Simulation Of Production Line Research Articles

Design and application of virtual simulation teaching platform for intelligent manufacturing

Aiming at the practical teaching of intelligent manufacturing majors faced with lack of equipment, tense teachers and other problems such as high equipment investment, high material loss, high teaching risk, difficult to implement internship, difficult to observe production, difficult to reproduce the results, and so on, we take the electrical automation technology, mechatronics technology and industrial robotics technology majors of intelligent manufacturing majors as an example, and design and establish a virtual simulation teaching platform for intelligent manufacturing majors by using the cloud computing platform, edge computing technology, and terminal equipment synergy. The platform includes six major virtual simulation modules, including virtual simulation of electrician electronics and PLC control, virtual and real combination of typical production lines of intelligent manufacturing, dual-axis collaborative robotics workstation, digital twin simulation, virtual disassembly of industrial robots, virtual simulation of magnetic yoke axis flexible production line. The platform covers the virtual simulation teaching content of basic principle experiments, advanced application experiments, and advanced integration experiments in intelligent manufacturing majors. In order to test the effectiveness of this virtual simulation platform for practical teaching in engineering, this paper organizes a teaching practice activity involving 246 students from two parallel classes of three different majors. Through a one-year teaching application, we analyzed the data on the grades of 7 core courses involved in three majors in one academic year, the proportion of participation in competitions and innovative activities, the number of awards and certificates of professional qualifications, and the subjective questionnaires of the testers. The analysis shows that the learners who adopt the virtual simulation teaching platform proposed in this paper for practical teaching are better than the learners under the traditional teaching method in terms of academic performance, proportion of participation in competitions and innovative activities, and proportion of awards and certificates by more than 13%, 37%, 36%, 27% and 22%, respectively. Therefore, the virtual simulation teaching platform of intelligent manufacturing established in this paper has obvious superiority in solving the problem of "three highs and three difficulties" existing in the practical teaching of engineering, and according to the questionnaire feedback from the testers, the platform can effectively alleviate the shortage of practical training equipment, stimulate the interest in learning, and help to broaden and improve the knowledge system of the learners.

Integrating human-centric simulations in educational production lines: advancing ergonomics for industry 5.0 applications

This research in the Industry 5.0 field focuses on a human-centered simulation of the FAS200 SMC educational production line, utilizing Tecnomatix Process Simulate Human software for developing a virtual human environment. A key aspect of this study is the integration of inertial sensors, enhancing the accuracy and depth of ergonomic analysis. These sensors play a pivotal role in capturing precise human movement data, crucial for ergonomic assessments. Adopting a defined working methodology, the study extensively employs the RULA method to evaluate operator postures in the production line. This approach has led to significant ergonomic improvements, evidenced by a 40 percent reduction in the RULA index at each workstation. The integration of inertial sensors has been instrumental in achieving these results, providing detailed insights into human movements and interactions with the production environment. The research transcends traditional ergonomic assessments by incorporating a new human-centered approach, emphasizing the well-being of individuals working alongside machines. This approach, bolstered by the use of inertial sensors, marks a significant advancement in ergonomic studies, aligning with the principles of Industry 5.0. The findings hold substantial potential for application in industrial settings, signaling a shift towards more human-friendly and efficient industrial practices.

DIGITAL TWIN COLLABORATION: A COMMON TECHNICAL STRUCTURE FOR THE AUTOMOTIVE AND THE BUILDING INDUSTRY

During the planning stage of production sites for the automotive industry, the building industry and the automotive industry clash. Nevertheless, the planning in both industries is generally done separately and there is not enough communication which leads to problems later on in the process. In the automotive industry, the digital twin is already used as a common tool for the planning and simulation of production lines. In the building industry however, the digitalization is not as well-advanced. Since the workflows, the degree of digitalization and the used software tools differ so much, the combination of the different processes and data of the automotive industry and the building industry is still very difficult nowadays. In order to solve that problem, the aim is to develop a common structure that allows both industries to collaborate and share their data, starting early on in the planning process. The current workflows of both industries were analyzed by conducting interviews with experts in their field. Evaluation of the answers and further discussion in the interdisciplinary team of the research project “CoLab4DigiTwin” showed that the workflows of both industries actually have the similar approach of starting the planning process by thinking in three-dimensional spaces that get more detailed information over time. Based on this finding, a hierarchical technical structure was developed, combining the spaces of the building industry and the automotive industry. This structure acts as a clear common base that facilitates an organized data exchange and improves the interdisciplinary collaboration.

