A Modeling and Analysis Framework To Support Monitoring, Assessment, and Control of Manufacturing Systems Using Hybrid Models

The manufacturing industry has constantly been challenged to improve productivity, adapt to continuous changes in demand, and reduce cost. The need for a competitive advantage has motivated research for new modeling and control strategies able to support reconfiguration considering the coupling between different aspects of plant floor operations. However, models of manufacturing systems usually capture the process flow and machine capabilities while neglecting the machine dynamics. The disjoint analysis of system-level interactions and machine-level dynamics limits the effectiveness of performance assessment and control strategies. This dissertation addresses the enhancement of productivity and adaptability of manufacturing systems by monitoring and controlling both the behavior of independent machines and their interactions. A novel control framework is introduced to support performance monitoring and decision making using real-time simulation, anomaly detection, and multi-objective optimization. The intellectual merit of this dissertation lies in (1) the development a mathematical framework to create hybrid models of both machines and systems capable of running in real-time, (2) the algorithms to improve anomaly detection and diagnosis using context-sensitive adaptive threshold limits combined with context-specific classification models, and (3) the construction of a simulation-based optimization strategy to support decision making considering the inherent trade-offs between productivity, quality, reliability, and energy usage. The result is a framework that transforms the state-of-the-art of manufacturing by enabling real-time performance monitoring, assessment, and control of plant floor operations. The control strategy aims to improve the productivity and sustainability of manufacturing systems using multi-objective optimization. The outcomes of this dissertation were implemented in an experimental testbed. Results demonstrate the potential to support maintenance actions, productivity analysis, and decision making in manufacturing systems. Furthermore, the proposed framework lays the foundation for a seamless integration of real systems and virtual models. The broader impact of this dissertation is the advancement of manufacturing science that is crucial to support economic growth. The implementation of the framework proposed in this dissertation can result in higher productivity, lower downtime, and energy savings. Although the project focuses on discrete manufacturing with a flow shop configuration, the control framework, modeling strategy, and optimization approach can be translated to job shop configurations or batch processes. Moreover, the algorithms and infrastructure implemented in the testbed at the University of Michigan can be integrated into automation and control products for wide availability.PHDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttps://deepblue.lib.umich.edu/bitstream/2027.42/147657/1/migsae_1.pd

Industry 4.0 for SME

Dissertation presented as the partial requirement for obtaining a Master's degree in Data Science and Advanced Analytics, specialization in Business AnalyticsIndustry 4.0 has been growing within companies and impacting the economy and society, but this has been a more complex challenge for some types of companies. Due to the costs and complexity associated with Industry 4.0 technologies, small and medium enterprises face difficulties in adopting them. This thesis proposes to create a model that gives guidance and simplifies how to implement Industry 4.0 in SMEs with a low-cost perspective. It is intended that this model can be used as a blueprint to design and implement an Industry 4.0 project within a manufactory SME. To create the model, a literature review of the different fields regarding Industry 4.0 were conducted to understand the most suited technologies to leverage within the manufacturing industry and the different use cases where these would be applicable. After the model was built, expert interviews were conducted, and based on the received feedback, the model was tweaked, improved, and validated

A framework for smart production-logistics systems based on CPS and industrial IoT

Industrial Internet of Things (IIoT) has received increasing attention from both academia and industry. However, several challenges including excessively long waiting time and a serious waste of energy still exist in the IIoT-based integration between production and logistics in job shops. To address these challenges, a framework depicting the mechanism and methodology of smart production-logistics systems is proposed to implement intelligent modeling of key manufacturing resources and investigate self-organizing configuration mechanisms. A data-driven model based on analytical target cascading is developed to implement the self-organizing configuration. A case study based on a Chinese engine manufacturer is presented to validate the feasibility and evaluate the performance of the proposed framework and the developed method. The results show that the manufacturing time and the energy consumption are reduced and the computing time is reasonable. This paper potentially enables manufacturers to deploy IIoT-based applications and improve the efficiency of production-logistics systems

Implementation of a Large-Scale Platform for Cyber-Physical System Real-Time Monitoring

