Concept Of Production System Research Articles

Development of an Adaptive Human-centered Work Station for Fuel Cell Stack Assembly

Facing the challenges of modern production, such as increased product variability and individuality, assembly systems must strive for maximum flexibility. Consequently, despite the continuous advancements in automation, the human workforce retains its crucial role in industrial assembly due to its exceptional adaptability and learning capabilities. However, the industry is confronted with the additional challenge of addressing a shortage of skilled workers, managing ongoing demographic changes, and handling an increasingly heterogenous workforce in terms of age, skills, and experience. As a result, there is a growing emphasis on the efficient and ergonomic use of the human workforce. In this context, the concept of human-centered production systems has emerged as an important approach.The objective of this paper is to propose a general concept for the implementation of a human-centered assembly system that can adapt to different human characteristics in terms of anthropometry, functional capabilities, knowledge, and personal needs during the assembly process. This in-process adaptation is based on the tracking of human movements and actions during the assembly process using LiDAR and camera technology. The collected data is utilized to feed a recommender system that serves to suggest possible configuration optimizations in the assembly system dimensions of Working height, Range of vision, gripping area, and handedness, Lighting and Use of information and assistance systems, encompassing a laser projector, spatial augmented reality facilitated by a dynamic beamer, and intelligent tools.Subsequently this general approach is applied to the development of a work station designed for the assembly of fuel cell stack components.

Toyota Production System Concepts: Application of Lean in Non-manufacturing Environments - Series Books 18 to 19

Toyota Production System Concepts: Application of Lean in Non-manufacturing Environments - Series Books 18 to 19

Toyota Production System Concepts: The Guidebook to Toyota's Corporate Strategy and Leadership – Series Books 1 to 6

Toyota Production System Concepts: The Guidebook to Toyota's Corporate Strategy and Leadership – Series Books 1 to 6

Machine Learning for the Detection and Diagnosis of Anomalies in Applications Driven by Electric Motors.

Manufacturing systems are becoming increasingly flexible, necessitating the adoption of new technologies that allow adaptations to a turbulent and complex modern market. Consequently, modern concepts of production systems require horizontal and vertical integration, extending across value networks and within a factory or production shop. The integration of these environments enables the acquisition of a substantial amount of data containing information pertaining to production, processes, and equipment located on the shop floor. When these data and information are processed and analyzed, they have the potential to reveal valuable insights and knowledge about the manufacturing systems, offering interpretive outcomes for strategic decision making. One of the opportunities presented in this context includes the implementation of predictive maintenance (PdM). However, industrial adoption of PdM is still relatively low. In this paper, the aim is to propose a methodology for selecting the main attributes (variables) to be considered in the instrumentation setup of rotating machines driven by electric motors to decrease the associated costs and the time spent defining them. For this, the most well-known data science and machine learning algorithms are investigated to choose the one most adequate for this task. For the experiments, different testing scenarios were proposed to detect the different possible types of anomalies, such as uncoupled, overloaded, unbalanced, misaligned, and normal. The results obtained show how these algorithms can be effective in classifying the different types of anomalies and that the two models that presented the best accuracy values were k-nearest neighbor and multi-layer perceptron.

A human-centred workstation in industry 4.0 for balancing the industrial productivity and human well-being

Cyber-physical productions systems (CPPS) play a fundamental role in the fourth industrial revolution along with human centred design. The consideration of these two factors leads to the concept of human centred cyber-physical production systems (H-CPPSs), which are defined as systems that support humans, machines, and software to integrate virtual and physical worlds. H-CPPS are not intended to substitute for human operators but rather to support and augment their capabilities and ensure their well-being. Limited information currently exists about workstation design from an ergonomic perspective and a proper method for including a workstation in a H-CPPS. This paper proposes a methodology that allows identification of industrial requirements and ergonomic considerations for establishing guidelines to integrate Industry 4.0 principles in the manufacturing shopfloor of large and small-medium enterprises by designing a workstation framework that balances operator well-being and manufacturing productivity. First, this approach evaluates a set of general production tasks from the manufacturing industry, assesses the ergonomic risks during execution and identifies the technological enablers to balance human productivity and well-being. Second, this approach provides a set of guidelines for deploying a generic human centred workstation with ergonomic considerations. Finally, this paper describes a case study in which a human-centred workstation was constructed as a proof of concept of the proposed methodology. Experimental tests were applied to find significant statistical improvements between controlled and experimental scenario. The experimental results determined from the methodological constructed workstation with human-centred considerations contributes to reduce the ergonomic risk on industrial operators without affecting its productivity.