DIGITAL TWIN COLLABORATION: A COMMON TECHNICAL STRUCTURE FOR THE AUTOMOTIVE AND THE BUILDING INDUSTRY

During the planning stage of production sites for the automotive industry, the building industry and the automotive industry clash. Nevertheless, the planning in both industries is generally done separately and there is not enough communication which leads to problems later on in the process. In the automotive industry, the digital twin is already used as a common tool for the planning and simulation of production lines. In the building industry however, the digitalization is not as well-advanced. Since the workflows, the degree of digitalization and the used software tools differ so much, the combination of the different processes and data of the automotive industry and the building industry is still very difficult nowadays. In order to solve that problem, the aim is to develop a common structure that allows both industries to collaborate and share their data, starting early on in the planning process. The current workflows of both industries were analyzed by conducting interviews with experts in their field. Evaluation of the answers and further discussion in the interdisciplinary team of the research project “CoLab4DigiTwin” showed that the workflows of both industries actually have the similar approach of starting the planning process by thinking in three-dimensional spaces that get more detailed information over time. Based on this finding, a hierarchical technical structure was developed, combining the spaces of the building industry and the automotive industry. This structure acts as a clear common base that facilitates an organized data exchange and improves the interdisciplinary collaboration.

Design and Motion Simulation of Conveyor Production Line for Salted Kelp Turnover Box

Design and Motion Simulation of Conveyor Production Line for Salted Kelp Turnover Box

Implementation of process optimization to maximize line productivity in pharmaceutical industries

Macro Group is the largest player in Egypt’s fast-growing cosmeceutical industry founded in 2002, and Macro has about 149 stock-keeping units (“SKUs”) with a 31.4% market share in 2022. The macro group has three-ampoule products for hair, namely, Atrakta, Verdex, and Solodex with an expected forecast of 134,655 FG in 2023 and it’s expected to reach 261,000 FG in 2027. 188 working days per year in 2023 are required to manufacture the forecasted units and 365 working days to manufacture 2027 forecasted units. Through observing the production line of Atrakta, it has been noticed that the production line could be enhanced to increase the production rate, and hence, meet market demands efficiently. Therefore, this paper aims to study and investigate the Atrakta hair ampoules production line to reach the optimum line productivity and to commit to market needs. Studying the Atrakta hair ampules production line is conducted through interviews, production line observation, data collection, and modeling and simulation of the production line. Two scenarios recommending improvements to the production lines are proposed and simulated. The two scenarios differ mainly in the probability distribution of probabilistic inputs. Simulating the system with the recommended improvements for the two scenarios shows similar results of increased productivity. Simulation results of improved systems show an increase of 300% in daily production from 720 FG per day to 2176 FG per day. According to Atrakta's results, the Macro group decided to implement the same recommended improvements on the similar process of Verdex and Solodex ampoules to reach 2176 FG. The required working days to reach forecasted units in 2023 decreased from 188 to 67 days and also decreased from 365 to 132 days in 2027.ArticleHighlightsThe primary pack items are decreased, and secondary pack of ampoules SKUs has been changed to avoid bottlenecks.The change of primary and secondary pack plays a significant role in increasing the productivity 3 times for the non-sterile ampoules production unit.The increasing of production capacity decreased the required working days in 2023 till 2027.

Research on Real-time Simulation of Automobile Production Line based on Discrete Event and Multiagent

To improve the production efficiency and quality of the automobile production line, optimize the balance rate of the production line, and realize the digital mapping of the new energy automobile production line. The critical production lines of new energy vehicles are accurately modeled and visualized in the Anylogic environment using multi-agent and discrete event modeling methods. Through the establishment of data connection with actual equipment and the simulation of the operation of the production line, a visual simulation and analysis interface of the production line is built to detect the impact of process time on the balance rate, whether the inventory strategy is reasonable and whether it meets the actual production requirements, reduce the optimization cost, and provide a new idea for the digital twin system of the automobile production line.

