Smart Manufacturing Systems Research Articles

Modelling resilience dynamics for smart manufacturing systems: quantification and empirical analysis

ABSTRACT Smart manufacturing contributes to a better management of uncertainties and risks in today’s business environment, leading to a more resilient system. Despite its significance, the quantification of resilience in manufacturing environments is not well developed and is considered a pressing research gap. This study introduces a novel approach for assessing resilience through the development of a mathematical model for smart manufacturing systems. The sensitivity and applicability of the proposed model are investigated through simulation-based experimentation. The results demonstrate the level of resilience with the adaptability of smart manufacturing technologies. Interestingly, the trigger point derived from the simulation results is an indicator of the threshold limit for effective implementation of smart manufacturing technologies for the desired system resilience. The research provides a tool for decision-makers in industry that are considering investing in smart manufacturing solutions to increase their operational resilience. Decision-makers can design the deployment of smart manufacturing systems based on an informative trade-off to maintain the required resilience capabilities and achieve a competitive edge in the market.

Blockchain‐based smart and secure manufacturing systems

AbstractIn the current data sharing environment of smart manufacturing systems, there is a lack of a transparent, open, and fair interaction environment, and there exists a serious imbalance in data sharing and transmission, which leads to data trust issues. To address this challenge, we propose a fine‐grained access control method for IoT data sharing based on blockchain technology (the Bayesian information criterion [BIC] scheme for IoT data sharing). This approach includes ex‐ante supervision and authentication of data sources, fine‐grained access control during data usage, and ex‐post tracking of malicious users. Firstly, a system model is built, and symmetric encryption is used to encrypt the data in order to improve computational efficiency. Subsequently, scheme design and algorithm design are carried out to encrypt the symmetric key using ciphertext‐policy attribute‐based encryption to achieve one‐to‐many data sharing, which greatly reduces the number of repeated encryptions and computational overheads. The data owner uploads the encrypted data to the cloud server, and the data user must hold the token generated by the blockchain to interact with the cloud and obtain the corresponding information. The results show that the BIC scheme not only ensures the legitimacy and security of data access but also locks up and traces malicious users who may have compromised their private keys, preventing illegal data sharing and key misuse; it offers significant advantages in terms of storage efficiency and time consumption, and also facilitates a flexible and secure data sharing process.

Learning-based production, maintenance, and quality optimization in smart manufacturing systems: A literature review and trends

With the introduction of manufacturing paradigms, including Industry 4.0, production research has shifted its focus to enabling intelligent manufacturing systems within industrial environments. These systems can efficiently schedule and control processes and operations using artificial intelligence methods, including machine learning and deep learning. Since 1995, relevant literature has presented several examples of such implementations, addressing topics, for example equipment fault diagnosis and quality inspections. To this end, the present paper strives to present a state-of-the-art review of the learning-based scheduling and control frameworks, which are exploited in the production research. The review is limited to the relevant research between the years 1995 and 2024, surveying approaches in the domains of manufacturing, maintenance, and quality control. To this end, the paper follows a meta-analysis method for the selection and evaluation of relevant research articles. Moreover, research questions are formulated to analyze the obtained findings and seek out insights on aspects of the relevant research, including the inclusion of decision-making models and dissemination of literature. The provided answers, among others, reveal trends and limitations of the state-of-the art research in relation to learning-based scheduling and control.

Robustness analysis of smart manufacturing systems against resource failures: A two-layered network perspective

Complex and changing environments often cause resource failures in smart manufacturing systems (SMSs), significantly affecting their robustness. This paper introduces a novel methodology to assess the robustness of SMSs facing resource failures, using a complex network approach. It divides SMSs into social and technical layers, analyzes resources and relationships within and between these layers, and establishes a two-layered network model. It also categorizes various types of failures and proposes three robustness metrics to evaluate system performance at individual, local, and global levels. Simulations visually demonstrate the methodology and key findings: (1) the robust-but-fragile trait of SMSs only reacts to node failures and keeps significant in terms of the gradient of robustness; (2) there exists no edge failure that keeps damaging system robustness to the maximal or minimal degrees, and edge failures cause less damage to system robustness than node failures; (3) when failures occur, SMS robustness at all levels changes with inconsistent paces, and the optimal link mode varies by network structures and failure strategies. Finally, managerial implications are presented to guide practical robustness control at different stages of SMS lifecycles.

