinski ◽  
Bartholomaeus Wolff
Keyword(s):  
Business Processes ◽  
Industrial Revolution ◽  
Production Systems ◽  
Labour Productivity ◽  
Smart Devices ◽  
Shop Floor ◽  
Manufacturing Companies ◽  
Core Element ◽  
Cyber Physical Production Systems ◽  
Management Staff

The importance of knowledge workers and management staff in manufacturing companies is increasing due to a rising complexity within indirect business processes. As a result, current overhead costs account for most of the overall manufacturing costs. Despite this fact manufacturing companies disregard the productivity potentials of their indirect areas and focus predominantly on the optimisation of shop-floor processes.Cyber-physical systems constitute a technological paradigm of the current forth industrial revolution and promise a further push of labour productivity in the upcoming decades. We expand the vision of cyber-physical production systems on business processes and develop a mathematical approach to predict and analyse productivity potentials of management staff in the context of emerging cyber-physical production systems. The core element of the presented model states the collaborative productivity between people, people and smart devices and between these smart devices themselves.

Toward the Ideal of Automating Production Optimization

2013 ◽  
Author(s):  
J. Michaloski ◽  
F. Proctor ◽  
J. Arinez ◽  
J. Berglund
Keyword(s):  
Data Acquisition ◽  
Production Systems ◽  
Cost Effective ◽  
Integrated Approach ◽  
Production Optimization ◽  
Efficient Manner ◽  
Casting Operation ◽  
Automated Generation ◽  
Manufacturing Optimization ◽  
Production Models

The advent of improved factory data collection offers a prime opportunity to continuously study and optimize factory operations. Although manufacturing optimization tools can be considered mainstream technology, most U.S. manufacturers do not take full advantage of such technology because of the time-intensive procedures required to manually develop models, deal with factory data acquisition problems, and resolve the incompatibility of factory and optimization data representations. Therefore, automated data acquisition, automated generation of production models, and the automated integration of data into the production models are required for any optimization analysis to be timely and cost effective. In this paper, we develop a system methodology and software framework for the optimization of production systems in a more efficient manner towards the goal of fully automated optimization. The case study of an automotive casting operation shows that a highly integrated approach enables the modeling and simulation of the complex casting operation in a responsive, cost-effective and exacting nature. Technology gaps and interim strategies will be discussed.

Einfluss von Industrie 4.0 auf die Fabrikplanung*/Impact of Industry 4.0 on factory planning - Effects of the special characteristics of cybertronic production systems on factory planning

2015 ◽  
Vol 105 (04) ◽  
pp. 190-194
Author(s):  
J. C. Aurich ◽  
C. Steimer ◽  
H. Meissner ◽  
N. Menck
Keyword(s):  
Industry 4.0 ◽  
Production Systems ◽  
Industrie 4.0 ◽  
Shop Floor ◽  
Factory Planning

Im Rahmen von Industrie 4.0 ergeben sich durch cybertronische Produktionssysteme (CTPS) neue Möglichkeiten in der Produktion. Dieser Fachbeitrag thematisiert die Fragestellung, wie sich neue Charakteristika zukünftiger CTPS auf deren Planung auswirken und welchen Einfluss Industrie 4.0 auf den Fabrikplanungsprozess ausübt.   In the context of Industry 4.0 (Integrated Industry), cybertronic production systems (CTPS) provide new opportunities on the shop floor. This article addresses how new characteristics of future CTPS affect the planning of these systems and how Industry 4.0 impacts factory planning.

scholarly journals Shop Floor Digital Twin in Smart Manufacturing: A Systematic Literature Review

2021 ◽  
Vol 13 (23) ◽  
pp. 12987
Author(s):  
Angelo Corallo ◽  
Vito Del Del Vecchio ◽  
Marianna Lezzi ◽  
Paola Morciano
Keyword(s):  
Literature Review ◽  
Systematic Literature Review ◽  
Past Research ◽  
Smart Manufacturing ◽  
Shop Floor ◽  
Manufacturing Companies ◽  
Holistic View ◽  
Digital Twin ◽  
Unique Framework ◽  
Main Components

