Towards a Framework for Smart Manufacturing adoption in Small and Medium-sized Enterprises

Smart Manufacturing (SM) paradigm adoption can scale production with demand without compromising on the time for order fulfillment. A smart manufacturing system (SMS) is vertically and horizontally connected, and thus it can minimize the chances of miscommunication. Employees in an SME are aware of the operational requirements and their responsibilities. The machine schedules are prepared based on the tasks a machine must perform. Predictive maintenance reduces the downtime of machines. Design software optimizes the product design. Production feasibility is checked with the help of simulation. The concepts of product life cycle management are considered for waste reduction. Employee safety, and ergonomics, identifying new business opportunities and markets, focus on employee education and skill enhancement are some of the other advantages of SM paradigm adoption. This dissertation develops an SM paradigm adoption framework for manufacturing SMEs by employing the instrumental research approach. The first step in the framework identified the technical aspects of SM, and this step was followed by identifying the research gaps in the suggested methods (in literature) and managerial aspects for adopting SM paradigm. The technical and the managerial aspects were integrated into a toolkit for manufacturing SMEs. This toolkit contains seven modular toolboxes that can be installed in five levels, depending on an SME’s readiness towards SM. The framework proposed in this dissertation focuses on how an SME’s readiness can be assessed and based on its present readiness what tools and practices the SMEs need to have to realize their tailored vision of SM. The framework was validated with the help of two SMEs cases that have recently adopted SM practices

Discrete event simulation and virtual reality use in industry: new opportunities and future trends

This paper reviews the area of combined discrete event simulation (DES) and virtual reality (VR) use within industry. While establishing a state of the art for progress in this area, this paper makes the case for VR DES as the vehicle of choice for complex data analysis through interactive simulation models, highlighting both its advantages and current limitations. This paper reviews active research topics such as VR and DES real-time integration, communication protocols, system design considerations, model validation, and applications of VR and DES. While summarizing future research directions for this technology combination, the case is made for smart factory adoption of VR DES as a new platform for scenario testing and decision making. It is put that in order for VR DES to fully meet the visualization requirements of both Industry 4.0 and Industrial Internet visions of digital manufacturing, further research is required in the areas of lower latency image processing, DES delivery as a service, gesture recognition for VR DES interaction, and linkage of DES to real-time data streams and Big Data sets

Robust design of collaborative information system in a prototype assembly facility

The intent of this research was to engineer a collaborative data management system for an assembly facility supplying prototype products to a development and test centre. During the assembly of prototypes, multiple parts and subcomponents are exposed to engineering design changes, necessitating meticulous documentation and archiving of the bills of material. The findings from this research suggest, by using sound engineering methodologies and by extending the research to multiple fields of science, it is possible to design a data management system that has analytical proof for being robust and simple in its design. Robustness of the design is proven using a novel approach combining Axiomatic Design with the House of Quality. Improvements are mathematically evaluated by calculating the complexity of the designs using an innovative complexity formula originating from this research. A step-by-step approach is also developed, lending this research to be a framework for future design improvements

Inventory Optimization in Manufacturing Organizations

Inventories totaling 1.7 trillion U.S. dollars represent an opportunity for U.S. manufacturers. This exploratory case study researched supply chain strategies used to manage inventory in manufacturing operations of a U.S. manufacturing company. A mature value chain contained within a single organization using the value chain framework was the basis for this study. Individual interviews conducted with 16 managers responsible for defining and implementing inventory control strategies, and 4 internal users provided primary information for the study. Other sources of information included a value chain map created through the observation of operations, various inventory measurements, and policies and guidelines related to managing inventory levels. An inductive content analysis employing zero-level coding of the interview transcripts identified 4 themes that describe inventory control strategies as economic order quantity, kanban, vendor managed inventory, and process integration. Physical observation of the value chain, review of supporting documents, and analysis of inventory data ensured the trustworthiness of interpreted themes. Findings identified no single inventory control strategy that fit all applications. Findings also revealed that the financial governing bodies\u27 measurements were not the best tools for operational managers\u27 improvement activities related to inventory control. Included are measures providing alternative means to gauge inventory efficiency. With the results of this study, managers may develop effective strategies to optimize inventory and improve material flow. Manufacturing managers improving material flow may promote sustainability of raw materials and business efficiencies through reduced waste, improved environmental conditions, and increased employment opportunities in associated communities

Powertrain Assembly Lines Automatic Configuration Using a Knowledge Based Engineering Approach