The emergence of Industry 4.0 and the Internet of Things (IoT) has meant that the manufacturing industry has evolved from embedded systems to cyber-physical systems (CPSs). This transformation has provided manufacturers with the ability to measure the performance of industrial equipment by means of data gathered from on-board sensors. This allows the status of industrial systems to be monitored and can detect anomalies. However, the increased amount of measured data has prompted many companies to investigate innovative ways to manage these volumes of data. In recent years, cloud computing and big data technologies have emerged among the scientific communities as key enabling technologies to address the current needs of CPSs. This paper presents a large-scale platform for CPS real-time monitoring based on big data technologies, which aims to perform real-time analysis that targets the monitoring of industrial machines in a real work environment. This paper is validated by implementing the proposed solution on a real industrial use case that includes several industrial press machines. The formal experiments in a real scenario are conducted to demonstrate the effectiveness of this solution and also its adequacy and scalability for future demand requirements. As a result of the implantation of this solution, the overall equipment effectiveness has been improved.The authors are grateful to Goizper and Fagor Arrasate for providing the industrial case study, and specifically Jon Rodriguez and David Chico (Fagor Arrasate) for their help and support. Any opinions, findings and conclusions expressed in this article are those of the authors and do not necessarily reflect the views of the funding agencies

A Cognitive Framework to Secure Smart Cities

The advancement in technology has transformed Cyber Physical Systems and their interface with IoT into a more sophisticated and challenging paradigm. As a result, vulnerabilities and potential attacks manifest themselves considerably more than before, forcing researchers to rethink the conventional strategies that are currently in place to secure such physical systems. This manuscript studies the complex interweaving of sensor networks and physical systems and suggests a foundational innovation in the field. In sharp contrast with the existing IDS and IPS solutions, in this paper, a preventive and proactive method is employed to stay ahead of attacks by constantly monitoring network data patterns and identifying threats that are imminent. Here, by capitalizing on the significant progress in processing power (e.g. petascale computing) and storage capacity of computer systems, we propose a deep learning approach to predict and identify various security breaches that are about to occur. The learning process takes place by collecting a large number of files of different types and running tests on them to classify them as benign or malicious. The prediction model obtained as such can then be used to identify attacks. Our project articulates a new framework for interactions between physical systems and sensor networks, where malicious packets are repeatedly learned over time while the system continually operates with respect to imperfect security mechanisms

A digital twin framework for predictive maintenance in industry 4.0

The rapid advancements in manufacturing technologies are transforming the current industrial landscape through Industry 4.0, which refers not only to the integration of information technology with industrial production, but also to the use of innovative technologies and novel data management approaches. The target is to enable the manufacturers and the entire supply chain to save time, boost productivity, reduce waste and costs, and respond flexibly and efficiently to consumers’ requirements. Industry 4.0 moves the digitization of manufacturing components and processes a step further by creating smart factories. Within this context, one of the key enabling technologies for Industry 4.0 is the adoption and integration of the Digital Twin (DT). However, most of the DT solutions provided by the current leading vendors are in fact digital models or digital shadows, and not digital twins. This is due to the fact that there is no common understanding of the definition of the DT amongst the leading vendors, and its usage is slightly different but showcased under the same umbrella of DT. In this paper, a DT framework is proposed that replicates the processes of a real production line for product assembly using the Festo Cyber Physical Factory for Industry 4.0 located at Middlesex University. Moreover, the paper introduces a viable framework for interlinking the physical system with its digital instance in order to offer extended predictive maintenance services and form a fully integrated digital twin solution

