Metodología para el diseño y simulación de instalaciones industriales y sistemas de producción basada en una visión modular bajo un contexto de "industria 4.0"

[EN] The design of the industrial facilities distribution is one of the most important decisions to be made, as it will condition the operation thereof. The concept of industrial installation as it is known today has evolved to the point that it integrates automation and information systems. Indeed, such evolution has given rise to the so-called intelligent factory. At present, in order to produce customized mass products according to customers' requirements, it is become an important issue the distribution of facilities with the generation of successful layout designs, based on the flexibility, modularity and easy configuration of production systems. This paper proposes a methodology to solve the problem of plant distribution design and redesign based upon a novel modular approach within an industry 4.0 context. Proposed methodology is an adaptation of the "SLP" Methodology (Systematic Layout Planning-Simulation) so-called SLP Modulary 4.0 (systematic planning of the Layout based on a modular vision under a context of Industry 4.0); this methodology incorporates in its structure an integrated design system (IDS) into its structure, which allows collaborative work with different CAD design and simulation tools. For the validation of the proposed methodology, a case study of a coffee processing plant is considered. The distribution design results obtained from the case study prove the benefit and usefulness of the proposed methodology[ES] El diseño de la distribución en planta es una de las decisiones más relevantes pues condicionará la operación de la misma. La forma de concebir una instalación industrial como se la conoce hoy en día ha ido evolucionando hasta el punto de integrar sistemas de automatización y de información, dando lugar a la denominada fabrica inteligente. En la actualidad, con el fin de producir productos personalizados en masa según requerimientos de los clientes, ha tomado considerable importancia la distribución de instalaciones con la generación de diseños exitosos de layout, basados en la flexibilidad, modularidad y fácil configuración de los sistemas de producción. En este trabajo se propone una metodología para resolver el problema del diseño y rediseño de distribución en planta con un novedoso enfoque modular basado en un contexto de industria 4.0. La metodología presentada es una adaptación de la Metodología ¿SLP¿ (Systematic Layout Planning) denominada SLP Modulary 4.0 (planificación sistemática de Layout basada en una visión modular bajo un contexto de Industria 4.0), esta metodología incorpora en su estructura un diseño integrado de sistemas (IDS) que permite trabajar de forma colaborativa con diferentes herramientas de Diseño CAD y simulación. Para la validación de la metodología propuesta se considera un caso de estudio de una planta de procesado de café. Los resultados de diseño de distribución obtenidos comprueban el beneficio y la utilidad de la metodología propuesta.Authors acknowledge the invaluable support given by the SDAS Research Group (www.sdas-group.com).Alpala, L.; Alemany Díaz, MDM.; Peluffo, D.; Bolaños, F.; Rosero, A.; Torres, J. (2018). Methodology for the design and simulation of industrial facilities and production systems based on a modular approach in an "industry 4.0" context. DYNA. 85(207):243-252. https://doi.org/10.15446/dyna.v85n207.68545S2432528520

An Agent-Based Approach to Self-Organized Production

The chapter describes the modeling of a material handling system with the production of individual units in a scheduled order. The units represent the agents in the model and are transported in the system which is abstracted as a directed graph. Since the hindrances of units on their path to the destination can lead to inefficiencies in the production, the blockages of units are to be reduced. Therefore, the units operate in the system by means of local interactions in the conveying elements and indirect interactions based on a measure of possible hindrances. If most of the units behave cooperatively ("socially"), the blockings in the system are reduced. A simulation based on the model shows the collective behavior of the units in the system. The transport processes in the simulation can be compared with the processes in a real plant, which gives conclusions about the consequencies for the production based on the superordinate planning.Comment: For related work see http://www.soms.ethz.c

A virtual environment for the design and simulated construction of prefabricated buildings

The construction industry has acknowledged that its current working practices are in need of substantial improvements in quality and efficiency and has identified that computer modelling techniques and the use of prefabricated components can help reduce times, costs, and minimise defects and problems of on-site construction. This paper describes a virtual environment to support the design and construction processes of buildings from prefabricated components and the simulation of their construction sequence according to a project schedule. The design environment can import a library of 3-D models of prefabricated modules that can be used to interactively design a building. Using Microsoft Project, the construction schedule of the designed building can be altered, with this information feeding back to the construction simulation environment. Within this environment the order of construction can be visualised using virtual machines. Novel aspects of the system are that it provides a single 3-D environment where the user can construct their design with minimal user interaction through automatic constraint recognition and view the real-time simulation of the construction process within the environment. This takes this area of research a step forward from other systems that only allow the planner to view the construction at certain stages, and do not provide an animated view of the construction process

Computer aided manufacturing system modelling and development using virtual reality serum

