Abstract
In the context of Industry 4.0, the demand for the mass production of highly customized products will lead to complex products and an increasing demand for production system flexibility. Simply implementing lean production-based human-centered production or high automation to improve system flexibility is insufficient. Currently, lean automation (Jidoka) that utilizes cyber-physical systems (CPS) is considered a cost-efficient and effective approach for improving system flexibility under shrinking global economic conditions. Therefore, a smart lean automation engine enabled by CPS technologies (SLAE–CPS), which is based on an analysis of Jidoka functions and the smart capacity of CPS technologies, is proposed in this study to provide an integrated and standardized approach to design and implement a CPS-based smart Jidoka system. A set of comprehensive architecture and standardized key technologies should be presented to achieve the above-mentioned goal. Therefore, a distributed architecture that joins service-oriented architecture, agent, function block (FB), cloud, and Internet of things is proposed to support the flexible configuration, deployment, and performance of SLAE–CPS. Then, several standardized key techniques are proposed under this architecture. The first one is for converting heterogeneous physical data into uniform services for subsequent abnormality analysis and detection. The second one is a set of Jidoka scene rules, which is abstracted based on the analysis of the operator, machine, material, quality, and other factors in different time dimensions. These Jidoka rules can support executive FBs in performing different Jidoka functions. Finally, supported by the integrated and standardized approach of our proposed engine, a case study is conducted to verify the current research results. The proposed SLAE–CPS can serve as an important reference value for combining the benefits of innovative technology and proper methodology.
Highlights
The market globalization and diversification of customer demands have increased the mass production of highly customized products
This study aims to provide an integrated and standardized approach to design and implement a cyber-physical systems (CPS)-based smart Jidoka system
This paper discusses four types of general architectures related to production systems: Industry 4.0, Internet of things (IoT), CPS, and cyber-physical production system (CPPS) architectures
Summary
The market globalization and diversification of customer demands have increased the mass production of highly customized products. This study aims to provide an integrated and standardized approach to design and implement a CPS-based smart Jidoka system To achieve this goal, a set of comprehensive architecture and standardized key technologies are proposed based on service-oriented architecture (SOA), agent, function block (FB), cloud, and IoT. A set of comprehensive architecture and standardized key technologies are proposed based on service-oriented architecture (SOA), agent, function block (FB), cloud, and IoT This CPS-enabled smart lean automation system is composed of sensors, actuators, controllers, ICT, software parts, and Jidoka rules, among others, and can autonomously convert heterogeneous data, analyze data, detect abnormalities, and control feedback. Conclusions are drawn and the challenges and future research objectives of SLAE–CPS are discussed
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