digital factory technologies for robotic automation and enhanced manufacturing cell design

The fourth industrial revolution is characterised by the increased use of digital tools, allowing for the virtual representation of a real production environment at different levels, from the entire production plant to a single machine or a specific process or operation. In this framework, Digital Factory technologies, based on the employment of digital modelling and simulation tools, can be used for short-term analysis and validation of production control strategies or for medium term production planning or production system design/redesign. In this research work, a Digital Factory methodology is proposed to support the enhancement of an existing manufacturing cell for the fabrication of aircraft engine turbine vanes via robotic automation of its deburring station. To configure and verify the correct layout of the upgraded manufacturing cell with the aim to increase its performance in terms of resource utilization and throughput time, 3D Motion Simulation and Discrete Event Simulation are jointly employed for the modeling and simulation of different cell settings for proper layout configuration, safe motion planning and resource utilization improvement. Validation of the simulation model is carried out by collecting actual data from the physical reconfigured manufacturing cell and comparing these data to the model forecast with the aim to adapt the digital model accordingly to closely represent the physical manufacturing system

Energy efficiency in discrete-manufacturing systems: insights, trends, and control strategies

Since the depletion of fossil energy sources, rising energy prices, and governmental regulation restrictions, the current manufacturing industry is shifting towards more efficient and sustainable systems. This transformation has promoted the identification of energy saving opportunities and the development of new technologies and strategies oriented to improve the energy efficiency of such systems. This paper outlines and discusses most of the research reported during the last decade regarding energy efficiency in manufacturing systems, the current technologies and strategies to improve that efficiency, identifying and remarking those related to the design of management/control strategies. Based on this fact, this paper aims to provide a review of strategies for reducing energy consumption and optimizing the use of resources within a plant into the context of discrete manufacturing. The review performed concerning the current context of manufacturing systems, control systems implemented, and their transformation towards Industry 4.0 might be useful in both the academic and industrial dimension to identify trends and critical points and suggest further research lines.Peer ReviewedPreprin

An investigation into current production challenges facing the Libyan cement industry and the need for innovative Total Productive Maintenance (TPM) strategy

Purpose - The purpose of this paper is to investigate maintenance and production problems in the cement industry in Libya with particular emphasis on future implementation of Total Productive Maintenance (TPM). Methodology/ Approach - The paper presents the use of case study approach of production data and history, field visits, a survey methodology using a detailed questionnaire with employees and interviews with top and middle managers in four cement factories. Findings - It has been found that the four factories under investigation have low productivity and production levels when compared with the design values. There is no clear TPM strategy and it has been also found that the lack of training and personal development is the main cause of this problem. In addition, employees are found not to be motivated as a result of the lack of poor management strategy and reward structure. Implications - Based on the findings, a new framework for TPM has been developed. This TPM strategy could be implemented in other Libyan factories as a result of the potential similarities in the cultural and environmental aspects. Practical implications - The current challenges have been identified and comparative analysis is developed into a model for the implementation of TPM. Originality/Value of pape r- The paper highlights limitation is the cement factories in Libya in relation to TPM and production strategies. The importance of adopting a realistic strategy and framework by managers is discussed. This work is developed as collaboration between Academia and Libyan Cement industry for solving productivity problems and develop a strategic framework of TPM for improving the Libyan industry

Factory Eco-Efficiency Modelling: Framework Development and Testing

Eco-efficiency is becoming an increasingly important organisational performance measure. Its indicators are regularly used alongside productivity, cost, quality, health and safety in operations and corporate social responsibility reporting. The purpose of this paper is to show an eco-efficiency modelling framework, and its application in the case of an automotive manufacturer. The framework composes, models and analyses resource and production data. Focus on energy, water distributions and material transformations in manufacturing, utility and facility assets are used to analyse eco-efficiency. Resources are examined in respect to three data granularity factors: subdivision, pulse, and magnitude. Models are linked with performance indicators to assess asset eco-efficiency. This work contributes to industrial sustainability literature by introducing a modelling framework that links with data granularity and eco-efficiency indicators

Applied scientific and systemic problems of the related ore-dressing plants interaction in the event of decommissioning the massif that separates their quarries