The digital twin is currently recognized as a key technology allowing the digital representation of a real-world system. In smart manufacturing, the digital twin enables the management and analysis of physical and digital processes, products, and people in order to foster the sustainability of their lifecycles. Although past research addressed this topic, fragmented studies, a lack of a holistic view, and a lack of in-depth knowledge about digital twin concepts and structures are still evident in the domain of the shop floor digital twin. Manufacturing companies need an integrated reference framework that fits the main components of both physical and digital space. On the basis of a systematic literature review, this research aims to investigate the characteristics of the digital twin for shop floor purposes in the context of smart manufacturing. The “hexadimensional shop floor digital twin” (HexaSFDT) is proposed as a comprehensive framework that integrates all the main components and describes their relationships. In this way, manufacturing organizations can rely on an inclusive framework for supporting their journey in understanding the shop floor digital twin from a methodological and technological viewpoint. Furthermore, the research strengthens the reference literature by collecting and integrating relevant contributions in a unique framework.

Integrated portfolio planning of products and production systems

2014 ◽  
Vol 25 (2) ◽  
pp. 155-174 ◽  
Author(s):  
Jessica Bruch ◽  
Monica Bellgran
Keyword(s):  
Production System ◽  
Production Systems ◽  
System Development ◽  
Cost Effective ◽  
Product Portfolio ◽  
Manufacturing Companies ◽  
Longitudinal Case Study ◽  
Content Type ◽  
Portfolio Strategy ◽  
Context Specific

Purpose – The purpose of the research presented is to analyse and discuss critical challenges related to the development of a production system portfolio. Design/methodology/approach – The study employs a longitudinal case study of an industrialization project at a global supplier in the automotive industry. Findings – This research makes two clear theoretical contributions. First, it extends the existing research on the manufacturing and R&D interface by proposing an innovative structure for production system development facilitating manufacturing companies in their efforts of being fast and cost-effective when introducing new products to the market. Second, this research identifies challenges related to the adoption of a production system portfolio and the necessary actions of a manufacturing company applying such a portfolio strategy. Research limitations/implications – The findings should be seen as a first attempt at assisting the development of a production system portfolio that matches the product portfolio. However, since the findings are based on only one case, the findings are to some extent context-specific and thus need to be complemented by more research. Practical implications – The research unveils challenges related to production system development and provides managers with a better understanding of some of the implications of the adoption of a portfolio strategy. Originality/value – This empirical study is among the first to explore the implications of a production system portfolio strategy. It advances the understanding towards a fully integrated product and production system development.

Mineral/microfibrillated cellulose composite materials: High performance products, applications, and product forms

TAPPI Journal ◽  
2018 ◽  
Vol 17 (09) ◽  
pp. 507-515 ◽  
Author(s):  
David Skuse ◽  
Mark Windebank ◽  
Tafadzwa Motsi ◽  
Guillaume Tellier
Keyword(s):  
Composite Materials ◽  
High Performance ◽  
Aqueous Suspension ◽  
Production Capacity ◽  
Cost Savings ◽  
Cost Effective ◽  
New Materials ◽  
Wet Strength ◽  
Product Forms ◽  
Cellulose Composite

When pulp and minerals are co-processed in aqueous suspension, the mineral acts as a grinding aid, facilitating the cost-effective production of fibrils. Furthermore, this processing allows the utilization of robust industrial milling equipment. There are 40000 dry metric tons of mineral/microfbrillated (MFC) cellulose composite production capacity in operation across three continents. These mineral/MFC products have been cleared by the FDA for use as a dry and wet strength agent in coated and uncoated food contact paper and paperboard applications. We have previously reported that use of these mineral/MFC composite materials in fiber-based applications allows generally improved wet and dry mechanical properties with concomitant opportunities for cost savings, property improvements, or grade developments and that the materials can be prepared using a range of fibers and minerals. Here, we: (1) report the development of new products that offer improved performance, (2) compare the performance of these new materials with that of a range of other nanocellulosic material types, (3) illustrate the performance of these new materials in reinforcement (paper and board) and viscosification applications, and (4) discuss product form requirements for different applications.

