Digital twin-driven complexity management in intelligent manufacturing

Complexity management is one of the most crucial and challenging issues in manufacturing. As an emerging technology, digital twin provides an innovative approach to manage complexity in a more autonomous, analytical and comprehensive manner. This paper proposes an innovative framework of digital twin-driven complexity management in intelligent manufacturing. The framework will cover three sources of manufacturing complexity, including product design, production lines and supply chains. Digital twin provides three services to manage complexity: (1) real-time monitors and data collections; (2) identifications, diagnoses and predictions of manufacturing complexity; (3) fortification of human-machine interaction. A case study of airplane manufacturing is presented to illustrate the proposed framework.

Immunosensing Based on Optical Fiber Technology: Recent Advances

The evolution of optical fiber technology has revolutionized a variety of fields, from optical transmission to environmental monitoring and biomedicine, given their unique properties and versatility. For biosensing purposes, the light guided in the fiber core is exposed to the surrounding media where the analytes of interest are detected by different techniques, according to the optical fiber configuration and biofunctionalization strategy employed. These configurations differ in manufacturing complexity, cost and overall performance. The biofunctionalization strategies can be carried out directly on bare fibers or on coated fibers. The former relies on interactions between the evanescent wave (EW) of the fiber and the analyte of interest, whereas the latter can comprise plasmonic methods such as surface plasmon resonance (SPR) and localized SPR (LSPR), both originating from the interaction between light and metal surface electrons. This review presents the basics of optical fiber immunosensors for a broad audience as well as the more recent research trends on the topic. Several optical fiber configurations used for biosensing applications are highlighted, namely uncladded, U-shape, D-shape, tapered, end-face reflected, fiber gratings and special optical fibers, alongside practical application examples. Furthermore, EW, SPR, LSPR and biofunctionalization strategies, as well as the most recent advances and applications of immunosensors, are also covered. Finally, the main challenges and an outlook over the future direction of the field is presented.

A Personal Respirator to Improve Protection for Healthcare Workers Treating COVID-19 (PeRSo)

Introduction: SARS-CoV-2 infection is a global pandemic. Personal Protective Equipment (PPE) to protect healthcare workers has been a recurrent challenge in terms of global stocks, supply logistics and suitability. In some settings, around 20% of healthcare workers treating COVID-19 cases have become infected, which leads to staff absence at peaks of the pandemic, and in some cases mortality.Methods: To address shortcomings in PPE, we developed a simple powered air purifying respirator, made from inexpensive and widely available components. The prototype was designed to minimize manufacturing complexity so that derivative versions could be developed in low resource settings with minor modification.Results: The “Personal Respirator – Southampton” (PeRSo) delivers High-Efficiency Particulate Air (HEPA) filtered air from a battery powered fan-filter assembly into a lightweight hood with a clear visor that can be comfortably worn for several hours. Validation testing demonstrates that the prototype removes microbes, avoids excessive CO2 build-up in normal use, and passes fit test protocols widely used to evaluate standard N95/FFP2 and N99/FFP3 face masks. Feedback from doctors and nurses indicate the PeRSo prototype was preferred to standard FFP2 and FFP3 masks, being more comfortable and reducing the time and risk of recurrently changing PPE. Patients report better communication and reassurance as the entire face is visible.Conclusion: Rapid upscale of production of cheaply produced powered air purifying respirators, designed to achieve regulatory approval in the country of production, could protect healthcare workers from infection and improve healthcare delivery during the COVID-19 pandemic.

Unsettled Topics on the Benefit of Additive Manufacturing for Production at the Point of Use in the Mobility Industry

An oft-cited benefit of additive manufacturing (AM), or “3D-printing,” technology is the ability to produce parts at the point of use by downloading a digital file and making the part at a local printer. This has the potential to greatly compress supply chains, lead times, inventories, and design iterations for custom parts. As a result of this, both manufacturing and logistics companies are investigating and investing in AM capacity for production at the point of use. However, it can be imagined that the feasibility and benefits are a function of size, materials, build time, manufacturing complexity, cost, and competing technologies. Because of this, there are instances where the viability of point-of-use manufacturing ranges from the perfect solution to the worst possible choice. Unsettled Topics on the Benefits of Additive Manufacturing for Production at the Point of Use in the Mobility Industry discusses the benefits, challenges, trade-offs, and other determining factors regarding this new level of AM possibilities.

Forensic Research of Phaleristic Items for Their Estimation

Collecting phaleristics is quite a common hobby in all countries. The cost of awards, medals, and other items of phaleristics is determined by their rarity, condition, manufacturing complexity, presence of precious metals and stones.Forensic research of phaleristics for estimation differs from their appraisal by collectors themselves, appraisers of antique trade organizations, pawnshops, and auctioneers in the legal significance of the costing for interested parties. It is conducted according to the methodology of forensic commodity research to determine the market value of objects of various product groups; besides, there is a need to establish authenticity for certain types of products.The article presents an algorithm for forensic appraisal of phaleristic objects. It is shown that state awards of the USSR, RSFSR, and the Russian Federation do not have market cost according to the current Russian legislation as they are removed from the civil circulation. For these items, only the cost of the precious metals used in their production can be established. This cost is determined according to the methodology approved by the Russian Ministry of Finance.

Management of Product Configuration Conflicts to Increase the Sustainability of Mass Customization

An important role in product variety management is finding an accurate variety extent to which the product matches the consumer’s expectations. In principle, customers prefer to have more rather than less versions of a product from which to choose. This motivates producers to offer a richer variety of goods. As a consequence, it brings a large amount of manufacturing complexity, and configuration conflicts may frequently occur. In order to avoid a situation in which a customer will select mutually incompatible components, product configurators usually recommend corrective actions for generating valid configurations. Nevertheless, the presence of infeasible configurations in customer options are negatively perceived by customers, and therefore it has an unfavorable impact on the sustainability of mass customization. One way to solve this problem is to eliminate, or at least reduce, mutually incompatible components. When considering the fact that eliminating all incompatible components may cause a rapid decrease in product variety, then the reduction of incompatible components can help to solve the product configuration problem. The proposed method aims to find a trade-off solution between minimizing configuration conflicts and maintaining a sufficient level of mass customization. Moreover, two supplementary methods for the determination of infeasible product configurations are proposed in this paper. The applicability and effectiveness of the proposed methods are demonstrated by two practical examples.

An Entropy-Based Formulation for Assessing the Complexity Level of a Mass Customization Industry 4.0 Environment

It has been stated that Industry 4.0’s goal is, among others, the sustainable success in a market characterized by exigent and informed consumers demanding personalized products and services, where the level of manufacturing complexity increases with level of product customization. Even though different manufacturing complexity measures have been developed, there seems to be a lack of a comprehensive metric that address both the mass customization variety-induced complexity, and the complexity derived from the adoption of the Industry 4.0 paradigm. The main original contribution of this paper is the development of an entropy-based (entropic) formulation to address this last issue. Its validity and usefulness is put to the test via a discrete-event simulation study of a mass customization production system operating within an Industry 4.0 context. Our findings show that the entropic formulation acts as a fairly good trend indicator of the system’s performance parameter increase/decrease, but not as an estimator of the final values. A discussion of the managerial implications of the obtained results is offered at the end of the paper.