Purpose. Determining the possible and substantiating expedient alternate design and engineering decisions regarding the stage of spacial union of the adjacent quarries belonging to various owners by mining the rock pillar between the No. 3 quarry of PJSC “ArcelorMittal Kryvyi Rih” and the quarry of PJSC “Southern Mining Factory” with involvement into mining the reserves, extraction of which is possible within the existing mining and land allotments. Methods. It was used an integrated methodological approach, including mining and geological analysis of the rock massif between two adjacent quarries, which is subject to decommissioning; technical-economical analysis of the operational efficiency of the ore-dressing plant when decreasing the ore mine productivity as a result of cleaning-up the deposit; theoretical substabtiation of design and engineering decisions regarding the quarry objects parameters in the specified conditions and with the efficient development of a rock pillar that separates quarries. Findings. The state of the projects and plans for the development of mining operations in the No. 3 quarry of PJSC “ArcelorMittal Kryvyi Rih” and the quarry of PJSC “Southern Mining Factory” has been analyzed, which, in the coming years, indicates their spacial union. It has been revealed that the decommissioning of the rock pillar between the quarries is complicated both spacely and technologically, especially as a result of seismic restrictions, but the proposed solutions and measures simplify and make safe this stage as much as possible. The problem has been defined of reduce in the loading at the dressing plants proportionally to the decline in ore output. The technical-economical calculations substantiate that the corresponding sequential decommissioning the enrichment sections of the ore-dressing plants is expedient at one of the two cooperating ore mining and processing plants. Originality. An integrated approach has been improved regarding the evolution of mining and processing enterprises at the stage when their quarries approach to the maximum depths and final contours by taking into account adjacent ore mines as a single complex dynamic system. The analytical substantiation of drilling and blasting technology of the rocks destruction has been adapted to the specific conditions of decommissioning the pillar adjacent to both quarries. Practical implications. It is distinguished their high level of suitability for implementation and use in the designing of mining operations development in the quarries of PJSC “ArcelorMittal Kryvyi Rih” and PJSC “Southern Mining Factory”.Мета. Визначення можливих і обґрунтування доцільних варіантів проектно-технологічних рішень щодо етапу просторового з’єднання суміжних кар’єрів різних власників на прикладі розробки породного цілика між кар’єром №3 ПрАТ “АрселорМіттал Кривий Ріг” і кар’єром ПрАТ “Південний гірничо-збагачувальний комбінат” з включенням до відпрацювання запасів, виїмка яких є можливою в межах існуючих гірничого та земельного відводів. Методика. Використано комплексний методичний підхід, що включає гірничо-геологічний аналіз породного масиву між двома суміжними кар’єрами, який підлягає ліквідації; техніко-економічний аналіз ефективності експлуатації рудозбагачувальної фабрики при зниженні продуктивності рудника внаслідок доробки родовища; теоретичне обґрунтування проектних і технологічних рішень щодо параметрів об’єктів кар’єру за даних умов та продуктивної розробки розділяючого кар’єри породного цілика. Результати. Проаналізовано стан проектів і планів розвитку гірничих робіт кар’єру №3 ПрАТ “АрселорМіттал Кривий Ріг” і кар’єру ПрАТ “Південний гірничо-збагачувальний комбінат”, що свідчить про їх просторове з’єднання в найближчі роки. Виявлено, що ліквідація породного цілика між кар’єрами ускладнюється як просторово, так і технологічно, особливо внаслідок сейсмічних обмежень, але запропоновані рішення і заходи максимально спрощують й убезпечують даний етап. Встановлена проблема зниження завантаження збагачувальних фабрик пропорційна падінню видобутку руд. Техніко-економічні розрахунки доводять, що відповідне зазначеному послідовне виведення збагачувальних секцій рудозбагачувальних фабрик є доцільним на одному зі взаємодіючих ГЗК. Наукова новизна. Вдосконалено комплексний підхід щодо еволюції гірничо-збагачувальних комбінатів на стадії наближення їх кар’єрів до граничних глибин та кінцевих контурів за рахунок врахування суміжних рудників як єдиної складної динамічної системи. Адаптовано аналітичні обґрунтування технології буро-підривного руйнування скельних порід до конкретних умов ліквідації міжкар’єрного цілика. Практична значимість визначається високим рівнем придатності їх до впровадження та використання в проектуванні розвитку гірничих робіт кар’єрів ПрАТ “АрселорМіттал Кривий Ріг” і ПрАТ “Південний гірничо-збагачувальний комбінат”.