This work focused on virtual factory environment created to assess the value of Virtual Reality (VR) and animation based software for design, visualisation and planning of production facilities (i.e. their user friendliness for the user to perform specific operation). The project largely focused on what desk-top VR techniques can do to assist the design and planning of production facilities and application of techniques to solve plant layout problems using 3D and 2D views. The first part describes an approach to a virtual bi-cycle factory by means of a three dimensional modelling system and animation based simulation package (PC version o f Animation Package 3D Studio Max) by taking into account the real data of a factory. This part also discussed how 3D solid modelling and animation based simulation can aid engineers in analysing the virtual factory's layout with a view (i) to identify bottlenecks in the existing factory (ii) proper utilisation of space and other facilities by applying plant layout problem solving techniques. Also the usability of the Superscape VRT 5.5 and 3D Studio Max System were assessed for how easy or difficult it was for the user to perform specific operations. The last part of the work deals with the application of CIM (Computer Intregated Manufacturing) concept in one of the virtual factories created earlier and to analyse the simulation result. Firstly, the applicability of the 3D Studio Max system was assessed for its user friendliness (for the user to perform specific operations). The designer can build a virtual factory ju st like constructing a miniature model of the real factory. A 3D model of a real bi-cycle parts manufacturing factory has been modelled using 3D Studio Max Software. Participant can navigate through virtual factory and examine the virtual factory from different viewing points. After visualising different sections of the factory using viewing points, it is considered that both the factory walkthrough and the visualisation facilities were useful for designing and planning activities in virtual environment. Various bottlenecks of the bi-cycle parts manufacturing factory layout were identified using 2D and 3D views and scientific factory layout problem solving concepts and techniques. The old layout and the new layout were compared using the concept of CRAFT (Computerised relocation of facilities technique) and further changes were made until the new layout was found to be the better one. Secondly, a simple toy factory, which makes a toy sports car (for four to six year old children), has been modelled using Desktop Virtual Reality System (Superscape VRT 5.5).The factory model has been designed to visualise shop floor virtually and to test both the factory walk through and visualisation facilities. It was found that the factory walkthrough and viewing point facilities o f Superscape VRT 5.5 is better th an that o f 3D Studio MAX. Participant can navigate freely through the virtual factory using Superscape VRT 5.5 mouse where as for the case o f 3D Studio MAX, participant cannot navigate freely through the virtual factory using the mouse. Lastly the process modelling and simulation software SimCad has been used to simulate the processes o f the bi-cycle parts manufacturing factory in 2D. Simulation results were analysed. The results were found to be satisfactory

Feasibility Study: Vertical Farm EDEN

Hundreds of millions of people around the world do not have access to sufficient food. With the global population continuing to increase, the global food output will need to drastically increase to meet demands. At the same time, the amount of land suitable for agriculture is finite, so it is not possibly to meet the growing demand by simply increasing the use of land. Thus, to be able to feed the entire global population, and continue to do so in the future, it will be necessary to drastically increase the food output per land area. One idea which has been recently discussed in the scientific community is called Vertical Farming (VF), which cultivates food crops on vertically stacked levels in (high-rise) buildings. The Vertical Farm, so it is said, would allow for more food production in a smaller area. Additionally, a Vertical Farm could be situated in any place (e.g. Taiga- or desert regions, cities), which would make it possible to reduce the amount of transportation needed to deliver the crops to the supermarkets. The technologies required for the Vertical Farm are well-known and already being used in conventional terrestrial greenhouses, as well as in the designs of bioregenerative Life Support Systems for space missions. However, the economic feasibility of the Vertical Farm, which will determine whether this concept will be developed or not, has not yet been adequately assessed. Through a Concurrent Engineering (CE) process, the DLR Institute for Space Systems (RY) in Bremen, aims to apply its know-how of Controlled Environment Agriculture (CEA) Technologies in space systems to provide valuable spin-off projects on Earth and to provide the first engineering study of a Vertical Farm to assess its economic feasibility

Arrival processes in port modeling: insights from a case study

This paper investigates the impact of arrival processes on the ship handling process. Two types of arrival processes are considered: controlled and uncontrolled. Simulation results show that uncontrolled arrivals of ships perform worst in terms of both ship delays and required storage capacity. Stock-controlled arrivals perform best with regard to large vessel delays and storage capacity. The combination of stock-controlled arrivals for large vessels and equidistant arrivals for barges also performs better than the uncontrolled process. Careful allocation of ships to the mooring points of a jetty further improves the efficiency.supply chain management;logistics;simulation;transportation;case study

Deriving a systematic approach to changeable manufacturing system design

It has long been argued that Factories are long life and complex products. The complexity of designing factories, and their underlying manufacturing systems, is further amplified when dealing with continuously changing customer demands. At the same time, due to research fragmentation, little if any scientific explanations are available supporting and exploiting the paradigm that "factories are products". In order to address this weakness, this paper presents research results arising from a comparative analysis of systematic "product design" and "manufacturing system design" approaches. The contribution emerging from this research is an integrated systematic design approach to changeable manufacturing systems, based on scientific concepts founded upon product design theories, and is explained through a case study in the paper. This research is part of collaboration between the CERU University of Malta and IAO Fraunhofer aimed at developing a digital decision support tool for planning changeable manufacturing systems.peer-reviewe