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

Annals of Scientific Society for Assembly, Handling and Industrial Robotics

This Open Access proceedings present a good overview of the current research landscape of industrial robots. The objective of MHI Colloquium is a successful networking at academic and management level. Thereby the colloquium is focussing on a high level academic exchange to distribute the obtained research results, determine synergetic effects and trends, connect the actors personally and in conclusion strengthen the research field as well as the MHI community. Additionally there is the possibility to become acquainted with the organizing institute. Primary audience are members of the scientific association for assembly, handling and industrial robots (WG MHI)

Mobile and adaptive User interface for human robot collaboration in assembly tasks

The manufacturing sector is constantly looking for more efficient ways of production. The Industry 4.0 related technologies such as augmented and mixed reality, connectivity and digitalisation as well as the current trend of robotisation have resulted a number of technical solutions to support the production in factories. The combination of human-robot collaboration and augmented reality shows good promises. The challenges in this case come from the need to reconfigure the physical production layout and how to deliver the digital instructions to the operator. This paper introduces a model for collaborative assembly tasks that uses a mobile user interface based on the depth sensors and a projector. The novelty of this research comes from the adaptivity of the user interface, as it can be freely moved between the tasks around the workstation based on the operator needs and requirements of the tasks. The ability to move projection surface is achieved by detecting the surface position using Aruco markers and computing required transformation of the projector image.acceptedVersionPeer reviewe

Implementing Industry 4.0 in SMEs

This open access book addresses the practical challenges that Industry 4.0 presents for SMEs. While large companies are already responding to the changes resulting from the fourth industrial revolution , small businesses are in danger of falling behind due to the lack of examples, best practices and established methods and tools. Following on from the publication of the previous book ‘Industry 4.0 for SMEs: Challenges, Opportunities and Requirements’, the authors offer in this new book innovative results from research on smart manufacturing, smart logistics and managerial models for SMEs. Based on a large scale EU-funded research project involving seven academic institutions from three continents and a network of over fifty small and medium sized enterprises, the book reveals the methods and tools required to support the successful implementation of Industry 4.0 along with practical examples

Smart Technologies for Precision Assembly

This open access book constitutes the refereed post-conference proceedings of the 9th IFIP WG 5.5 International Precision Assembly Seminar, IPAS 2020, held virtually in December 2020. The 16 revised full papers and 10 revised short papers presented together with 1 keynote paper were carefully reviewed and selected from numerous submissions. The papers address topics such as assembly design and planning; assembly operations; assembly cells and systems; human centred assembly; and assistance methods in assembly

Productivity and flexibility improvement of assembly lines for high-mix low-volume production. A white goods industry case

Las tendencias globales de la personalización e individualización en masa impulsan la producción industrial en serie corta y variada; y por tanto una gran variedad de productos en pequeñas cantidades. Por ello, la customización en masa precisa de sistemas de ensamblaje que sean a la vez altamente productivos y flexibles, a diferencia de la tradicional oposición entre ambas características. La llamada cuarta revolución industrial trae diversas tecnologías habilitadoras que podrían ser útiles para abordar este problema. Sin embargo, las metodologías para implementar el ensamblaje 4.0 todavía no han sido resueltas. De hecho, para aprovechar todas las ventajas potenciales de la Industria 4.0, es necesario contar con un nivel previo de excelencia operacional y un análisis holístico de los sistemas productivos. Esta tesis tiene como objetivo entender y definir cómo mejorar la productividad y la flexibilidad de las operaciones de montaje en serie corta y variada.Esta meta se ha dividido en tres objetivos. El primer objetivo consiste en comprender las relaciones entre la Industria 4.0 y las operaciones de ensamblaje, así como sus implicaciones para los operarios. El segundo objetivo consiste en desarrollar una metodología y las herramientas necesarias para evaluar el rendimiento de diferentes configuraciones de cadenas de ensamblaje. El último objetivo consiste en el diseño de sistemas de ensamblaje que permitan incrementar su productividad al menos un 25 %, produciendo en serie corta y variada, mediante la combinación de puestos de montaje manual y estaciones automatizadas.Para abordar la fase de comprensión y definición del problema, se llevó a cabo una revisión bibliográfica sistemática y se desarrolló un marco conceptual para el Ensamblaje 4.0. Se desarrollaron, verificaron y validaron dos herramientas de evaluación del rendimiento: un modelo matemático analítico y varios modelos de simulación por eventos discretos. Para la verificación, y como punto de partida para los análisis, se ha utilizado un caso de estudio industrial de un fabricante global de electrodomésticos. Se han empleado múltiples escenarios de simulación y técnicas de diseño de experimentos para investigar tres cuestiones clave.En primer lugar, se identificaron los factores más críticos para el rendimiento de líneas de montaje manuales multi-modelo. En segundo lugar, se analizó el rendimiento de líneas de montaje semiautomáticas paralelas con operarios móviles en comparación con líneas semiautomáticas o manuales con operarios fijos, empleando diversos escenarios de demanda en serie corta y variada. Por último, se investigó el uso de trenes milkrun para la logística interna de líneas de ensamblaje multi-modelo bajo la influencia de perturbaciones.Los resultados de las simulaciones muestran que las líneas paralelas con operarios móviles pueden superar a las de operarios fijos en cualquier escenario de demanda, alcanzando como mínimo el objetivo de mejorar la productividad en un 25% o más. También permiten reducir cómodamente el número de operarios trabajando en la línea sin afectar negativamente al equilibrado de la misma, posibilitando la producción eficiente de bajo volumen. Los resultados de las simulaciones de logística interna indican que los milkrun pueden proteger las líneas de ensamblaje de las perturbaciones originadas en procesos aguas arriba.Futuras líneas de investigación en base a los resultados obtenidos en esta tesis podrían incluir la expansión e integración de los modelos de simulación actuales para analizar las cadenas de montaje paralelas con operarios móviles incorporando logística, averías y mantenimiento, problemas de control de calidad y políticas de gestión de los retrabajos. Otra línea podría ser el uso de diferentes herramienta para el análisis del desempeño como, por ejemplo, técnicas de programación de la producción que permitan evaluar el desempeño operacional de diferentes configuraciones de cadenas de montaje con operarios móviles, tanto en términos de automatización como de organización en planta. Podrían incorporarse tecnologías de la Industria 4.0 a los modelos de simulación para evaluar su impacto operacional global ¿como cobots para ensamblaje o para la manipulación de materiales, realidad aumentada para el apoyo cognitivo a los operarios, o AGVs para la conducciónde los trenes milkrun. Por último, el trabajo presentado en esta tesis acerca las líneas de ensamblaje semiautomáticas con operarios móviles a su implementación industrial.<br /