Intrusion Detection for Cyber-Physical Attacks in Cyber-Manufacturing System

In the vision of Cyber-Manufacturing System (CMS) , the physical components such as products, machines, and tools are connected, identifiable and can communicate via the industrial network and the Internet. This integration of connectivity enables manufacturing systems access to computational resources, such as cloud computing, digital twin, and blockchain. The connected manufacturing systems are expected to be more efficient, sustainable and cost-effective. However, the extensive connectivity also increases the vulnerability of physical components. The attack surface of a connected manufacturing environment is greatly enlarged. Machines, products and tools could be targeted by cyber-physical attacks via the network. Among many emerging security concerns, this research focuses on the intrusion detection of cyber-physical attacks. The Intrusion Detection System (IDS) is used to monitor cyber-attacks in the computer security domain. For cyber-physical attacks, however, there is limited work. Currently, the IDS cannot effectively address cyber-physical attacks in manufacturing system: (i) the IDS takes time to reveal true alarms, sometimes over months; (ii) manufacturing production life-cycle is shorter than the detection period, which can cause physical consequences such as defective products and equipment damage; (iii) the increasing complexity of network will also make the detection period even longer. This gap leaves the cyber-physical attacks in manufacturing to cause issues like over-wearing, breakage, defects or any other changes that the original design didn’t intend. A review on the history of cyber-physical attacks, and available detection methods are presented. The detection methods are reviewed in terms of intrusion detection algorithms, and alert correlation methods. The attacks are further broken down into a taxonomy covering four dimensions with over thirty attack scenarios to comprehensively study and simulate cyber-physical attacks. A new intrusion detection and correlation method was proposed to address the cyber-physical attacks in CMS. The detection method incorporates IDS software in cyber domain and machine learning analysis in physical domain. The correlation relies on a new similarity-based cyber-physical alert correlation method. Four experimental case studies were used to validate the proposed method. Each case study focused on different aspects of correlation method performance. The experiments were conducted on a security-oriented manufacturing testbed established for this research at Syracuse University. The results showed the proposed intrusion detection and alert correlation method can effectively disclose unknown attack, known attack and attack interference that causes false alarms. In case study one, the alarm reduction rate reached 99.1%, with improvement of detection accuracy from 49.6% to 100%. The case studies also proved the proposed method can mitigate false alarms, detect attacks on multiple machines, and attacks from the supply chain. This work contributes to the security domain in cyber-physical manufacturing systems, with the focus on intrusion detection. The dataset collected during the experiments has been shared with the research community. The alert correlation methodology also contributes to cyber-physical systems, such as smart grid and connected vehicles, which requires enhanced security protection in today’s connected world

Tool And Task Design Challenges For Left Handers: A Brief Review

Left-handed users are often overlooked by equipment and hand tool designers. Designers may assume that left handers will eventually learn to adapt themselves in a right-handed environment. However in reality left handers face a lot of difficulties when trying to perform tasks meant for right-handed users. Medical personnel are most affected by this issue, followed by workers in non-medical field such as services and manufacturing. This review aims to highlight the issues faced left handers by analysing common household product examples as well as hand tools in occupational settings. Discussions are centred on the differences between the right-handed tools versus left-handed tools, as well as task/procedural challenges faced by left handers. In summary, the notion of designing an ambidextrous tool may not be a realistic recommendation for tool manufacturers and designers

Machine Tool Communication (MTComm) Method and Its Applications in a Cyber-Physical Manufacturing Cloud

The integration of cyber-physical systems and cloud manufacturing has the potential to revolutionize existing manufacturing systems by enabling better accessibility, agility, and efficiency. To achieve this, it is necessary to establish a communication method of manufacturing services over the Internet to access and manage physical machines from cloud applications. Most of the existing industrial automation protocols utilize Ethernet based Local Area Network (LAN) and are not designed specifically for Internet enabled data transmission. Recently MTConnect has been gaining popularity as a standard for monitoring status of machine tools through RESTful web services and an XML based messaging structure, but it is only designed for data collection and interpretation and lacks remote operation capability. This dissertation presents the design, development, optimization, and applications of a service-oriented Internet-scale communication method named Machine Tool Communication (MTComm) for exchanging manufacturing services in a Cyber-Physical Manufacturing Cloud (CPMC) to enable manufacturing with heterogeneous physically connected machine tools from geographically distributed locations over the Internet. MTComm uses an agent-adapter based architecture and a semantic ontology to provide both remote monitoring and operation capabilities through RESTful services and XML messages. MTComm was successfully used to develop and implement multi-purpose applications in in a CPMC including remote and collaborative manufacturing, active testing-based and edge-based fault diagnosis and maintenance of machine tools, cross-domain interoperability between Internet-of-things (IoT) devices and supply chain robots etc. To improve MTComm’s overall performance, efficiency, and acceptability in cyber manufacturing, the concept of MTComm’s edge-based middleware was introduced and three optimization strategies for data catching, transmission, and operation execution were developed and adopted at the edge. Finally, a hardware prototype of the middleware was implemented on a System-On-Chip based FPGA device to reduce computational and transmission latency. At every stage of its development, MTComm’s performance and feasibility were evaluated with experiments in a CPMC testbed with three different types of manufacturing machine tools. Experimental results demonstrated MTComm’s excellent feasibility for scalable cyber-physical manufacturing and superior performance over other existing approaches