A framework for SFC/DC system data analysis

The Shop Floor Control/Data Collection (SFC/DC) system is one of four major modules of the Integrated Work Control System being implemented at the NASA Kennedy Space Center. The SFC/DC system, which has been in operation approximately one and a half years, collects detailed information regarding the duration of tasks as well as work stoppages duration. This information needs to be effectively analyzed, so as be able to manage the shuttle processing activities under the continuous improvement philosophy. We have studied the contents and form of the SFC/DC database, and based on the results of such study, we have designed a Shop floor Modeling, Analysis, and Reporting Tool (SMART). SMART is a collection of compatible tools (off-the-shelf as well as customized C-based tools) that work cohesively to prepare inputs for the analysis models and process the various models. The feasibility of SMART has been demonstrated through an initial prototype

A CHANGEABILITY APPROACH FOR PROCESS MANAGEMENT AND DECISION SUPPORT ON THE SHOP FLOOR

This document contains an approach to map the changeability possibilities of machine tools used on the shop floor onto line management understandable business processes. The identified gap is a lack of information transparency on the line management level due to constraints, complexity and speed of a production process on the shop floor. Especially medium-sized enterprises in the supplier sector are forced to operate under strong time restrictions which are predetermined by original equipment manufacturers. Due to competitors and shareholders these enterprises often use a lean management approach which allows them on the one hand to produce under low costs but on the other hand handicaps them to react on disruptive events on the shop floor. We argue that nowadays industrial small and medium sized industrial enterprises have to have a fast reaction on changes and events. It is seen by the authors that changeability of production processes is an essential success factor in this globalized world. Because of the fact that more and more responsibility is handed over to the lower line management, the information support has to be improved in order to make them capable for choosing the best decision. In this paper a concept is shown how the lower management can reallocate production process steps in order to avoid penalty costs if a just in time production is requested by an original equipment manufacturer. To be able to do this, an information support concept for the lower management has to be established within the company to meet the requirements for choosing the best fitting reaction to a disruptive event. The future research concept is described after the analysis of an example production process scenario which is illustrated within this paper

Corporate memory in the lean context. Preventing short- and long-term information loss

A large part of the information necessary for an organization to function is stored exclusively in people's memories. This applies to two different kinds of information - short-term information related to daily operations in the shop floor as well as long-term accumulated knowledge and expertise. In the present article we propose several solutions for preventing short- and long-term information loss in an industrial setting. We analyze information loss and its consequences at an automotive component factory in the North of Portugal. For the short-term information loss, we propose lean tools such as gravity flow racks, kanban and andon screens. For long-term information loss, we propose the implementation of mentorship programs, the creation of a knowledge repository based on wiki technology and the use of explanatory labelsPortuguese Foundation for Science and Technology (FCT) within the Project Scope UID/CEC/00319/2019 (ALGORITMI Center

A cyber-physical machine tools platform using OPC UA and MTConnect

Cyber-Physical Machine Tools (CPMT) represent a new generation of machine tools that are smarter, well connected, widely accessible, more adaptive and more autonomous. Development of CPMT requires standardized information modelling method and communication protocols for machine tools. This paper proposes a CPMT Platform based on OPC UA and MTConnect that enables standardized, interoperable and efficient data communication among machine tools and various types of software applications. First, a development method for OPC UA-based CPMT is proposed based on a generic OPC UA information model for CNC machine tools. Second, to address the issue of interoperability between OPC UA and MTConnect, an MTConnect to OPC UA interface is developed to transform MTConnect information model and its data to their OPC UA counterparts. An OPC UA-based CPMT prototype is developed and further integrated with a previously developed MTConnect-based CPMT to establish a common CPMT Platform. Third, different applications are developed to demonstrate the advantages of the proposed CPMT Platform, including an OPC UA Client, an advanced AR-assisted wearable Human-Machine Interface and a conceptual framework for CPMT powered cloud manufacturing environment. Experimental results have proven that the proposed CPMT Platform can significantly improve the overall production efficiency and effectiveness in the shop floor

Digitalization of Whiteboard for Work Task Allocation to Support Information Sharing between Operators and Supervisor

The increase of complexity in modern production systems has put new demands on shop-floor operators. Therefore, proper sharing of information on shop-floors has become more important as means to support operators’ cognition. To this aim, the development of Information and Communication Technology has provided new support tools, but many of these tools lack empirical testing in live production. This paper studies how information sharing between operators and supervisor, at a small production company, is affected by the use of one of these tools: namely, replacing a whiteboard for work task allocation with a digital counterpart. In this study, questionnaires, polls, and interviews about the operators’ perception towards shared information and its quality were assessed. This assessment was based on the MEET model, which includes both an organizational and an informational perspective for studying various areas that affect meetings and information sharing. The results indicate that, while the information quality was improved by the digital whiteboard, the Organization System supporting the changed Information System need to keep up with the changes. Future practice needs to better match the two systems, and research needs to study the relations of the subcomponents of the two systems

A Framework for Online Detection and Reaction to Disturbances on the Shop Floor Using Process Mining and Machine Learning

