Cyber physical systems implementation for asset management improvement: A framework for the transition

Libro en Open AccessThe transformation of the industry due to recent technologies introduction is an evolving process whose engines are competitiveness and sustainability, understood in its broadest sense (environmental, economic and social). This process is facing, due to the current state of scientific and technological development, a new challenge yet even more important: the transition from discrete technological solutions that respond to isolated problems, to a global conception where the assets, plant, processes and engineering systems are conceived, designed and operated as an integrated complex unit. This vision is evolving besides a set of concepts that are, in some way, to guide this development: Smart Factories, Cyber-Physical Systems, Factory of the Future or Industry 4.0, are examples. The full integration of the operation and maintenance (O&M) processes in the production systems is a key topic within this new paradigm. Not only that, this evolution necessarily results in the emergence of new processes and needs of O&M, i.e. also, the O&M will undergo a profound transformation. The transition from actual isolated production assets to such Industry 4.0 with CPS is far from easy. This document presents a proposal to develop such transition adapting one iteration of the Model of Maintenance Management (MMM) integrated into ISO 55000 to the complexity of incorporating “System of Systems” CPSs maintenance. It involves several stages: identification, prioritization, risk management, planning, scheduling, execution, control, and improvement supported by system engineering techniques and agile/concurrent project managemen

"The Shift from Belt Conveyor Line to Work-cell Based Assembly Systems to Cope with Increasing Demand Variation and Fluctuation in The Japanese Electronics Industries"

As consumption patterns become increasingly sophisticated and manufacturers strive to improve their competitiveness, not only offering higher quality at competitive costs, but also by providing broader mix of products, and keeping it attractive by launching successively new products, the turbulence in the markets has intensified. This has impelled leading manufacturers to search the development of alternative production systems supposed to enable them operate more responsively. This paper discusses the trend of abandoning the strategy of relying on factory automation technologies and conveyor-based assembly lines, and shifting towards more human-centered production systems based on autonomous work-cells, observed in some industries in Japan (e.g. consumer electronics, computers, printers) since mid-1990s. The purpose of this study is to investigate this trend which is seemingly uneconomic to manufacturers established in a country where labor costs are among the highest in the world, so as to contribute in the elucidation of its background and rationality. This work starts with a theoretical review linking the need to cope with nowadays' market turbulence with the issue of nurturing more agile organizations. Then, a general view of the diffusion trend of work-cell based assembly systems in Japanese electronics industries is presented, and some empirical facts gathered in field studies conducted in Japan are discussed. It is worthy mentioning that the abandonment of short cycle-time tasks performed along conveyor lines and the organization of workforce around work-cells do not imply a rejection of the lean production paradigm and its distinctive process improvement approach. High man-hour productivity is realized as a key goal to justify the implementation of work-cells usually devised to run in longer cycle-time, and the moves towards this direction has been strikingly influenced by the kaizen philosophy and techniques that underline typical initiatives of lean production system implementation. Finally, it speculates that even though the subject trend is finding wide diffusion in the considered industries, it should not be regarded as a panacea. In industries such as manufacturing of autoparts, despite the notable product diversification observed in the automobile market, its circumstances have still allowed the firms to rely on capital-intensive process, and this has sustained the development of advanced manufacturing technologies that enable the agile implementation and re-configuration of highly automated assembly lines.

Dynamic Organizations: Achieving Marketplace and Organizational Agility with People

Driven by dynamic competitive conditions, an increasing number of firms are experimenting with new, and what they hope will be, more dynamic organizational forms. This development has opened up exciting theoretical and empirical venues for students of leadership, business strategy, organizational theory, and the like. One domain that has yet to catch the wave, however, is strategic human resource management (SHRM). In an effort to catch up, we here draw on the dynamic organization (DO) and human resource strategy (HRS) literatures to delineate both a process for uncovering and the key features of a carefully crafted HRS for DOs. The logic is as follows. DOs compete through marketplace agility. Marketplace agility requires that employees at all levels engage in proactive, adaptive, and generative behaviors, bolstered by a supportive mindset. Under the right conditions, the essential mindset and behaviors, although highly dynamic, are fostered by a HRS centered on a relatively small number of dialectical, yet paradoxically stable, guiding principles and anchored in a supportive organizational infrastructure. This line of reasoning, however, rests on a rather modest empirical base and, thus, is offered less as a definitive statement than as a spur for much needed additional research