Teaching Practice Exploration based on Digital Twin Technology

This paper studies the application of digital twin technology in practical courses, aiming at the pain points that the teaching of industrial robot application practical courses relies heavily on the number of practical training sites and equipment, and it is difficult to match the actual production. This paper focuses on the online digital simulation of key equipment, production products, processing technology and typical production lines in the application scenarios such as school training site and factory workshop through the twin technology, so as to build the digital twin training platform, restore the typical work tasks of enterprises, support the practice of online or online offline mixed digital teaching, and deepen the collaborative education between schools and enterprises.

An Automatic Assembly SMT Production Line Operation Technological Process Simulation Model Development

This article describes an automatic assembly SMT production line operation technological process simulation model development within the framework of modern cyber-physical production systems. In the course of the research, the authors conduct an analysis of modern publications on the topic of research, and the need to find new approaches for modeling the work of a production line at the initial stages of design. This makes it possible to assess the load on each element of the system at the design stage, and identify disadvantages at the early stages of production planning. The authors give an example of the task solution for modeling a fragment of an automated production line of SMT assembly, based on the use of typical mathematical schemes of mass service systems (MSS). A description of the functioning of the technological link of the process is carried out, and a Q-diagram of the technological process of SMT assembly is developed. Using the simulation modeling language GPSS and the technological parameters of the selected equipment, a block diagram was developed, on the basis of which the program was written and the work of the SMT assembly production line was simulated. The obtained results further allow us to estimate the production capacity, the loading of each equipment, the functioning processes of both the selected fragment, and the developed model and they can be applied to the simulation of large production lines within the framework of PCB production.

Construction and Practice of New Technology Course "Digital Design and Simulation of Production Line"

Digital Production Line Design and Simulation is a practical and comprehensive major course for electromechanical and automation majors in higher vocational colleges. This course is based on digital technology to construct automatic production lines, and uses virtual simulation and virtual reality combination technology for teaching, creating a new digital teaching ecology. In this paper, the teaching innovation means and methods are proposed, and specific exploration and practice are carried out for this course, which has achieved good teaching results.

Digital Twins-Based Production Line Design and Simulation Optimization of Large-Scale Mobile Phone Assembly Workshop

The mobile phone is a typical 3C electronic product characterized by frequent replacement, multiple product specifications, high flexibility, high-frequency production line switching, and urgent delivery time during production. Therefore, the optimized design of the mobile phone production workshop is crucial. This paper takes the assembly process of a specific type of mobile phone assembly as the research object and adopts the heuristic balance method to combine the production procedures. Moreover, it considers the automation degree of the process and the demand for production line rhythm to carry out station division and working hours design for the assembly process. The advantages and disadvantages of the plug-and-play production line and unit production line architecture are integrated, aiming at the production line’s construction cost and unit area capacity. A hybrid workshop with a mixed combination of two types of production lines is designed and an optimization model of hybrid workshop design is established. The semi-physical simulation technology of digital twins is utilized to verify the proposed design scheme to achieve the balance optimization of the production line, improve production efficiency, and reduce production costs. This work provides a technical scheme for designing and optimizing large-scale mobile phone assembly workshops with multi-batch and high-frequency production changes.

Research on Virtual Human Motion Control Based on Computer-Assisted Multimedia Simulation.

In order to reproduce realistic human motion in a virtual environment, a study of virtual human motion control based on computer-aided ergonomics simulation is proposed. First, we establish the required human body, workpiece, and production line simulation environment, and on this basis, we use OWAS, BSHA, and other analysis tools to carry out ergonomic simulation of virtual human motion simulation research, seek solutions to man-machine problems, and provide a new, efficient, and quantitative evaluation method for production line planning. The simulation results show that during the operation of virtual human 1, the ratio of the actual load on the left and right hands to the ultimate load has reached up to 70%. Therefore, it is necessary to revise the production line plan, and through analysis, it is concluded that the reason for the bad posture is due to the low height of the storage point and the machine tool. We believe that with continuous development, ProcessSimulate and ProcessDesigner will play a greater role in enterprise digitization.