Цель. Определение возможных и обоснование целесообразных вариантов проектно-технологических решений относительно этапа пространственного соединения смежных карьеров различных собственников на примере разработки породного целика между карьером №3 ЧАО “АрселорМиттал Кривой Рог” и карьером ЧАО “Южный горно-обогатительный комбинат” с включением в отработку запасов, выемка которых возможна в рамках существующих горного и земельного отводов. Методика. Использован комплексный методический подход, включающий горно-геологический анализ породного массива между двумя смежными карьерами, который подлежит ликвидации; технико-экономический анализ эффективности эксплуатации рудообогатительной фабрики при снижении производительности рудника в результате доработки месторождения; теоретическое обоснование проектных и технологических решений относительно параметров объектов карьера при данных условиях и продуктивной разработки разделяющего карьеры породного целика. Результаты. Проанализировано состояние проектов и планов развития горных работ карьера №3 ЧАО “АрселорМиттал Кривой Рог” и карьера ЧАО “Южный горно-обогатительный комбинат”, что свидетельствует об их пространственном соединении в ближайшие годы. Выявлено, что ликвидация породного целика между карьерами осложняется как пространственно, так и технологически, особенно в результате сейсмических ограничений, но предложенные решения и меры максимально упрощают и защищают данный этап. Установленная проблема снижения загрузки обогатительных фабрик пропорциональна падению добычи руд. Технико-экономические расчеты доказывают, что соответствующее указанному последовательное выведение обогатительных секций рудообогатительных фабрик является целесообразным на одном из взаимодействующих ГОК. Научная новизна. Усовершенствован комплексный подход к эволюции горно-обогатительных комбинатов на стадии приближения их карьеров до предельных глубин и конечных контуров за счет учета смежных рудников как единой сложной динамической системы. Адаптировано аналитические обоснования технологии буровзрывного разрушения скальных пород к конкретным условиям ликвидации междукарьерного целика. Практическая значимость определяется высоким уровнем пригодности их к внедрению и использованию в проектировании развития горных работ карьеров ЧАО “АрселорМиттал Кривой Рог” и ЧАО “Южный горно-обогатительный комбинат”.The authors express their deep gratitude to the Head of the Research and Development Laboratory for quality control of iron ore raw materials, Professor A.A. Azaryan, as well as the staff of the Department of Open Pit Mining at Kryvyi Rih National University for their assistance when implementing the scientific developments and their introduction into production

Discrete event simulation and virtual reality use in industry: new opportunities and future trends

This paper reviews the area of combined discrete event simulation (DES) and virtual reality (VR) use within industry. While establishing a state of the art for progress in this area, this paper makes the case for VR DES as the vehicle of choice for complex data analysis through interactive simulation models, highlighting both its advantages and current limitations. This paper reviews active research topics such as VR and DES real-time integration, communication protocols, system design considerations, model validation, and applications of VR and DES. While summarizing future research directions for this technology combination, the case is made for smart factory adoption of VR DES as a new platform for scenario testing and decision making. It is put that in order for VR DES to fully meet the visualization requirements of both Industry 4.0 and Industrial Internet visions of digital manufacturing, further research is required in the areas of lower latency image processing, DES delivery as a service, gesture recognition for VR DES interaction, and linkage of DES to real-time data streams and Big Data sets

Integrating power flow modelling with building simulation

The inclusion of photovoltaic facades and other local sources of both heat and power within building designs has given rise to the concept of embedded generation: where some or all of the heat and power demands are produced close to the point of use. This paper describes recent work to simulate the heat and power flows associated with both an embedded generation system and the building it serves. This is achieved through the development of an electrical power flow model and its integration within the ESP-r simulation program