The Impact of Industrial Robot Applications on Global Value Chains Division Position

This paper surveys the GVC division position across forty-five countries and fourteen manufacturing sub-sectors during the period from 1999 to 2018 to illustrate the impact of applications of industrial robots on the GVC position. The study proves that an increasing level of utilization of industrial robots significantly improves the GVC division position in the manufacturing sector. By automating repetitive and precision tasks, robots enhance efficiency and productivity, therefore allowing deeper specialization in specific stages of the manufacturing process. This technological progress allows for a more connected global production network and hence better integration into GVC. The study also evaluates the spillover effects across value chains and the moderating impact of industrial agglomeration on smart manufacturing.The empirical results show that the application of industrial robots enhances productivity and encourages innovation in related sectors, thereby driving downstream industry growth and promoting industry specialization.Despite the improvement in GVC division positions, robots also contribute to making global value chains more diversified and resilient. Flexible and adaptive manufacturing systems can adapt to disruptions, such as pandemics and geopolitical tensions, ensuring continuity in production and increasing stability and competitiveness in smart manufacturing systems.

IoT and Edge Computing for Smart Manufacturing: Architecture and Future Trends

The integration of the Internet of Things (IoT) and Edge Computing is revolutionizing the manufacturing industry, ushering in the era of smart manufacturing as part of Industry 4.0. This paper explores the synergy between IoT and Edge Computing, focusing on their combined architecture and the future trends driving innovation in smart factories. IoT enables the connection and communication of machines, sensors, and systems, allowing for real-time data collection and monitoring. However, traditional cloud-based approaches face challenges such as latency, bandwidth limitations, and security risks, which can hinder real-time decision-making in fast-paced manufacturing environments. Edge Computing addresses these issues by processing data closer to the source, minimizing latency and reducing dependence on cloud infrastructures. By combining IoT and edge solutions, smart manufacturing systems can make faster, data-driven decisions, leading to improved efficiency, reliability, and operational flexibility. This paper delves into the architectural design of IoT and edge computing in manufacturing, outlining how data flows from IoT devices to edge nodes and cloud services. Several real-world use cases and industry examples are analyzed to highlight the practical benefits of these technologies. Additionally, this research identifies key challenges such as security vulnerabilities, the need for robust network infrastructures (e.g., 5G), and issues related to data standardization. The future of smart manufacturing is also explored, emphasizing trends like the adoption of artificial intelligence (AI) and machine learning (ML) at the edge, digital twins for real-time monitoring, and the role of IoT and edge computing in fostering sustainability through energy-efficient production processes.This study provides a comprehensive overview of IoT and edge computing architectures in smart manufacturing and offers insights into future technological trends that will shape the industry.

An Integrated Smart Manufacturing System for Customer Design Experience

This study focuses on the development of an integrated smart manufacturing system (ISMS) that centers on custom design experiences, utilizing virtual reality (VR) and cloud integration to enhance operational value. Through a Design for Excellence (DFX) approach, this system aims to seamlessly incorporate customer-specific designs into the manufacturing process, thus aligning closely with consumer needs. The research contributes significantly by (1) implementing a customer-focused design system that enhances sales benefits, (2) enabling a smooth transition from design drawings to automated production, thereby increasing manufacturing efficiency, and (3) establishing a digital transformation framework that integrates design, production, and marketing to boost overall business value.