Technical knowledge and experience are intangible assets crucial for competitiveness. Knowledge is particularly important when it comes to complex design activities such as the configuration of manufacturing systems. The preliminary design of manufacturing systems relies significantly on experience of designers and engineers, lessons learned and complex sets of rules and is subject to a huge variability of inputs and outputs and involves decisions which must satisfy many competing requirements. This complicated design process is associated with high costs, long lead times and high probability of risks and reworks. It is estimated that around 20% of the designer’s time is dedicated to searching and analyzing past available knowledge, while 40% of the information required for design is identified through personally stored information. At a company level, the design of a new production line does not start from scratch. Based on the basic requirements of the customers, engineers use their own knowledge and try to recall past layout ideas searching for production line designs stored locally in their CAD systems [1]. A lot of knowledge is already stored, and has been used for a long time and evolved over time. There is a need to retrieve this knowledge and integrate it into a common and reachable framework. Knowledge Based Engineering (KBE) and knowledge representation techniques are considered to be a successful way to tackle this design problem at an industrial level. KBE is, in fact, a research field that studies methodologies and technologies for capturing and re-using product and process engineering knowledge to achieve automation of repetitive design tasks [2]. This study presents a methodology to support the configuration of powertrain assembly lines, reducing design times by introducing a best practice for production systems provider companies. The methodology is developed in a real industrial environment, within Comau S.p.A., introducing the role of a knowledge engineer. The approach includes extraction of existing technical knowledge and implementation in a knowledge-based software framework. The macro system design requirements (e.g. cycle time, production mix, etc.) are taken as input. A user driven procedure guides the designer in the definition of the macro layout-related decisions and in the selection of the equipment to be allocated within the project. The framework is then integrated with other software tools allowing the first phase design of the line including a technical description and a 2D and 3D CAD line layout. The KBE application is developed and tested on a specific powertrain assembly case study. Finally, a first validation among design engineers is presented, comparing traditional and new approach and estimating a cost-benefit analysis useful for future possible KBE implementations

Analysis of the performance of Demand Driven Material Requirements Planning on supply chain management: A multiple case study

En el 2011 se desarrolló la metodología Demand-Driven Material Requirements Planning (DDMRP) con el objetivo de aumentar el flujo de materiales e información y así mejorar la ventaja competitiva de las empresas de fabricación y distribución. Varios trabajos de investigación que simulan el comportamiento del DDMRP han sido realizados desde entonces. Sin embargo, en la revisión de la literatura no se han encontrado estudios que analicen la implementación del DDMRP en una empresa. El presente trabajo, por lo tanto, analiza la evolución que tres empresas han tenido tras migrar del MRP al DDMRP y el impacto de este proceso en la ventaja competitiva. Para analizar y comprender en detalle los hechos de cada estudio de caso, se ha realizado una investigación cualitativa. Para la recogida de datos se han utilizado entrevistas semiestructuradas, documentos y registros de archivos. Tras recopilar todos los datos se han comparado los resultados de antes y después de cada implementación de DDMRP y se ha evaluado la evolución del desempeño de cada empresa. Finalmente, se ha realizado un estudio de casos cruzados. Los resultados obtenidos, demuestran que con la metodología DDMRP las empresas aumentan la visibilidad en la cadena de suministro reduciendo considerablemente el efecto bullwhip y los pedidos urgentes. Cabe destacar también la evolución del inventario, ya que en los tres casos el inventario sufre una reducción importante mientras que el consumo de los materiales aumenta. Todo esto mientras que las empresas son capaces de mantener el nivel de servicio prácticamente en un 100%

From BlM to asset management – data–driven guidelines for operations & maintenance