Conceptual control architecture for future highly flexible production systems

The trend towards more customized products with shorter product life cycles requires rethinking of current production systems. Due to the increasing demands for flexibility and adaptability, agile state of the art production systems come close to their limits. To improve adaptability to volatile markets, the fundamental concepts of production systems must be reviewed. With the novel production system Wertstromkinematik, the limits of flexibility and agility will be pushed further. By using several units of an identical universal robot kinematic with suitable end effectors, complete versatile value streams can be mapped. In this paper a conceptual control architecture for this novel production concept is presented and discussed in four different test environments. These examined environments comprise the core functions of the new production concept coupling of robot kinematics and machine self-optimization as well as two use cases involving the use of digital CAD-CAM-chains will be discussed in detail. Based on these topics possible restrictions and solutions regarding the overall communication architecture will be presented and discussed.

Dynamic Partial Reconfiguration for Adaptive Sensor Integration in Highly Flexible Manufacturing Systems

As new production system concepts emerge to face an increasing demand for individualized production, sensor integration for Industry 4.0 functions is becoming a major challenge. Flexibility- and scalability-focused concepts rely on reconfigurable machines that automatically replace smart end effectors between production steps. To ensure adaptability to future demands, these smart components, comprising the main tool and sensors, are connected to the static part of the machine via a unified electro-mechanical interface. In robot-based concepts, these components are furthermore space- and weight-constrained and should be cost-optimized. With respect to sensor integration, this leads to the challenge of interfacing sensors using different communication protocols and electrical signal properties through a fixed, minimal set of signal lines. In this paper, an architecture for an adaptive sensor integration unit is presented, targeting highly flexible production systems. Leveraging dynamic partial FPGA reconfiguration to exchange communication logic and an extensible hardware module located in the static part of the machine, it efficiently supports alternating communication protocols over static signal lines. It thereby reduces the number of signal lines as well as the need for protocol conversion units in the exchangeable components. A prototype implementation using industrial bus protocols shows its suitability and is evaluated concerning relevant timing characteristics and resource usage.

A Content Analysis on Lean Manufacturing - Concept and Benefits for Manufacturing Industry

Abstract: Nowadays, every organization must be required to determine its strength and weaknesses to enlarge productivity and output of their operations. The concept of lean production system has been acknowledged as a means to increase competitiveness for manufacturing concerns all over the world. The present paper has been planned to analyze the concept of Lean Production and its benefits for manufacturing industries. On the basis of the content analysis, the study found that lean manufacturing is gaining popularity day by day among manufacturing industries due to its potential of increasing operational performance. This is done with the help of its set of tools and principles which are used in the systematic elimination of seven wastes, namely, overproduction; waiting; scrap; conveyance; processing; inventory; and motion. Elimination of wastes enable manufacturer to produce the product with superior quality, lower cost and on time with lesser efforts. Keywords: Lean Production, Benefits, Tools and Techniques, Principles

Understanding vulnerabilities in cyber physical production systems

ABSTRACT Development of future manufacturing systems is featured with flexibility, mass customization, intelligence and context based learning to produce smart products. These production systems are characterized through networked, cooperating objects called cyber physical systems (CPSs). From the manufacturing perspective, the ability to communicate data and develop interaction between devices, manufacturing machinery, raw materials, working robots, humans and the plant environment develops the concept of cyber physical production systems (CPPS). Human-robot collaboration is a technology area that will be an integrated part of the future factory floor and the CPPS. With the involvement of human part in the automated system industrial scenarios, practical safety issues are expected to arise in the connected environment due to the use of a large number of devices, sensors, and cloud services causing complex network, IP conflicts, compromised nodes and communication issues. This all may lead to occupational safety issues on the factory floor in different ways and combinations. Overall, the system’s physical vulnerability will be increased in the context of compromised connected working space and cyber-security. In this paper, the authors developed a risk assessment based on system vulnerability of a CPPS developed for a use case requirement and performed a simulated approach by launching a cyber-attack and measuring the causal effect to identify implications on human worker safety.