An adaptable Digital Twin model for manufacturing

In a smart manufacturing system, physical assets are often connected to their Digital Twins in the virtual world that composes a cyber-physical production system (CPPS). Digital Twin is synchronized with the physical asset. Digital Twin is therefore considered an enabling technology of smart manufacturing. In the process of developing Digital Twins, the Digital Twin model is of great significance. Many Digital Twin models have been proposed in the past decades, including geometry models, information models, and ontology models. However, there has not been an adaptable and generic Digital Twin model that can be used for various scenarios in a manufacturing system. This paper proposes an adaptable Digital Twin model based on the object-oriented concept. The proposed Digital Twin model can be applied to different situations using object-oriented concept features. Firstly, the base Digital Twin model is developed according to ISO 23247, including the essential attributes of a Digital Twin. The aggregation and composition mechanism of the proposed Digital Twin model is also described based on the object-oriented concept. After that, according to the categories of the physical assets on the shop floor, Digital Twin models of different physical assets are developed based on the base Digital Twin model, inheriting the features of the base Digital Twin model. In the end, a case study is carried out for verification on a machine tool in the Laboratory for Industry 4.0 Smart Manufacturing Systems (LISMS).

High-resolution time-series classification in smart manufacturing systems

High-resolution time-series data is increasingly prevalent in today’s smart manufacturing systems driven by the proliferation of sensors and data acquisition technologies. However, classification tasks on such data face challenges like collinearity, model instability, poor generalization, and overfitting. This paper investigates techniques capable of handling high-resolution time-series classification (TSC) tasks in the manufacturing domain. High-resolution time-series data presents challenges impacting the concepts essential for classification algorithms. Additionally, increased noise and the extensive feature space further complicate classification performance, emphasizing the need for innovative solutions to process this data efficiently on resource-constrained devices. In this paper, we address this research gap by defining the problem in depth, investigating possible solutions, and evaluating a subset of solutions in a manufacturing case study. We utilize a CNC machining dataset with over 100,000 data points per time-series. We examine algorithms representing two main approaches: feature engineering for data transformation and dimensionality reduction, and advanced machine learning and deep learning models to capture long-term dependencies. Specifically, we implement Discrete Fourier Transform, Symbolic Aggregate Approximation, Symbolic Fourier Approximation, ARSENAL, DrCIF, and ResNet algorithms for TSC. Experimental results highlight the trade-off between accuracy and computational expense. While ARSENAL and DrCIF achieve high accuracy, their runtimes are notably high. Feature engineering methods offer competitive accuracy with very low runtimes, and ResNet strikes a compelling balance by surpassing benchmarks in accuracy while maintaining reasonable computational costs. These findings can aid in adopting appropriate tools to successfully harness manufacturing big data to derive actionable insights for process improvements and optimization. The novelty of this research lies in addressing the specific challenges of classification tasks on high-resolution time-series data within the manufacturing domain, exploring diverse techniques, applying them to a case study, and providing a nuanced analysis of algorithmic performance with practical implications.

Mass customization using hybrid manufacturing and smart assembly: An optimal configuration and platform design approach

Hybrid Manufacturing (HM) and smart assembly stand as pivotal pillars in advanced smart manufacturing systems, offering manufacturers highly efficient and adaptable solutions for manufacturing. This paper delves into the configuration of a production line that integrates HM and assembly stages, each comprising multiple cells, with each cell housing one or more parallel stations. The objective is to manufacture a family of final assemblies, leveraging the platform concept to defer mass customization to later stages and thereby minimize processing costs. A mathematical programming model is proposed to identify the optimal configuration for such production lines, considering constraints such as an allowable capital cost and machine availabilities. In addition, the precedence, inclusion, and seclusion restrictions imposed on the part family are considered. The proposed mathematical programming model aims to delineate which HM features are processed in the part platform cell versus those processed in the mass customization (part variants) cells. Simultaneously, the model determines the components (variants from the HM stage) of final assemblies processed in the assembly platform cell, as well as components assembled or disassembled in the final assembly cells. Furthermore, the model seeks to determine the required number of stations in each cell to meet periodic demand. The overall objective of the model is to minimize the capital and the processing cost. A detailed case study illustrates the effectiveness of the proposed configuration approach and mathematical model. The proposed model is solvable in a few seconds by using commercial solvers.

