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

Supporting Discrete Event Simulation with 3D Laser Scanning and Value Stream Mapping: Benefits and Drawbacks

Discrete Event Simulation (DES) has been applied to analyze and understand production systems for many decades, however the models created may not accurately represent the spatial data of the system. 3D laser scanning can be utilized to capture and digitalize the spatial data of production systems, giving proper references for the simulation model. This paper evaluates the benefits and drawbacks of using a DES model supported with Value Stream Mapping (VSM) and 3D laser scanning to analyze a low volume production system. Results show benefits in several steps of a DES study, mainly at the cost of simulation speed

Brownfield Factory Layout Planning using Realistic Virtual Models

To stay competitive in an increasingly digitalised and global context, manufacturing companies need to increase productivity and decrease waste. This means their production systems must improve; something they can achieve in a multitude of ways. For example, increasing the level of automation, improving scheduling and improving product and process flows. Often, these production system improvements entail redesigning the system to incorporate these ensuing changes; a unique and temporary endeavour that is often structured as a project. One part of the production system design process is layout planning, in which the positions of operators, workstations, machines and other parts of the system are decided. This planning process can have a major impact on the overall efficiency of operations.In industrial settings, factory layout planning is often conducted in brownfield settings. In other words, in operational facilities. Since every production system and facility is unique, so is every factory layout planning project. Each such project has different preconditions, existing knowledge, availability and quality of data, lead-times, expectations and driving forces, to name just a few. If factory layout planning were treated as a design problem (more subjective than mathematical in nature), it would be hard to produce a mathematical solution for an optimal layout that would also work in reality. Instead, if a layout is developed and adapted to all real constraints and factors while it is being developed, the result would more likely be installable and work as expected.The long-term vision of this thesis is of a future in which sustainable manufacturing industry continues playing a vital role in society, because its contribution is more than just economic. A future in which the manufacturing industry is appreciated and engaged with by the local community; in which high performance is connected to the successful adoption and efficient use of digital tools in developing and improving existing brownfield production systems. This thesis aims to ensure that manufacturing industry adopts realistic virtual models in its brownfield factory layout planning processes. It does this by identifying and describing common challenges and how they may be reduced by developing and using realistic virtual models. This leads to improvements in the planning, installation and operational phases of production systems.The findings of this thesis show that brownfield factory layout planning represents a significant proportion of industrial layout planning. Its challenges lie mainly in the areas of data accuracy and richness. There are difficulties in grasping scale and perspective, communicating ideas and gathering input in the layout planning phase. By applying 3D laser scanning to provide accurate data and virtual reality to provide immersion and scale, realistic virtual models have been created. These reduce or eliminate the challenges stated above and allow more employees to be involved in the layout planning process. This, in turn, results in the identification of flaws in the layout and improvements in the early stages, rather than during or after installation. There is also an overall improvement to brownfield factory change processes, with costs that pale by comparison to the total cost of layout changes

A Framework for Systematic use of Realistic Visualisation to Support Layout Planning of Production Systems

The process of designing production systems comprises a sequence of steps toward the final design and realisation. Layout planning is a significant part of this process. Its outcome should be a layout which matches the existing spatial conditions of the factory building and desired performance of the production system. To support layout planning, virtual representations of layouts can be created to plan and evaluate layout alternatives. Costly problems can arise during the realisation, if the virtual representations are inaccurate or lack details of the factory building and planned production systems. 3D laser scanning can be used to create accurate and detailed virtual representations by capturing the spatial conditions of existing factory buildings. The data from a 3D laser scan can be used for realistic visualisation of the existing factory building. If this is combined with 3D CAD models of new equipment, the planned production system layout can also be visualised realistically. Realistic visualisation has been shown to enable accurate planning and evaluation of production system layouts, but it does require a systematic working method.The aim of this thesis is to outline and evaluate a framework for systematic use of realistic visualisation to support layout planning of production systems. This aim is addressed using an action research design; this incorporates five industrial studies targeting industrial projects designing production systems. The framework is outlined and evaluated based on the results of the industrial studies.The outlined framework follows a project model for production systems design. It includes several design activities which rely on realistic visualisation of the planned production system layouts. The framework can be used to support the layout planning of industrial projects designing production systems. Its outcomes include making the correct decisions, reducing costly risks and problems and reducing overall project time. Layout planning supported by realistic visualisation allows manufacturing companies to reduce uncertainty when realising planned production systems

Combining Point Cloud Technologies with Discrete Event Simulation

Utilizing point cloud models from 3D laser scans for visualization of manufacturing facilities and systemsprovides highly realistic representations. Recent developments has improved the accuracy of point cloudmodels in terms of color and positioning. This technology has the potential to generate savings in timeand money compared to traditional methods. Visualization in terms of accurate geometrical factory datahas traditionally not been feasible when developing discrete event simulation (DES) models. Currently,methods for utilizing point clouds in DES models are lacking. Better visualization could improve communicationof results and make them available to a wider target audience. Creating methods to combinepoint cloud technologies with DES would enable realistic visualization and improved accuracy includinglevel of detail regarding geometric representation in DES models