Maintainability and evolvability of control software in machine and plant manufacturing -- An industrial survey

Automated Production Systems (aPS) have lifetimes of up to 30-50 years, throughout which the desired products change ever more frequently. This requires flexible, reusable control software that can be easily maintained and evolved. To evaluate selected criteria that are especially relevant for maturity in software maintainability and evolvability of aPS, the approach SWMAT4aPS+ builds on a questionnaire with 52 questions. The three main research questions cover updates of software modules and success factors for both cross-disciplinary development as well as reusable models. This paper presents the evaluation results of 68 companies from machine and plant manufacturing (MPM). Companies providing automation devices and/or engineering tools will be able to identify challenges their customers in MPM face. Validity is ensured through feedback of the participating companies and an analysis of the statistical unambiguousness of the results. From a software or systems engineering point of view, almost all criteria are fulfilled below expectations

Model for web-application based configuration of modular production plants with automated PLC line control code generation

The international competition leads manufacturers in high-wage countries to focus more on high-value products, which often come at the disadvantage of small batch sizes. To remain competitive, the plant engineering for should be time and cost effective. One approach to achieve this are modular production lines. In the presented contribution, a product orientated web- service for the configuration of a modular production plant investigated. The resulting model then is interpreted by a code generator to generate a PLC line control. The approach is validated with a plant of metal hybrid carbon fiber seat rests

Cyber-Physical-Systems for Fluid Manufacturing Systems

Increased volatility continues to challenge the automotive manufacturer's production performance. More than a century after the start of mass production, changeable production systems that allow the flexibility for the economic mass production of customized products have arisen. Limitations on established production systems are driving the development of changeable production systems like the Fluid Manufacturing System (FLMS). In an FLMS, the individual production modules are mobile and consist of Cyber-Physical Systems (CPS) which can be combined ad-hoc to adapt to changing requirements. By connecting different CPS - e.g., Autonomous Mobile Robots (AMR) or smart load carriers - adaptable and flexible production will be achieved. This paper presents the first real-world initiation of an FLMS with the design and development of CPS and digital twins for production and logistics at the ARENA2036 research campus

Lean manual assembly 4.0: A systematic review

In a demand context of mass customization, shifting towards the mass personalization of products, assembly operations face the trade-off between highly productive automated systems and flexible manual operators. Novel digital technologies—conceptualized as Industry 4.0—suggest the possibility of simultaneously achieving superior productivity and flexibility. This article aims to address how Industry 4.0 technologies could improve the productivity, flexibility and quality of assembly operations. A systematic literature review was carried out, including 234 peer-reviewed articles from 2010–2020. As a result, the analysis was structured addressing four sets of research questions regarding (1) assembly for mass customization; (2) Industry 4.0 and performance evaluation; (3) Lean production as a starting point for smart factories, and (4) the implications of Industry 4.0 for people in assembly operations. It was found that mass customization brings great complexity that needs to be addressed at different levels from a holistic point of view; that Industry 4.0 offers powerful tools to achieve superior productivity and flexibility in assembly; that Lean is a great starting point for implementing such changes; and that people need to be considered central to Assembly 4.0. Developing methodologies for implementing Industry 4.0 to achieve specific business goals remains an open research topic

A conceptual model for megaprogramming

Megaprogramming is component-based software engineering and life-cycle management. Magaprogramming and its relationship to other research initiatives (common prototyping system/common prototyping language, domain specific software architectures, and software understanding) are analyzed. The desirable attributes of megaprogramming software components are identified and a software development model and resulting prototype megaprogramming system (library interconnection language extended by annotated Ada) are described

Construction industry 4.0 and sustainability: an enabling framework

Governments worldwide are taking actions to address the construction sector's sustainability concerns, including high carbon emissions, health and safety risks, low productivity, and increasing costs. Applying Industry 4.0 technologies to construction (also referred to as Construction 4.0) could address some of these concerns. However, current understanding about this is quite limited, with previous work being largely fragmented and limited both in terms of technologies as well as their interrelationships with the triple bottom line of sustainability perspectives. The focus of this article is therefore on addressing these gaps by proposing a comprehensive multi-dimensional Construction 4.0 sustainability framework that identifies and categorizes the key Construction 4.0 technologies and their positive and negative impacts on environmental, economic, and social sustainability, and then establishing its applicability/usefulness through an empirical, multimethodology case study assessment of the UAE's construction sector. The findings indicate Construction 4.0’s positive impacts on environmental and economic sustainability that far outweigh its negative effects, although these impacts are comparable with regards to social sustainability. On Construction 4.0 technologies itself, their application was found to be nonuniform with greater application seen for building information modeling and automation vis-à-vis others such as cyber-physical systems and smart materials, with significant growth expected in the future for blockchain- and three-dimensional-printing-related technologies. The proposed novel framework could enable the development of policy interventions and support mechanisms to increase Construction 4.0 deployment while addressing its negative sustainability-related impacts. The framework also has the potential to be adapted and applied to other country and sectoral contexts

Tradespace and Affordability – Phase 1

One of the key elements of the SERC’s research strategy is transforming the practice of systems engineering – “SE Transformation.” The Grand Challenge goal for SE Transformation is to transform the DoD community’s current systems engineering and management methods, processes, and tools (MPTs) and practices away from sequential, single stovepipe system, hardware-first, outside-in, document-driven, point-solution, acquisition-oriented approaches; and toward concurrent, portfolio and enterprise-oriented, hardware-software-human engineered, balanced outside-in and inside-out, model-driven, set-based, full life cycle approaches.This material is based upon work supported, in whole or in part, by the U.S. Department of Defense through the Office of the Assistant Secretary of Defense for Research and Engineering (ASD(R&E)) under Contract H98230-08- D-0171 (Task Order 0031, RT 046).This material is based upon work supported, in whole or in part, by the U.S. Department of Defense through the Office of the Assistant Secretary of Defense for Research and Engineering (ASD(R&E)) under Contract H98230-08- D-0171 (Task Order 0031, RT 046)

On systematic approaches for interpreted information transfer of inspection data from bridge models to structural analysis

In conjunction with the improved methods of monitoring damage and degradation processes, the interest in reliability assessment of reinforced concrete bridges is increasing in recent years. Automated imagebased inspections of the structural surface provide valuable data to extract quantitative information about deteriorations, such as crack patterns. However, the knowledge gain results from processing this information in a structural context, i.e. relating the damage artifacts to building components. This way, transformation to structural analysis is enabled. This approach sets two further requirements: availability of structural bridge information and a standardized storage for interoperability with subsequent analysis tools. Since the involved large datasets are only efficiently processed in an automated manner, the implementation of the complete workflow from damage and building data to structural analysis is targeted in this work. First, domain concepts are derived from the back-end tasks: structural analysis, damage modeling, and life-cycle assessment. The common interoperability format, the Industry Foundation Class (IFC), and processes in these domains are further assessed. The need for usercontrolled interpretation steps is identified and the developed prototype thus allows interaction at subsequent model stages. The latter has the advantage that interpretation steps can be individually separated into either a structural analysis or a damage information model or a combination of both. This approach to damage information processing from the perspective of structural analysis is then validated in different case studies