Increasing Resilience of Production Systems by Integrated Design

The paper presents a framework for considering resilience as an integrated aspect in the design of manufacturing systems. The framework comprises methods for the assessment of resilience, supply chain and production planning, flexible execution and control as well as modular and skill-based methods for automation systems. A basic classification of risk categories and their impacts on manufacturing environments is given so that a concept of reconfigurable and robust production systems can be derived. Based on this, main characteristics and concepts of resilience are applied to manufacturing systems. As a lever of increased resilience on business and supply chain level, options for synchronized production planning are presented in a discrete event simulation. Furthermore, a concept to increase resilience on the level of business process execution is investigated, allowing manufacturing tasks to be rescheduled during runtime using a declarative approach to amend conventional business process models.

Subsea Electrification: Is the Tide About To Turn?

The concept of a standalone production system on the seabed with automated wellbore construction and production processes has been an industry goal for a long time. Electrification of subsea facilities and of wellbore and reservoir equipment offers many opportunities to improve operational efficiency, reduce life-of-field capital and operating expenses, and reduce carbon footprint, among other benefits. Talk of a subsea electrification revolution being “just around the corner” has been ongoing for more than 20 years. And, millions of dollars in investments and numerous joint industry projects (JIPs) over the past decade have moved the vision closer to fruition (Fig. 1). But the upstream industry continues to lag others in replacing hydraulics with electrics. The reasons echo those for slow uptake of other new technologies and methodologies—fear of change, the unknown, and failure. Now, recent events are stirring up interest and expectations. “Four to five years ago, only a very small percentage of the buying community were making big noises about the future state of the electrified subsea or subsurface,” said John Kerr, subsea production systems and technology director for Baker Hughes, in a recent interview. “During the past 18 months the narrative has increased rapidly with many more operators looking at electrification as the base case for subsea solutions. We’ve seen a groundswell of interest to the point that we now see 3-, 5-, and 7-year lookaheads with electric solutions as the base case design concept,” Kerr said. What has changed? “Electrification of subsea devices has always been a solution to solve specific technical needs,” said Kerr. “The predominant one was extreme long-distance stepouts, where once you get to 250 miles or so, the ability to pump hydraulic fluids through small umbilicals presented so much pressure loss that it became impractical to implement a hydraulic solution, so all-electric became the solution of choice. Now we are seeing much more understanding of what electrification can deliver in the commercial and operational sense. “During the last 2 years, there has also been rapid adoption of dialogue around the aspect of increased carbon credentials and carbon reduction as an advantage,” Kerr continued. “The interest is much more comprehensive, driving different behavior in concept selection for operators.” Has the pandemic played a role? The consensus of participants in a subsea electrification panel at the virtual 2020 SPE Annual Technical Conference and Exhibition (ATCE) was that unless you’re surrounded by a crisis, you’re not encouraged to change. “The moment you put someone in a crisis situation, they understand that they have to change,” said Rory Mackenzie, leader for subsea electrical technologies at Total. “2020—the pandemic, oil price collapse, and environmental issues—this created a crisis. People are now much more open to considering change.” The panelists included Alvaro Arrazola, completions engineer, Chevron, North America Upstream; Glenn-Roar Halvorsen, project manager subsea all-electric, Equinor; Christina Johansen, managing director, Norway, TechnipFMC; Samantha McClean, intelligent wells technical advisor, BP; Rory Mackenzie, head of subsea electrical technologies, Total R&D; and Thomas Scott, global product line director, intelligent production systems and reservoir information, Baker Hughes. Edward O’Malley, director of strategy and portfolio, oilfield services, Baker Hughes, moderated the session.

Cyber-Physical Production Systems in Settings with Limited Infrastructure

During the last decade production innovation was mainly focused on connectivity aspects. The vision of smart factories running on software, that uses collected machine data, has become true but foremost for leading industrial companies in highly developed countries. Apart from these, production can also be found in non-industrialized craft professions as well as in less developed countries. As digitalization does not necessarily require an industrial or developed setting the latter could possibly benefit from it as well. Socio-cyber-physical production systems have been used to describe the interdependencies of linked production systems but usually focus on highly developed regions as well as for industrial applications. This paper lines out similarities and differences for each case, introduces the concept of cyber-physical production systems (CPPS) and its extension to socio-CPPS (SCPPS), which emphasizes the role of human workers in the production environment. The relation between industrial, non-industrial production and innovations is examined. Furthermore, the widening of SCCPS concepts for non-industrial production is discussed.