Development and Application of Digital Twin Control in Flexible Manufacturing Systems

Flexible manufacturing systems (FMS) are highly adaptable production systems capable of producing a wide range of products in varying quantities. While this flexibility caters to evolving market demands, it also introduces complex scheduling and control challenges, making it difficult to optimize productivity, quality, and energy efficiency. This paper explores the application of digital twin technology to tackle these challenges and enhance FMS optimization and control. A digital twin, constructed by integrating simulation models, data acquisition, and machine learning algorithms, was employed to replicate the behavior of a real-world FMS. This digital twin enabled real-time dynamic optimization and adaptive control of manufacturing operations, facilitating informed decision making and proactive adjustments to optimize resource utilization and process efficiency. Computational experiments were conducted to evaluate the digital twin implementation on an FMS equipped with robotic material handling, CNC machines, and automated inspection. Results demonstrated that the digital twin significantly improved FMS performance. Productivity was enhanced by 14.53% compared to conventional methods, energy consumption was reduced by 13.9%, and quality was increased by 15.8% through intelligent machine coordination. The dynamic optimization and closed-loop control capabilities of the digital twin significantly improved overall equipment effectiveness. This research highlights the transformative potential of digital twins in smart manufacturing systems, paving the way for enhanced productivity, energy efficiency, and defect reduction. The digital twin paradigm offers valuable capabilities in modeling, prediction, optimization, and control, laying the foundation for next-generation FMS.

Vibration energy-based indicators for multi-target condition monitoring in milling operations

The demand for intelligent process monitoring is increasing in aerospace manufacturing to ensure tight tolerances and high surface quality. Real-time monitoring in machining is crucial for machined accuracy and process reliability, reducing production times and costs, and enhancing automation of the manufacturing process. This study presents a robust multi-target condition monitoring method based on the vibration signals. Firstly, three new energy ratio indicators with dimensionless characteristics were defined for tool wear, breakage, and chatter monitoring. Secondly, the vibration energy loss from the tool tip to the tool holder, and spindle housing was measured and compared, and the rules of vibration loss from the tool tip to the spindle housing were revealed. Using force signals as a reference, the monitoring performance of industrially acceptable acceleration and sound signals in multi-target condition monitoring was quantitatively analyzed. Finally, the performance of the proposed vibration energy-based indicators was experimentally illustrated and quantitatively evaluated. It is shown that these indicators can be used to discriminate between tool breakage and chatter, as well as to assess tool wear. The new monitoring method can also minimize the costs of process monitoring by reducing the use of expensive sensors or overusing multiple sensors in a smart manufacturing system.

Web tension AI modeling and reconstruction for digital twin of roll-to-roll system

AbstractDigital twins (DT) are gaining attention as an emerging technology in Smart manufacturing systems. These DTs comprise various units that enable simulation, monitoring, and prediction of the manufacturing process. This study introduces a predictive model for web tension and a tension reconstruction algorithm for the DT of the roll-to-roll (R2R) system. The observed web tension signals from tension sensors decomposed into a mean component, a sinusoidal wave, and a random noise. Utilizing deep neural networks, the predictive model integrated various sub-models to forecast statistical (mean, standard deviation) and frequency domain (main frequency, signal-to-noise ratio) features of the web tension signal. Through fivefold cross-validation, 23 model architectures were optimized, with selected architectures ranging from 16-32-32-1 to 16-32-64-32-1 nodes per layer. Overall, R2 scores on the test set ranged from approximately 52 to 100%. The proposed reconstruction algorithm generated tension signals from the model’s predictions that closely resemble the original tension signals, indicating credible reconstructions. The proposed predictive model and reconstruction algorithm were integrated into the DT of the R2R system, offering a valuable tool for monitoring and optimizing the R2R process.