Pound Wise and Penny Foolish? Weight Loss and The Dynamics of Health Care Spending

2011 ◽  
Vol 14 (2) ◽  
Author(s):  
Thomas G Koch
Keyword(s):  
Weight Loss ◽  
Cost Savings ◽  
Cost Effective ◽  
Economic Consequences ◽  
Health Care Spending ◽  
Order Of Magnitude ◽  
Dynamic Measures ◽  
The Cost ◽  
The Impact ◽  
The Relationship

Current estimates of obesity costs ignore the impact of future weight loss and gain, and may either over or underestimate economic consequences of weight loss. In light of this, I construct static and dynamic measures of medical costs associated with body mass index (BMI), to be balanced against the cost of one-time interventions. This study finds that ignoring the implications of weight loss and gain over time overstates the medical-cost savings of such interventions by an order of magnitude. When the relationship between spending and age is allowed to vary, weight-loss attempts appear to be cost-effective starting and ending with middle age. Some interventions recently proven to decrease weight may also be cost-effective.

Cost Avoidance and Clinical Benefits Derived from a Pharmacy-Managed Anemia Program

2000 ◽  
Vol 35 (2) ◽  
pp. 169-175 ◽  
Author(s):  
Robert A. Quercia ◽  
Ronald Abrahams ◽  
C. Michael White ◽  
John D'Avella ◽  
Mary Campbell
Keyword(s):  
Cost Savings ◽  
Cost Effective ◽  
Hemodialysis Patients ◽  
Cost Avoidance ◽  
Number Of Patients ◽  
Epoetin Alpha ◽  
Clinical Benefits ◽  
Unit Dose ◽  
One Year ◽  
Alpha Therapy

A pharmacy-managed anemia program included distribution and clinical components, with the goal of making epoetin alpha therapy for hemodialysis patients more cost-effective. The Pharmacy Department prepared epoetin alpha doses for patients in unit-dose syringes, utilizing and documenting vial overfill. Pharmacists dosed epoetin alpha and iron (oral and intravenous) per protocol for new and established patients. Baseline data were obtained in 1994, one year prior to implementation of the program, and were re-evaluated in 1995 and 1998. Cost avoidance from utilization of epoetin alpha vial overfill in 1995 and 1998 was $83,560 and $91,148 respectively. In 1995 and 1998, cost avoidance from pharmacy management of anemia was $191,159 and $203,985 respectively. The total cost avoidance from 1995 through 1998 was estimated at $1,018,638. The number of patients with hematocrits under 31% decreased from 32% in 1994 to 21% and 14% in 1995 and 1998 respectively. We conclude that a pharmacy-managed anemia program for hemodialysis patients results in significant cost savings and better achievement of target hematocrits.

The Future of Plasma-Based Surface Engineering Techniques in Tribology (Keynote)

2005 ◽  
Author(s):  
Allan Matthews ◽  
Adrian Leyland
Keyword(s):  
Surface Engineering ◽  
Performance Enhancement ◽  
Bulk Material ◽  
Cost Savings ◽  
Cost Effective ◽  
Ceramic Coatings ◽  
Performance Improvements ◽  
Treatment Techniques ◽  
Wide Range ◽  
Macro Scale

Over the past twenty years or so, there have been major steps forward both in the understanding of tribological mechanisms and in the development of new coating and treatment techniques to better “engineer” surfaces to achieve reductions in wear and friction. Particularly in the coatings tribology field, improved techniques and theories which enable us to study and understand the mechanisms occurring at the “nano”, “micro” and “macro” scale have allowed considerable progress to be made in (for example) understanding contact mechanisms and the influence of “third bodies” [1–5]. Over the same period, we have seen the emergence of the discipline which we now call “Surface Engineering”, by which, ideally, a bulk material (the ‘substrate’) and a coating are combined in a way that provides a cost-effective performance enhancement of which neither would be capable without the presence of the other. It is probably fair to say that the emergence and recognition of Surface Engineering as a field in its own right has been driven largely by the availability of “plasma”-based coating and treatment processes, which can provide surface properties which were previously unachievable. In particular, plasma-assisted (PA) physical vapour deposition (PVD) techniques, allowing wear-resistant ceramic thin films such as titanium nitride (TiN) to be deposited on a wide range of industrial tooling, gave a step-change in industrial productivity and manufactured product quality, and caught the attention of engineers due to the remarkable cost savings and performance improvements obtained. Subsequently, so-called 2nd- and 3rd-generation ceramic coatings (with multilayered or nanocomposite structures) have recently been developed [6–9], to further extend tool performance — the objective typically being to increase coating hardness further, or extend hardness capabilities to higher temperatures.

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