PRACTICAL APPLICATION OF FUZZY LOGIC IN PRODUCTION CONTROL SYSTEMS OF ENGINEER TO ORDER SMES

In this paper the method of improving production control in engineer to order [ETO] small and medium sized enterprises is presented. Briefly, the strategy of Mass Customization [MC] and a concept of the hybrid MC-ETO production system are demonstrated. Thereafter, a method of choosing components for small batch manu-facturing in advance, under conditions of single unit ETO production system, with application of fuzzy logic is described. This approach can be used in ETO companies during their transition into the hybrid MC-ETO production systems. The research was done in a collaboration with experts from the real ETO pro-duction system, in Polish SME, which manufactures mechanical parts.

Causal and temporal relationships within the combination of Lean Production Systems and Industry 4.0

The concept of Lean Production System is applied in manufacturing systems around the globe. With the help of avoidance of waste on the shop floor and a holistic view of the manufacturing system, efficient processes are created. The concept of a Lean Production System with its principles and tools is influenced by a newer concept that is increasingly introduced in manufacturing systems as well, named Industry 4.0. Here, the connection of every resource, object, and human in real-time is aspired to handle future production problems. Such problems are, for example, the high demand for customized products that require a high degree of flexibility. Numerous researches address the combination of both concepts to create an efficient and also a flexible manufacturing system. However, an investigation of the relationships of these combinations is still missing. In this paper, the relationships of a method library, which links the concept of Lean Production System and Industry 4.0, are analyzed. Especially the causal and temporal relationships are examined. These relationships establish the interdependencies between the methods of Lean Production Systems and the technologies of Industry 4.0 and their implementation order.

Concept and engineering development of cyber physical production systems: a systematic literature review

Cyber Physical Systems (CPSs) play a crucial role in the Industry 4.0 paradigm. The application of CPSs in production and manufacturing environments gave rise to the term Cyber Physical Production Systems (CPPSs). There is a growing interest in CPPSs, yet research in this area is scattered and needs to be reviewed for understanding their development status and maturity. The aim of this study is to carry out a systematic literature review (SLR) to analyze the current research activities on CPPSs according to their contributions to the engineering life cycle of such production system. Firstly, a method for SLR is presented. Then, literature analysis of CPPSs is conducted to present research activities in the light of the concept development and engineering development stages. Finally, based on the results of the literature analysis, a concept map of CPPSs research is proposed, which depicts the existing research topics in the engineering life cycle of CPPSs. And we exploit it to propose a research agenda of the CPPSs integration process required to ensure their efficient industrial use. Findings of this review can help researchers to examine the maturity of the development status of CPPSs, to discover which phases require improvement, and to know the future research directions for their industrial practices.

Computational Study on Strategyproofness of Resource Matching in Crowdsourced Manufacturing

The need for a sustainable society has grown rapidly. This trend requires new production system concepts following an era of mass customization. As one of these new concepts, “crowdsourced manufacturing” has attracted noticeable attention. In such systems, each participant shares their manufacturing resources for ecosystem co-prosperity, providing new value for the next society. To realize such a concept, it is important to (1) match resource requests and resource offers so as to achieve high efficiency, and (2) induce participants to act in a fair way. Previously, some studies showed production efficiency improvements. Nevertheless, relatively few studies have been conducted on induction mechanisms. The purpose of this study is to develop induction mechanisms for participants. Concerning induction mechanisms, we focus on two viewpoints: (a) matching stability, and (b) “strategyproofness.” These viewpoints are well-known concepts in the market design research field. We previously proposed a resource matching stability analysis method and mechanism for inducing participants to accept matching plans. Formally, a matching method is “strategyproof” when it is a dominant strategy for all participants to submit their true information. However, it is hard to satisfy this condition. Practically, it would be useful to evaluate the strength of an induction, even if the matching method is not strategyproof. In this study, we propose indices for showing the strength of induction (“strength of strategyproofness”). Subsequently, we evaluate matching methods, and show that participants will state false information to maximize their profit in a system with resource matching methods for the profit maximization of the entire system. As the resource providers, they can obtain greater profit by submitting false information regarding resource usage fees. Then, the profits of the resource requesters are unfairly impaired. Furthermore, we propose a new resource matching method, inspired from the “nucleolus” concept in cooperative game theory. The proposed method reduces the maximum dissatisfaction (i.e., profit loss) of resource requesters and resource providers, based on profit sharing. The computational results show that the proposed method induces participants to submit true information, while maintaining high production efficiency.