MSTAN: multi-scale spatiotemporal attention network with adaptive relationship mining for remaining useful life prediction in complex systems

Abstract In the era of smart manufacturing and advanced industrial systems, the high degree of integration and intelligence of equipment demands higher reliability and safety from systems. Existing methods often rely on historical data for Remaining Useful Life (RUL) prediction to achieve Prognostic and Health Management (PHM). However, the internal units of complex equipment exhibit significant spatial correlation and temporal diversity, making PHM for complex equipment a multidimensional challenge involving both temporal and spatial information, thereby severely limits the effectiveness of RUL prediction for complex systems. Addressing these challenges, this study introduces a multi-scale spatiotemporal attention network with adaptive relationship mining, specifically designed for the remaining useful life (RUL) prediction of such equipment. The core of the proposed method lies in the multi-scale feature perception module, which adeptly extracts varied scale features from multidimensional sensor data. Following this, an innovative adaptive relationship mining module is integrated to uncover multi-order coupling relationships between diverse sensors, enhancing the model’s predictive accuracy. Furthermore, a spatiotemporal attention module is employed to discern and emphasize crucial spatiotemporal correlations. To validate the effectiveness and superiority of the proposed method, the Commercial Modular Aero-propulsion System Simulation (C-MAPSS) dataset is employed for comprehensive performance evaluation, the IEEE 2012 PHM bearing dataset is also adopted to demonstrate the generalization and robustness of the proposed method. The results not only show a notable improvement over existing methods but also offer a more intuitive understanding through visual representations, marking a significant stride in enhancing the safety and efficiency of complex systems.

E-CARGO-based dynamic weight offload strategy with resource contention mitigation for edge networks

With the widespread use of Mobile Edge Computing (MEC) in smart manufacturing systems in Industrial Internet of Things (IIoT) and 5G networks, determining how to efficiently offload computing tasks has become a hot research area. The Role-Based Collaboration (RBC) Environments-Classes, Agents, Roles, Groups, and Objects (E-CARGO) model is introduced to comprehensively manage MEC servers and user computation tasks in edge network environments, thereby improving the effectiveness and performance of task offloading in smart manufacturing systems. To begin with, latency and energy consumption are important indicators for evaluating the offloading effect. A pre-allocation algorithm based on user latency tolerance is proposed to dynamically adjust the latency-energy consumption weighting factor to optimize system resource allocation for real-time adjustment of offloading decisions. Second, the Group Role Assignment of Agent Role Conflicts (GRACAR) model based on E-CARGO is extended, along with a dynamic weighting of the GRACAR (GRACAR-DW) model and formal modeling. By introducing resource contention constraints, the resource contention caused by excessive task data offloading to the same MEC server is proactively mitigated. Finally, a Gurobi solution based on Mixed-Integer Linear Programming (MILP) is developed to help validate and synthesize the proposed model. Simulation results show that the strategy considerably enhances the MEC system's overall performance in terms of latency and energy consumption while also providing new ideas and technological support for offloading decisions in edge networks.

Joint optimization of production, inspection, and maintenance under finite time for smart manufacturing systems

Given the flexible and configurable characteristics of smart manufacturing systems with a limited time per manufacturing task, the assumption of infinite time for prostems is no longer applicable to the joint-control strategy. Consequently, a joint-control model that considers production, inspection, and maintenance within a finite-time scenario for smart manufacturing systems is proposed in this paper. The objective is to optimize overall production and maintenance functions to minimize the total system cost. Comparing the joint strategy under infinite time with the proposed finite-time approach reveals significant differences in unit costs between the two scenarios. To enhance the effectiveness of the model, a discrete iterative algorithm with multiple loops was developed. Through a case study, it was observed that 1) joint strategies implemented within a finite time horizon were more cost-effective than those under infinite time, thus emphasizing the need for business managers to develop strategies within a finite time frame; 2) different production planning and efficiency levels had varying effects on the final joint strategy, necessitating customized strategies based on different production durations. Overall, the research gap regarding joint strategies within a finite-time context was addressed in this research, serving as a methodological foundation for practitioners to develop various strategies that minimize total costs across diverse real-world scenarios.