Buyer-supplier partnership in agile supply chains: A conceptual view

The purpose of this paper focuses on achieving agility within the supply chain and seeks to examine the impact of developing an integrated buyer-supplier partnership on achieving agility. It also aims to investigate the moderating role played by information sharing and technology in achieving such a goal. Supply chain management and agility have both been received great attention in recent years. In a highly dynamic and complex business market place the customer is demanding more choice and companies need to possess the means to rapidly adjust to market changes in order to satisfy its customers in an effective manner. Agility has been introduced to the supply chain context to enable companies to face the business environmental changes and deal with them effectively. The methodological approach used in this paper is an analysis and critique to the existing literature, as an initial step for developing the empirical study for the paper

Human Factors in Agile Software Development

Through our four years experiments on students' Scrum based agile software development (ASD) process, we have gained deep understanding into the human factors of agile methodology. We designed an agile project management tool - the HASE collaboration development platform to support more than 400 students self-organized into 80 teams to practice ASD. In this thesis, Based on our experiments, simulations and analysis, we contributed a series of solutions and insights in this researches, including 1) a Goal Net based method to enhance goal and requirement management for ASD process, 2) a novel Simple Multi-Agent Real-Time (SMART) approach to enhance intelligent task allocation for ASD process, 3) a Fuzzy Cognitive Maps (FCMs) based method to enhance emotion and morale management for ASD process, 4) the first large scale in-depth empirical insights on human factors in ASD process which have not yet been well studied by existing research, and 5) the first to identify ASD process as a human-computation system that exploit human efforts to perform tasks that computers are not good at solving. On the other hand, computers can assist human decision making in the ASD process.Comment: Book Draf

Reinforcement Learning Based Production Control of Semi-automated Manufacturing Systems

In an environment which is marked by an increasing speed of changes, industrial companies have to be able to quickly adapt to new market demands and innovative technologies. This leads to a need for continuous adaption of existing production systems and the optimization of their production control. To tackle this problem digitalization of production systems has become essential for new and existing systems. Digital twins based on simulations of real production systems allow the simplification of analysis processes and, thus, a better understanding of the systems, which leads to broad optimization possibilities. In parallel, machine learning methods can be integrated to process the numerical data and discover new production control strategies. In this work, these two methods are combined to derive a production control logic in a semi-automated production system based on the chaku-chaku principle. A reinforcement learning method is integrated into the digital twin to autonomously learn a superior production control logic for the distribution of tasks between the different workers on a production line. By analyzing the influence of different reward shaping and hyper-parameter optimization on the quality and stability of the results obtained, the use of a well-configured policy-based algorithm enables an efficient management of the workers and the deduction of an optimal production control logic for the production system. The algorithm manages to define a control logic that leads to an increase in productivity while having a stable task assignment so that a transfer to daily business is possible. The approach is validated in the digital twin of a real assembly line of an automotive supplier. The results obtained suggest a new approach to optimizing production control in production lines. Production control shall be centered directly on the workers’ routines and controlled by artificial intelligence infused with a global overview of the entire production system

An Approach to Reduce Commissioning and Ramp-up time for Multi-variant Production in Automated Production Facilities

A key requirement for future production facilities is to perform new production processes in a flexible and adaptive way with available and known resources. In this context, a comprehensive description (ontology) of involved components has a high significance. If certain technological aspects are missing during a production process, the production control should respond in a dynamic, versatile and adaptive (agile) manner to the overall value network. The possibility to describe the requirements of products for the necessary processes in the same namespace like the requirements of the necessary processes for the resources is a prerequisite to enable this behavior. Afterwards the different requirements will be placed in relation to the respective requirements. The aim is to define the necessary processes for the production based on the description of the product and the known resources in an agile way. Due to this a framework for a comprehensive description of automated production facilities, products and processes is described in this paper. The idea is that based on this framework a production facility can change the produced products without dedicated commissioning and ramp-up phases