Smart Society and Artificial Intelligence: Big Data Scheduling and the Global Standard Method Applied to Smart Maintenance

Abstract The implementation of artificial intelligence (AI) in a smart society, in which the analysis of human habits is mandatory, requires automated data scheduling and analysis using smart applications, a smart infrastructure, smart systems, and a smart network. In this context, which is characterized by a large gap between training and operative processes, a dedicated method is required to manage and extract the massive amount of data and the related information mining. The method presented in this work aims to reduce this gap with near-zero-failure advanced diagnostics (AD) for smart management, which is exploitable in any context of Society 5.0, thus reducing the risk factors at all management levels and ensuring quality and sustainability. We have also developed innovative applications for a human-centered management system to support scheduling in the maintenance of operative processes, for reducing training costs, for improving production yield, and for creating a human–machine cyberspace for smart infrastructure design. The results obtained in 12 international companies demonstrate a possible global standardization of operative processes, leading to the design of a near-zero-failure intelligent system that is able to learn and upgrade itself. Our new method provides guidance for selecting the new generation of intelligent manufacturing and smart systems in order to optimize human–machine interactions, with the related smart maintenance and education

A Novel Method for Adaptive Control of Manufacturing Equipment in Cloud Environments

The ability to adaptively control manufacturing equipment, both in local and distributed environments, is becoming increasingly more important for many manufacturing companies. One important reason for this is that manufacturing companies are facing increasing levels of changes, variations and uncertainty, caused by both internal and external factors, which can negatively impact their performance. Frequently changing consumer requirements and market demands usually lead to variations in manufacturing quantities, product design and shorter product life-cycles. Variations in manufacturing capability and functionality, such as equipment breakdowns, missing/worn/broken tools and delays, also contribute to a high level of uncertainty. The result is unpredictable manufacturing system performance, with an increased number of unforeseen events occurring in these systems. Events which are difficult for traditional planning and control systems to satisfactorily manage. For manufacturing scenarios such as these, the use of real-time manufacturing information and intelligence is necessary to enable manufacturing activities to be performed according to actual manufacturing conditions and requirements, and not according to a pre-determined process plan. Therefore, there is a need for an event-driven control approach to facilitate adaptive decision-making and dynamic control capabilities. Another reason driving the move for adaptive control of manufacturing equipment is the trend of increasing globalization, which forces manufacturing industry to focus on more cost-effective manufacturing systems and collaboration within global supply chains and manufacturing networks. Cloud Manufacturing is evolving as a new manufacturing paradigm to match this trend, enabling the mutually advantageous sharing of resources, knowledge and information between distributed companies and manufacturing units. One of the crucial objectives for Cloud Manufacturing is the coordinated planning, control and execution of discrete manufacturing operations in collaborative and networked environments. Therefore, there is also a need that such an event-driven control approach supports the control of distributed manufacturing equipment. The aim of this research study is to define and verify a novel and comprehensive method for adaptive control of manufacturing equipment in cloud environments. The presented research follows the Design Science Research methodology. From a review of research literature, problems regarding adaptive manufacturing equipment control have been identified. A control approach, building on a structure of event-driven Manufacturing Feature Function Blocks, supported by an Information Framework, has been formulated. The Function Block structure is constructed to generate real-time control instructions, triggered by events from the manufacturing environment. The Information Framework uses the concept of Ontologies and The Semantic Web to enable description and matching of manufacturing resource capabilities and manufacturing task requests in distributed environments, e.g. within Cloud Manufacturing. The suggested control approach has been designed and instantiated, implemented as prototype systems for both local and distributed manufacturing scenarios, in both real and virtual applications. In these systems, event-driven Assembly Feature Function Blocks for adaptive control of robotic assembly tasks have been used to demonstrate the applicability of the control approach. The utility and performance of these prototype systems have been tested, verified and evaluated for different assembly scenarios. The proposed control approach has many promising characteristics for use within both local and distributed environments, such as cloud environments. The biggest advantage compared to traditional control is that the required control is created at run-time according to actual manufacturing conditions. The biggest obstacle for being applicable to its full extent is manufacturing equipment controlled by proprietary control systems, with native control languages. To take the full advantage of the IEC Function Block control approach, controllers which can interface, interpret and execute these Function Blocks directly, are necessary

A framework concept for data visualization and structuring in a complex production process

This paper provides a concept study for a visual interface framework together with the software Sequence Planner for implementation on a complex industrial process for extracting process information in an efficient way and how to make use of a lot of data to visualize it in a standardized human machine interface for different user perspectives. The concept is tested and validated on a smaller simulation of a paint booth with several interconnected and supporting control systems to prove the functionality and usefulness in this kind of production system.The paper presents the resulting five abstraction levels in the framework concept, from a production top view down to the signal exchange between the different resources in one production cell, together with additional features. The simulation proves the setup with Sequence Planner and the visual interface to work by extract and present process data from a running sequence

Opticap XL Output and Workflow Improvement- Examining Production Line Dedication

Insufficient production capacity and backorder buildup motivated EMD Millipore to examine its Opticap XL filter encapsulation process. Through analyzing this process and interviews with key stakeholders our team confirmed the changeover process as a production bottleneck. One way to potentially reduce changeover time is through line dedication by product characteristics. In this project, we built a discrete-event simulation model to evaluate different dedication scenarios and ultimately recommended dedication by capsule size

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Reconfigurable and transportable container-integrated production system

In this paper, the concept and the prototype realization of a novel reconfigurable small-footprint manufacturing system in a transportable container is presented. The containerized format enables transportation of the system to provide on-site manufacturing, enabling the benefits of localized service delivery without duplication of equipment at multiple locations. Three industrial product use cases with varying manufacturing and performance requirements were analyzed. All of the use cases demanded highly customized products with high quality in low production volumes. Based on their requirements, a general system specification was derived and used to develop a concept for the container-integrated factory. A reconfigurable, modular manufacturing system is integral to the overall container concept. Production equipment was integrated in the form of interchangeable process modules, which can be quickly connected by standard utility supply and control interfaces. A modular and self-configuring control system provides assisted production workflow programming, while a modular process chain combining Additive Manufacturing, milling, precision assembly and cleaning processes has been developed. A prototype of the container-integrated factory with reconfigurable process modules and control system has been established, with full functionality and feasibility of the system demonstrated

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

© 2020 by the authors. Licensee MDPI, Basel, Switzerland. Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Service-oriented SCADA and MES supporting petri nets based orchestrated automation systems

The fusion of mechatronics, communication, control and information technologies has allowed the introduction of new automation paradigms into the production environment. The virtualization of the production environment facilitated by the application of the service-oriented architecture paradigm is one of major outcomes of that fusion. On one side, service-oriented automation works based on exposition, subscription and use of automation functions represented by e.g. web services. On the other side, the evolution of traditional industrial systems, particularly in the production area, as a response to architectural and behavioural (functional) viewpoints of the ISA95 enterprise architecture, where a close inter-relation between SCADA, DCS and MES systems facilitate the management and control of the production environment. Automation functions are increasingly performed by the composition and orchestration of services. Among other methods, the application of formal Petri net based orchestration approaches is being industrially established. This paper presents the major characteristics that such a Petri net based orchestration presents when it is developed, implemented and deployed in an industrial environmentThe research leading to these results has received funding from the European Union's Seventh Framework Programme (FP7/2007-2013) under grant agreement 258682 (IMC-AESOP: ArchitecturE for Service-Oriented Process - Monitoring and Control) and 224053 (CONET: Cooperating Objects NETwork of excellence)