AUGMENTED REALITY AND MOBILE SYSTEMS FOR HEAVY EQUIPMENT OPERATORS IN SURFACE MINING

U.S. federal laws mandate that mining companies ensure a safe workplace, implement approved training programs, and promptly report work-related injuries. The mining industry\u27s commitment to innovation reflects a history of adopting advancements to enhance environmental sustainability, workplace safety, and overall productivity, while simultaneously reducing operational costs. This thesis proposes the integration of Augmented Reality (AR) technology and digital applications to enhance the surface mining industry, presenting two innovative solutions: an AR Training System and an Operational Digital System. These business solutions have been developed and applied at a surface mine in the southwest of the US, having the potential to improve the mining industry by enhancing safety, training, operational efficiency, and data-driven decision-making, which comprehends a significant step toward a more sustainable, effective, and technologically driven mining sector, contributing to the industry\u27s evolution and growth. The AR Training System leverages Microsoft´s Power Platform and HoloLens 2 capacities to provide operators with immersive and step-by-step training guides in real working conditions for Dozers, Motor Graders, and End Dump trucks. These AR guides combine 3D models, videos, photos, and interactive elements overlapping mining equipment to enhance learning and safety. The system also offers an efficient approach to data collection during operator training, which has the potential to modify the training guides based on user performance. On the other hand, the Operational Digital System addresses the industry\u27s operational challenges. It streamlines the pre-operation inspection process, tracks equipment status, and accelerates defect identification, shift timing, delays, and loaded tonnage. The system offers a holistic approach to mining operation optimization, facilitating data sharing and management among different departments, enhancing collaboration, and expediting maintenance processes

Annals of Scientific Society for Assembly, Handling and Industrial Robotics 2021

This Open Access proceedings presents a good overview of the current research landscape of assembly, handling and industrial robotics. The objective of MHI Colloquium is the successful networking at both academic and management level. Thereby, the colloquium focuses an academic exchange at a high level in order to distribute the obtained research results, to determine synergy effects and trends, to connect the actors in person and in conclusion, to strengthen the research field as well as the MHI community. In addition, there is the possibility to become acquatined with the organizing institute. Primary audience is formed by members of the scientific society for assembly, handling and industrial robotics (WGMHI)

Annals of Scientific Society for Assembly, Handling and Industrial Robotics 2021

This Open Access proceedings presents a good overview of the current research landscape of assembly, handling and industrial robotics. The objective of MHI Colloquium is the successful networking at both academic and management level. Thereby, the colloquium focuses an academic exchange at a high level in order to distribute the obtained research results, to determine synergy effects and trends, to connect the actors in person and in conclusion, to strengthen the research field as well as the MHI community. In addition, there is the possibility to become acquatined with the organizing institute. Primary audience is formed by members of the scientific society for assembly, handling and industrial robotics (WGMHI)