Assessing Impact of AI on Resource Efficiency in Manufacturing in West Africa

This study investigates the impact of Artificial Intelligence (AI) on resource efficiency in the manufacturing sector within West Africa, a region characterized by infrastructural challenges and resource constraints. Through integrating Transaction Cost Economics (TCE) and the Resource-Based View (RBV) theories, the research explores how AI-driven technologies, including predictive maintenance, production optimization, real-time data analytics, and smart manufacturing systems, enhance resource efficiency. A quantitative research design with a correlational approach was employed, surveying 381 professionals across various manufacturing sectors. The study also examined the moderating role of the regulatory environment and the mediating effect of employee training and adaptation on these relationships. Findings indicate that AI-driven technologies significantly improve resource efficiency by reducing downtime, optimizing production processes, and enhancing decision-making. The regulatory environment positively moderates the relationship between AI technologies and resource efficiency, particularly when coupled with employee training. This study contributes to the existing body of knowledge by providing empirical evidence on the strategic role of AI in resource-constrained environments, emphasizing the importance of supportive regulations and workforce adaptation. The results offer practical implications for policymakers and industry leaders in West Africa, highlighting the need for targeted investments in AI infrastructure, regulatory development, and capacity building to fully leverage AI's potential in manufacturing.

Bibliometric Analysis on the Application of IoT in Smart Manufacturing System in Industry 4.0

The rapid integration of Internet of Things (IoT) technologies in smart manufacturing systems has been a pivotal development within the framework of Industry 4.0. This study conducts a comprehensive bibliometric analysis to examine the evolution, current trends, and emerging research areas related to IoT applications in smart manufacturing. By analyzing data from a decade of scholarly publications, this research identifies key themes, influential authors, and collaborative networks that have shaped the field. The findings reveal that foundational technologies such as the internet, cloud computing, and big data are central to the development of smart manufacturing, while newer innovations like digital twins and blockchain are gaining prominence. The study also emphasizes the importance of strategic collaboration among researchers and industry professionals in advancing IoT adoption. The practical implications suggest that manufacturers should prioritize both foundational digital infrastructure and emerging IoT applications to enhance efficiency, security, and sustainability. This analysis provides a roadmap for future research and practical implementation, highlighting the critical areas where IoT can further revolutionize smart manufacturing systems.

A machine learning-based simulation metamodeling method for dynamic scheduling in smart manufacturing systems

Conventional Digital Twins (DTs) in smart manufacturing rely on complex and time-intensive simulation models, hindering real-time DT-based decision-making. However, the availability of big data in Manufacturing Execution Systems (MES) enables training different Machine Learning (ML) models for fast and accurate predictions and decision assessments. Accordingly, this paper proposes an ML-Based Simulation Metamodeling Method (MLBSM) to facilitate DT-based decision-making for dynamic production scheduling in complex Stochastic Flexible Job Shop (SFJS) environments. The proposed MLBSM integrates three modules: a novel data vectorizing method (SPBM), multi-output Adaptive Boosting Regressor (ABR) models, and a new statistical risk evaluation method. SPBM converts unstructured production log data into numerical vectors for ABR training by calculating numeric penalty scores for each job based on the position of operations in the schedule queue. Each trained ABR predicts mean job completion times for various dynamic scenarios based on shift schedules. The risk evaluation method estimates the standard deviation of job completion times and calculates the delay probability scores for each job, aiding DT in promptly evaluating production schedules. Working seamlessly together, MLBSM modules present a novel way of using production log data for ML training and ultimately bypassing several computationally intensive simulation replications. In this research, a simulation model generates the synthetic MES data, focusing on the machining process at a photolithography workstation in the semiconductor manufacturing. Experiments demonstrate the MLBSM’s accuracy and efficiency, predicting high-risk jobs with over 80% recall and being at least 70 times faster than conventional simulation runs. Sensitivity analyses also confirm the MLBSM’s consistency under different workstation conditions.

Reconfigurable Digital Twin from the Perspective of Smart Manufacturing Systems in Industry 4.0/5.0

Reconfigurable Digital Twin from the Perspective of Smart Manufacturing Systems in Industry 4.0/5.0