Special Session on Industry 4.0

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Prerequisites and Barriers for the Development of Reconfigurable Manufacturing Systems for High Speed Ramp-up

AbstractIntensified global competition, fast developing technologies, and changing customer demands have resulted in a trend towards increased differences in customer requirements, increased need for customization, shorter product life cycles, shorter windows for market opportunity, and rapid new product introductions. Thus, production ramp-up is becoming a more and more important stage in the lifetime of a product, which manufacturers need to be able to handle frequently and efficiently in order to gain competitive advantage. Reconfigurable manufacturing systems (RMSs) are attractive options for handling this, as the system can be continuously reconfigured in accordance with the demanded volumes and products. However, the development of the RMS is a particularly challenging task compared to the development of a traditional manufacturing system. Therefore, the aim of the research presented in this paper is to investigate prerequisites and barriers for developing reconfigurable manufacturing. Initially, the paper presents a review of current literature on reconfigurable manufacturing with an identification of the prerequisites for its implementation. Moreover, through a long-term case study, their presence and the barriers towards their adoption and development in industry are investigated. The findings suggest multiple barriers for the successful development of reconfigurable manufacturing in industry. Conclusively, these findings are discussed and considerations for future research are proposed in order to aid the transition towards reconfigurability in industry

Modular architecture of the microfactories for automatic micro-assembly.

International audienceThe construction of a new generation of MEMS which includes micro-assembly steps in the current microfabrication process is a big challenge. It is necessary to develop new production means named micromanufacturing systems in order to perform these new assembly steps. The classical approach called “top-down” which consists in a functional analysis and a definition of the tasks sequences is insufficient for micromanufacturing systems. Indeed, the technical and physical constraints of the microworld (e.g. the adhesion phenomenon) must be taken into account in order to design reliable micromanufacturing systems. A new method of designing micromanufacturing systems is presented in this paper. Our approach combines the general “top-down” approach with a “bottom-up” approach which takes into account technical constraints. The method enables to build a modular architecture for micromanufacturing systems. In order to obtain this modular architecture, we have devised an original identification technique of modules and an association technique of modules. This work has been used to design the controller of an experimental robotic micro-assembly station

Product Variants Platform Customization Strategies and Performance of Reconfigurable Manufacturing Systems (RMS)

Customers’ demands and needs are changing over time. As a result, manufacturers are seeking new ways to respond to market changes effectively and efficiently. They include offering customers a wide range of product varieties in a reasonable time while reducing associated costs. One of the prime techniques adopted by manufacturers is mass customization and its enablers, such as product family and product platforms. The main objective of this research is to help manufacturers manage a high level of variety by implementing the most suitable manufacturing strategy and product platform design. Customized Platform To Order (CPTO) has been introduced and compared with existing manufacturing/production strategies, such as assemble to order (ATO). CPTO is a hybrid assemble-to-stock (ATS)/assemble-to-order (ATO) strategy that uses a platform customization approach to increase the efficiency and productivity of manufacturers. The platform(s) design is based on customers’ historical demand rather than on commonality between product variants. In this thesis, the CPTO approach was compared to the ATO and hybrid ATS/ATO strategies. A discrete-event simulation model of the learning factory iFactory in the Intelligent Manufacturing System Centre (IMSC) is developed. The results were then compared with a physical implementation conducted in the (IMS) Centre. The results of this investigation indicated that the CPTO approach provides manufacturers the ability to be more responsive by reducing the lead time by 30% and assembly time by 27% as well as lowering inventory and assembly costs by 24% and 18% respectively for the considered case study. This approach is applicable to products with modular and flexible platforms and both flexible and reconfigurable manufacturing systems

A categorical framework of manufacturing for industry 4.0 and beyond

AbstractWith rapid advancements in industry, technology and applications, many concepts have emerged in manufacturing. It is generally known that the far-sighted term ‘Industry 4.0’ was published to highlight a new industrial revolution. Many manufacturing organizations and companies are researching this topic. However, the achievement criteria of Industry 4.0 are as yet uncertain. In addition, the technology roadmap of accomplishing Industry 4.0 is still not clear in industry nor in academia to date. This paper focuses on the fundamental conception of Industry 4.0 and the state of current manufacturing systems. It also identifies the research gaps between current manufacturing systems and Industry 4.0 requirements. The major contribution is an implementation structure of Industry 4.0, consisting of a multi-layered framework is described, and is shown how it can assist people in understanding and achieving the requirements of Industry 4.0