Smart Manufacturing for Smart Cities—Overview, Insights, and Future Directions

With ‘smart’ being the order of the day, the shift in the landscape of a typical production‐oriented manufacturing environment to a more data‐oriented, automated and smart manufacturing is imminent. However, what is meant by smart manufacturing? And how can smart manufacturing contribute to a bigger picture by acting as enablers of smart cities? Given the paucity in literature that seeks to make sense in this direction, herein, first, six indices that represent or define a smart city are identified. Then, a holistic perspective of smart manufacturing is presented by collectively dwelling into the concepts of cyber physical production systems (CPPS) and industrial symbiosis—the recent and ongoing developments, applications, and relevant examples. In each subsequent section, the Review addresses how smart manufacturing contributes to smart cities, not just from a technology perspective, but also by satisfying the ergonometric factors and sustainability issues which are equally important indices that make up a smart city. A brief overview of Singapore as a smart nation and smart manufacturing hub is presented toward the end, along with highlights of a real‐world smart manufacturing platform called the Model Factory and its relevant modules.

A Connes correspondence approach to the dilation theory

Product systems have been originally introduced to classify E0-semigroups on type I factors by Arveson. The idea of product systems is influenced the constructions of dilations of CP0-semigroups. In this paper, we will develop the dilation theory and the classification theory of E0-semigroups on a general von Neumann algebra in the view point of Connes correspondences. For this, we will provide a concept of product system whose components are Connes correspondences. There exists a one-to-one correspondence between a CP0-semigroup and a unit of a product system of Connes correspondences. The correspondence enables us to construct dilations and classify E0-semigroups by product systems of Connes correspondences up to cocycle equivalence.

МЕТОДИКА ПЛАНИРОВАНИЯ ИЗМЕНЕНИЙ В БИЗНЕС-МОДЕЛИ ДЛЯ АДАПТАЦИИ СОВРЕМЕННЫХ ПРИНЦИПОВ ОРГАНИЗАЦИИ ПРОИЗВОДСТВА НА ОБОРОННОМ ПРЕДПРИЯТИИ

The reduction of the state defense order due to the implementation of the tasks of the state weapons program for the current period has led to the need for enterprises of the defense-industrial complex (DIC) to find additional opportunities to preserve their potential and prevent possible insolvency. The main one is the diversification, which implies a massive transition of defense enterprises to civilian production. Meanwhile, the long-standing orientation of such enterprises to the requirements of a single customer, the conservatism of production systems and the absence of market competences does not allow to take advantage of this opportunity without making changes in the organization of production. In turn, it is impossible to master progressive concepts of building production systems of defense enterprises without changing the entire business model implemented by them. The methodological provisions of this work are discussed in this article.

The Role of Process Improvements Tools in Building Relationship between Suppliers and Industrial Clients

The purpose of this research paper is to present the role of process improvements tools in building relationships between clients and suppliers on the industrial goods market. Their identification was based on an analysis of the literature, as well as on the results of empirical research conducted by the CATI technique and covered 300 producers that were suppliers for enterprises from the chemical, metal and automotive industry sectors operating in Poland. The results of the conducted research indicate that the main supplier requirements relating to technical quality of products, shortening cycles of process implementation and willingness of the supplier to reduce costs. One could also observe that for many industrial clients, their relationships with suppliers are not just confined to fulfilling rigorous requirements. Increasingly, they recognize that building their competitive advantage also requires building partnerships with suppliers that are manifested in joint projects in the field of effective application of the requirements of tool (like quality, environmental and safety management systems, Toyota Production System or Lean Management concept), which have an impact on the improvement of the products and processes in the supply chain.