An Industrial Data Analysis and Supervision Framework for Predictive Manufacturing Systems

Due to the advancements in the Information and Communication Technologies field in the modern interconnected world, the manufacturing industry is becoming a more and more data rich environment, with large volumes of data being generated on a daily basis, thus presenting a new set of opportunities to be explored towards improving the efficiency and quality of production processes. This can be done through the development of the so called Predictive Manufacturing Systems. These systems aim to improve manufacturing processes through a combination of concepts such as Cyber-Physical Production Systems, Machine Learning and real-time Data Analytics in order to predict future states and events in production. This can be used in a wide array of applications, including predictive maintenance policies, improving quality control through the early detection of faults and defects or optimize energy consumption, to name a few. Therefore, the research efforts presented in this document focus on the design and development of a generic framework to guide the implementation of predictive manufacturing systems through a set of common requirements and components. This approach aims to enable manufacturers to extract, analyse, interpret and transform their data into actionable knowledge that can be leveraged into a business advantage. To this end a list of goals, functional and non-functional requirements is defined for these systems based on a thorough literature review and empirical knowledge. Subsequently the Intelligent Data Analysis and Real-Time Supervision (IDARTS) framework is proposed, along with a detailed description of each of its main components. Finally, a pilot implementation is presented for each of this components, followed by the demonstration of the proposed framework in three different scenarios including several use cases in varied real-world industrial areas. In this way the proposed work aims to provide a common foundation for the full realization of Predictive Manufacturing Systems

Advancements in the Industrial Internet of Things for Energy Efficiency

The Internet of Things is an emerging field that leverages the connections of everyday objects for the betterment of society. A subfield of this trend, the Industrial Internet of Things (IIoT), has been referred to as an industrial revolution that enhances both productivity and safety in the industrial environment. While still in its early stages, identified improvements have the potential to markedly improve manufacturing productivity. Energy efficiency within manufacturing plants has traditionally received little focus. The Industrial Assessment Center Program demonstrates the potential energy improvements that can be realized in manufacturing plants, but these assessments also highlight some of the traditional barriers to energy efficiency. Some of these barriers include the lack of data to justify actionable improvements, unclear correlations between improvement costs and potential cost savings, and lack of knowledge on how energy improvements provide ancillary benefits to the plant. The IIoT has the potential to increase energy efficiency implementation in manufacturing plants by addressing these challenges. This dissertation discusses the framework in which energy efficiency enhancements within the IIoT environment can be realized. The dissertation initially details the potential benefits of IIoT for energy efficiency and presents a general framework for these improvements. While proposed IIoT frameworks vary, they all include the core elements of improved sensing capabilities, enhanced data analysis, and intelligent actuation. In addition to presenting the framework generally, the dissertation provides detailed case studies on how each of these framework elements lead to improved energy efficiency in manufacturing. The first case study demonstrates improved sensing capabilities in the IIoT framework. A non-intrusive flow meter for use in compressed air and other fluid systems is presented. The second case study discusses Autonomous Robotic Assessments of Energy, which use advanced data analysis to autonomously perform a lighting energy assessment in facilities. The third case study is then presented on intelligent actuation, which uses a novel k-means algorithm to autonomously determine appropriate times to actuate compressors for air systems in manufacturing plants. Each of the presented case studies includes experimental tests demonstrating their capabilities

Multiphysics Modeling and Numerical Simulation in Computer-Aided Manufacturing Processes

The concept of Industry 4.0 is defined as a common term for technology and the concept of new digital tools to optimize the manufacturing process. Within this framework of modular smart factories, cyber-physical systems monitor physical processes creating a virtual copy of the physical world and making decentralized decisions. This article presents a review of the literature on virtual methods of computer-aided manufacturing processes. Numerical modeling is used to predict stress and temperature distribution, springback, material flow, and prediction of phase transformations, as well as for determining forming forces and the locations of potential wrinkling and cracking. The scope of the review has been limited to the last ten years, with an emphasis on the current state of knowledge. Intelligent production driven by the concept of Industry 4.0 and the demand for high-quality equipment in the aerospace and automotive industries forces the development of manufacturing techniques to progress towards intelligent manufacturing and ecological production. Multi-scale approaches that tend to move from macro- to micro- parameters become very important in numerical optimization programs. The software requirements for optimizing a fully coupled thermo-mechanical microstructure then increase rapidly. The highly advanced simulation programs based on our knowledge of physical and mechanical phenomena occurring in non-homogeneous materials allow a significant acceleration of the introduction of new products and the optimization of existing processes.publishedVersio

An early-stage decision-support framework for the implementation of intelligent automation