Research on optimization and simulation of sand casting production line based on VSM

Purpose This paper aims to provide feasible countermeasures for the application of lean manufacturing in automatic sand casting workshops to optimize production line balance. Design/methodology/approach A production line balance optimization model for sand casting workshops is proposed. The value stream mapping (VSM) approach is applied to diagnose the problems in the production process. An optimization scheme is established based on eliminate, combine, rearrange, simplify and increase theory and Kanban management method. Further, simulation is done to compare current VSM and future VSM. Findings After implementing the proposed model, findings indicated that the idle time of equipment was effectively reduced, the line of balance of the production line was increased by 44.7%, the production lead time was shortened by 60.3% and the production capacity was increased by 50.0%. Research limitations/implications Application of the optimization model in this study is limited to sand casting workshops that have realized automatic or semi-automatic production. Originality/value This paper provides an optimization model for the implementation of lean manufacturing in sand casting workshops and provides a reference case that reflects the actual application of lean manufacturing tools in a real situation.

Research on the Process Simulation of robot automatic production line

Industrial robot is a high-tech product of modern society. It plays an important role in the operation of economic development. Especially in the manufacturing industry, industrial robots can replace manual labor to perform a variety of complex tasks, in order to intelligently build industrial automation, and improve the service of automated production lines.

Monitoring the Surface Quality for Various Deep Rolling Processes –Limits and Experimental Results

Mechanical surface treatments are specialized processes for improving part properties during their lifetime. However, they are additional processes within the process chain, which generate costs and use additional resources. In order to reduce the reject rate within the production line, process monitoring and process simulation need to be developed for these processes. Within the presented project, the effects of different materials, pre-machining and deep rolling tools are analyzed to simulate the surface quality. The effect of process parameters on the surface quality is measured to identify the limits of a surface integrity control system for deep rolling.

Research on simulation platform of intelligent production lines

In order to improve the ability of teachers and students to comprehensively apply intelligent production line technology, this paper provides an intelligent production line simulation method and system, which can simulate the operation of intelligent production line, and is easy to control and has lower cost, so as to meet the teaching needs of cultivating intelligent production line application talents. This paper introduces the development technology and implementation method of intelligent production line based on C language of single chip microcomputer.

Simulation and optimization of a factory automation production line based on Plant Simulation

Model an automated production line in a factory in order to understand and improve the automated production line. The layout and function of this automated production line were simulated on Plant Simulation, and the statistical results were obtained according to the actual situation. According to the results, the shortcomings of the production line were analyzed, an optimization method was proposed, and the results were simulated again by using genetic algorithm for comparison.

Simulation of vise production process using Flexsim Software

In the industrial the process of clamping on an object is an important process carried out to facilitate the work when the process of cutting, sculpting, welding and etc. A vise is a clamping tool to clamp a workpiece milled. Using the vise, the workpiece clamped tightly to facilitate the work and the results of a process is maximum. The components contained in a vise have their own functions. This research is about simulating vise production process. The purpose of this study is to model the vise production process using Flexsim software and compare the simulation results data with the vise production target data to find out whether the simulation describes the actual condition of the vise production process. The results obtained in the manufacture of vise production lines using Flexsim software produce an output of 22 units for 1 shift / day or 7 working hours. The vise production line simulation model produces 25 vise production target data, 22 simulation results data and 12% deviation occurs, so the simulation describes the actual condition of the vise production process.

A digital twin framework for the simulation and optimization of production systems

Industry 4.0 has raised the expectations on productivity, automation, and resource efficiency of manufacturing systems. This paper proposes a digital twin framework for the simulation and optimization of production lines and cells that can be used in the design and operation stages. The framework is supported by an architecture that connects manufacturing and machine tool data (digital shadow), the discrete event simulation model and the optimization engine, allowing for a variety of functionalities to plan and manage the production system. A use case is provided to demonstrate this framework, implemented in an automated line for the manufacturing of railway axles.

Aggregated models for decision-support in manufacturing systems management

Many industrial challenges can be related to the setup of manufacturing plants and supply chains. While there are techniques available for discrete event simulation of production lines, the opportu...