The shop floor is a dynamic environment, where deviations to the production plan frequently occur. While there are many tools to support production planning, production control is left unsupported in handling disruptions. The production controller evaluates the deviations and selects the most suitable countermeasures based on his experience. The transparency should be increased in order to improve the decision quality of the production controller by providing meaningful information during his decision process. In this paper, we propose a framework in which an interactive production control system supports the controller in the identification of and reaction to disturbances on the shop floor. At the same time, the system is being improved and updated by the domain knowledge of the controller. The reference architecture consists of three main parts. The first part is the process mining platform, the second part is the machine learning subsystem that consists of a part for the classification of the disturbances and one part for recommending countermeasures to identified disturbances. The third part is the interactive user interface. Integrating the user’s feedback will enable an adaptation to the constantly changing constraints of production control. As an outlook for a technical realization, the design of the user interface and the way of interaction is presented. For the evaluation of our framework, we will use simulated event data of a sample production line. The implementation and test should result in higher production performance by reducing the downtime of the production and increase in its productivity

Intelligent assistant system as a context-aware decision-making support for the workers of the future

International audienceThe key role of information and communication technologies (ICT) to improve manufacturing productivity within the paradigm of factory of the future is often proved. These tools are used in a wide range of product lifecycle activities, from the early design phase to product recycling. Generally, the assistance tools are mainly dedicated to the management board and fewer initiatives focus on the operational needs of the worker at the shop-floor level. This paper proposes a context-aware knowledge-based system dedicated to support the actors of the factory by the right information at the right time and in the appropriate format regarding their context of work and level of expertise. Particularly, specific assistance functionalities are dedicated to the workers in charge of the machine configuration and the realization of manufacturing operations. PGD-based (Proper Generalized Decomposition) algorithms are used for real time simulation of industrial processes and machine configuration. At the conceptual level, a semantic model is proposedas key enablersfor the structuration of the knowledge-based system

Software methodologies for the engineering of service-oriented industrial automation: the continuum project

Indexado InspecService-orientation represents a new wave of features and solutions by bringing closer Information Technology to the industrial domain, particularly factory shop floors. The service-oriented automation software entities (designated here by bots) used in such approach requires a short set of methodologies and software targeting their specification for both computer systems and embedded automation devices. The present work explains the adopted methodologies and software developments for the engineering of service-based automation systems. The main contents focus on the specification of a framework for the development of bots and supporting engineering tools that are part of the Continuum project. The paper also does an overview over the engineering steps from the system design to the operation, and focuses the importance of the maintenance of automation bots. Such applications will contribute to decrease the development time and reduce the components' interdependency, offering enough flexibility for automatic reconfiguration of shop-floor layouts.The authors would like to thank the European Commission and the partners of the EU IST FP6 project “Service-Oriented Cross-layer infrastructure for Distributed smart Embedded devices” (SOCRADES), the EU FP6 “Network of Excellence for Innovative Production Machines and Systems” (I*PROMS), and the European ICT FP7 project “Cooperating Objects Network of Excellence” (CONET) for their support

Digital Tools and Information Needs Assessment for Efficient Deviation Handling in SMEs

A shift to digitalization implies a high emphasis on both management and creation of data. In a time of change, when high emphasis is put on the application of technology, there is a high risk that too little is said about the compliance of internal needs. Companies and practitioners risk to not prioritizing the assessment and questioning the adoption of digital ways of working. The present paper intends to discuss the impact that digital tools may have on deviation management in Small to Medium Size Enterprises (SMEs) and under which circumstances digital tools will improve deviation management in SME context. The research study employs a qualitative approach using the case study methodology. The source of data comes from five different manufacturing companies categorized as SMEs, mainly doing business in the automotive and maritime industry. A multidisciplinary team performed semi-structured interviews and fieldwork at each site, along with regular online meetings with all the partners. The study employs five dimensions from the information quality perspective to assess information utilized to support deviation handling and then connects the information quality deficiencies to the digital tools impact. The empirical data indicate the need for the companies to perform a requirement analysis, as a prerequisite for them to assess their current state in terms of data and information, before the adoption of digital systems or digital tools. The research demonstrates the value for SMEs to understand their information needs and usage, in order to better determine their data needs and how to translate data into information. Lastly, this paper intends to provide a better foundation for SMEs prior to investments on automation and digitalization in the area of disturbance handling on the production shop floor

Communication and control in small batch part manufacturing

This paper reports on the development of a real-time control network as an integrated part of a shop floor control system for small batch part manufacturing. The shop floor control system is called the production control system (PCS). The PCS aims at an improved control of small batch part manufacturing systems, enabling both a more flexible use of resources and a decrease in the economical batch size. For this, the PCS integrates various control functions such as scheduling, dispatching, workstation control and monitoring, whilst being connected on-line to the production equipment on the shop floor. The PCS can be applied irrespective of the level of automation on the shop floor. The control network is an essential part of the PCS, as it provides a real-time connection between the different modules (computers) of the PCS, which are geographically distributed over the shop floor. An overview of the requirements of such a control network is given. The description of the design includes the services developed, the protocols used and the physical layout of the network. A prototype of the PCS, including the control network, has been installed and tested in a pilot plant. The control network has proven that it can supply a manufacturing environment, consisting of equipment from different vendors with different levels of automation, with a reliable, low cost, real-time communication facility