The constant pressure on manufacturing companies to improve productivity, reduce the lead time and progress in quality requires new technological developments and adoption.The rapid development of smart technology and robotics and autonomous systems (RAS) technology has a profound impact on manufacturing automation and might determine winners and losers of the next generation’s manufacturing competition. Simultaneously, recent smart technology developments in the areas enable an automation response to new production paradigms such as mass customisation and product-lifecycle considerations in the context of Industry 4.0. New paradigms, like mass customisation, increased both the complexity of the tasks and the risk due to smart technology integration. From a manufacturing automation perspective, intelligent automation has been identified as a possible response to arising demands. The presented research aims to support the industrial uptake of intelligent automation into manufacturing businesses by quantifying risks at the early design stage and business case development. An early-stage decision-support framework for the implementation of intelligent automation in manufacturing businesses is presented in this thesis.The framework is informed by an extensive literature review, updated and verified with surveys and workshops to add to the knowledge base due to the rapid development of the associated technologies. A paradigm shift from cost to a risk-modelling perspective is proposed to provide a more flexible and generic approach applicable throughout the current technology landscape. The proposed probabilistic decision-support framework consists of three parts:• A clustering algorithm to identify the manufacturing functions in manual processes from task analysis to mitigate early-stage design uncertainties• A Bayesian Belief Network (BBN) informed by an expert elicitation via the DELPHI method, where the identified functions become the unit of analysis.• A Markov-Chain Monte-Carlo method modelling the effects of uncertainties on the critical success factors to address issues of factor interdependencies after expert elicitation.Based on the overall decision framework a toolbox was developed in Microsoft Excel. Five different case studies are used to test and validate the framework. Evaluation of the results derived from the toolbox from the industrial feedback suggests a positive validation for commercial use. The main contributions to knowledge in the presented thesis arise from the following four points:• Early-stage decision-support framework for business case evaluation of intelligent automation.• Translating manual tasks to automation function via a novel clustering approach• Application of a Markov-Chain Monte-Carlo Method to simulate correlation between decision criteria• Causal relationship among Critical Success Factors has been established from business and technical perspectives.The implications on practise might be promising. The feedback arising from the created tool was promising from the industry, and a practical realisation of the decision-support tool seems to be desired from an industrial point of view.With respect to further work, the decision-support tool might have established a ground to analyse a human task automatically for automation purposes. The established clustering mechanisms and the related attributes could be connected to sensorial data and analyse a manufacturing task autonomously without the subjective input of task analysis experts. To enable such an autonomous process, however, the psychophysiological understanding must be increased in the future.</div

Knowledge representation within information systems in manufacturing environments

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Representing knowledge as information content alone is insufficient in providing us with an understanding of the world around us. A combination of context as well as reasoning of the information content is fundamental to representing knowledge in an information system. Knowledge Representation is typically concerned with providing structures and theories that are used as a basis for intelligent reasoning. For this research however, the author defines an alternative meaning, which is related to how knowledge is used in a given context. Thus, this dissertation provides a contribution to the field of knowledge within information systems, in terms of the development of a frame-of-reference that will support the reader in navigating through the different forms of explicit and tacit knowledge use within the manufacturing industry. In doing so, the dissertation also presents the generation of a novel classification of three forms of knowledge (Structural, Interpretive and Evaluative forms); the development of a conceptual framework which highlights the drivers for knowledge transformation; and the development of a conceptual model which seeks to envelop both the content as well as the context of knowledge (Semiotic as well as Symbiotic factors). This is established through the use of an Empirical, Quantitative case study approach, that seeks to explore an interpretivist view of knowledge representation within two information systems contexts, within two UK manufacturing organisations. The first case study presents how a-priori knowledge assumptions are used in a computer aided engineering decision-making task within a high technology manufacturing company. The second case study shows how knowledge is used within the IT/IS investment evaluation decision making process, within a manufacturing SME. In doing so, both case studies attempt to elucidate the inherent, underlying relationship between explicit and tacit knowledge, via a frame-of-reference developed by the author which defines key drivers for knowledge transformation

Special Session on Industry 4.0

No abstract available

Agent and cyber-physical system based self-organizing and self-adaptive intelligent shopfloor

The increasing demand of customized production results in huge challenges to the traditional manufacturing systems. In order to allocate resources timely according to the production requirements and to reduce disturbances, a framework for the future intelligent shopfloor is proposed in this paper. The framework consists of three primary models, namely the model of smart machine agent, the self-organizing model, and the self-adaptive model. A cyber-physical system for manufacturing shopfloor based on the multiagent technology is developed to realize the above-mentioned function models. Gray relational analysis and the hierarchy conflict resolution methods were applied to achieve the self-organizing and self-adaptive capabilities, thereby improving the reconfigurability and responsiveness of the shopfloor. A prototype system is developed, which has the adequate flexibility and robustness to configure resources and to deal with disturbances effectively. This research provides a feasible method for designing an autonomous factory with exception-handling capabilities

A framework for smart production-logistics systems based on CPS and industrial IoT

Industrial Internet of Things (IIoT) has received increasing attention from both academia and industry. However, several challenges including excessively long waiting time and a serious waste of energy still exist in the IIoT-based integration between production and logistics in job shops. To address these challenges, a framework depicting the mechanism and methodology of smart production-logistics systems is proposed to implement intelligent modeling of key manufacturing resources and investigate self-organizing configuration mechanisms. A data-driven model based on analytical target cascading is developed to implement the self-organizing configuration. A case study based on a Chinese engine manufacturer is presented to validate the feasibility and evaluate the performance of the proposed framework and the developed method. The results show that the manufacturing time and the energy consumption are reduced and the computing time is reasonable. This paper potentially enables manufacturers to deploy IIoT-based applications and improve the efficiency of production-logistics systems

Intelligent systems in manufacturing: current developments and future prospects

Global competition and rapidly changing customer requirements are demanding increasing changes in manufacturing environments. Enterprises are required to constantly redesign their products and continuously reconfigure their manufacturing systems. Traditional approaches to manufacturing systems do not fully satisfy this new situation. Many authors have proposed that artificial intelligence will bring the flexibility and efficiency needed by manufacturing systems. This paper is a review of artificial intelligence techniques used in manufacturing systems. The paper first defines the components of a simplified intelligent manufacturing systems (IMS), the different Artificial Intelligence (AI) techniques to be considered and then shows how these AI techniques are used for the components of IMS