Dissertação de mestrado em Modelação de Informação na Construção de Edifícios BIM A+Cada vez mais, o BIM é considerado como um elemento-chave no projeto, fabricação e gestão de informação digital na indústria AECO/O. A visualização tridimensional, quando combinada com a criação de uma base de dados permite a compreensão abrangente dos ativos, possibilitando o desenvolvimento contínuo e iniciando um ciclo de aprendizagem do ambiente construído. De todas as etapas de trabalho de um edifício, a fase de operação e manutenção, muitas vezes conhecida como fase “em uso”, é sinalizada como o maior custo no seu ciclo de vida. A recolha de dados relevantes para a atividade de Gestão de Instalações pode absorver mais de 80% do tempo disponível das equipas. A integração BIM pode auxiliar a indústria de AECO/O, atuando como um banco de dados dinâmico que evolui desde as fases iniciais de projeto, onde o BIM se desenvolve como uma solução completa para Gestão de Instalações, capaz de impulsionar fluxos de trabalho usando tecnologias recentes combinadas com processos orientados por dados. Cercada por uma multitude de fornecedores de software, a indústria vem reivindicando o desafio de determinar quais ferramentas a utilizar para transmitir efetivamente as informações para o Gestão de Instalações. Considerando os potenciais procedimentos que possibilitam as práticas de transmissão BIM-FM, pode-se encontrar um procedimento estruturado de entrega de dados, oferecido pelo protocolo de troca aberta COBie. O COBie destaca-se como uma ferramenta independente de fornecedor, capaz de fazer a transmissão de dados entre o Projeto e as etapas subsequentes, pois pode ser exportado de uma ferramenta de autoria BIM e utilizado em soluções de Gestão de Ativos Digitais. Além disso, permite aos proprietários e operadores implementar diferentes sistemas de manutenção, ao mesmo tempo em que fornece dados, verificáveis, confiáveis e precisos. A ausência de uma estrutura com variáveis de informação organizada constitui um hiato na consciencialização da utilização de informação gerada em BIM para integração em Gestão de Instalações, o resultado esperado desta dissertação é o desenvolvimento de um guia de utilização do COBie, uma ferramenta abrangente capaz de auxiliar a produção de entregáveis COBie válidos. O estudo de caso foi usado para implementar a ferramenta desenvolvida, em colaboração com um parceiro do mestrado, a LIMSEN Consulting. O desenvolvimento, a avaliação e a validação da ferramenta consistem nas três fases do procedimento que visam fornecer informação concisa sobre requisitos, responsabilidades e contextos para a entrega de dados. Finalmente, o trabalho apresentado visa fortalecer a prontidão da indústria para a transição de práticas orientadas a documentos para processos automatizados baseados em modelos e orientados por dados.BIM is increasingly considered as a key driver in the design, manufacturing, and management of digital information in the AECO/O industry. The tridimensional visualization combined with the data collection allows for a comprehensive understanding of assets, enabling continuous development, and launching a learning cycle for the built environment. Out of all work stages of a building, the operations and maintenance phase, often known as the “in use” phase, is flagged as the major cost in its lifecycle. Hunting relevant data for Facility Management (FM) may absorb over than 80% of the teams available time. BIM integration can assist the FM industry, by acting as a dynamic data pool evolving from preliminary stages of Design, BIM develops into a complete solution for FM, capable of boosting workflows by using recent technologies combined with data-driven processes. Surrounded by a swarm of software providers, the industry has been claiming the challenge of determining which tools to effectively transmit information to the FM stage. Out of the potential procedures that enable BIM-FM linking practices, a structured data delivery procedure can be found, offered by the open exchange protocol COBie. COBie stands out as a vendor-neutral tool, capable of data bridging between Design and subsequent stages, as it can be exported from a BIM authoring tool and loaded into Digital Asset Management solutions. Additionally, it liberates owners and operators to deploy different maintenance systems, while providing reliable and accurate data. Given that the lack of a clear framework continues to hinder BIM data awareness for integration inside facilities management, the expected outcome of this dissertation is the development of a comprehensive COBie guide, a tool cable to assist teams in producing valid COBie deliverables. A case study was used to implement the developed tool, in collaboration with a business partner, LIMSEN Consulting. The tool development, evaluation, and validation consist of the three major phases of the procedure intended to provide clear information requirements, responsibilities, and data drops. Finally, the presented work aims to strengthen the industry's readiness to transition from document oriented practices into model-based, data-driven automated processes.Erasmus Mundus Joint Master Degree Programme – ERASMUS

Improving Information Alignment and Distributed Coordination for Secure Information Supply Chains

Industries are constantly striving to incorporate the latest technology systems into their operations so that they can maintain a competitive edge in their respective markets. However, even when they are able to stay up to speed with technological advancement, there continues to be a gap between the workforce skill set and available technologies. Organizations may acquire advanced systems, yet end up spending extended periods of time in the implementation and deployment phases, resulting in lost resources and productivity. The primary focus of this research is on streamlining the implementation and integration of new information technology systems to avoid the dire consequences of the process being prolonged or inefficient. Specifically, the goal of this research is to mitigate business challenges in information sharing and availability for employees and managers interacting with business tools and each other. This was accomplished by first interviewing work professionals in order to identify gap parameters. Based on the interview findings, recommendations were made in order to enhance the usability of existing tools. At this point, the research setting was shifted from network operations to supply chain operations due to the restrictive nature of network operations. The research team succeeded in developing a user-centered methodology to implement and deploy new business systems to mitigate risk during integration of new systems as the transition is made from the classic way of performing tasks. While this methodology was studied in supply chain operations, it enabled the identification of a common trend of challenges in operations work settings, regardless of the business application. Hence the findings of this research can be extrapolated to any business setting, besides the ones actually studied by the team. In addition, this research ensures that operational teams are able to maximize their benefit out of the technology available, thus enabling them to keep up with the rapidly evolving world of technology while minimizing sacrifices in resources or productivity in the process