Predictive Maintenance in the Production of Steel Bars: A Data-Driven Approach

The ever increasing demand for shorter production times and reduced production costs require manufacturing firms to bring down their production costs while preserving a smooth and flexible production process. To this aim, manufacturers could exploit data-driven techniques to monitor and assess equipmen’s operational state and anticipate some future failure. Sensor data acquisition, analysis, and correlation can create the equipment’s digital footprint and create awareness on it through the entire life cycle allowing the shift from time-based preventive maintenance to predictive maintenance, reducing both maintenance and production costs. In this work, a novel data analytics workflow is proposed combining the evaluation of an asset’s degradation over time with a self-assessment loop. The proposed workflow can support real-time analytics at edge devices, thus, addressing the needs of modern cyber-physical production systems for decision-making support at the edge with short response times. A prototype implementation has been evaluated in use cases related to the steel industry

Manufacturing as a Data-Driven Practice: Methodologies, Technologies, and Tools

n recent years, the introduction and exploitation of innovative information technologies in industrial contexts have led to the continuous growth of digital shop floor envi- ronments. The new Industry-4.0 model allows smart factories to become very advanced IT industries, generating an ever- increasing amount of valuable data. As a consequence, the neces- sity of powerful and reliable software architectures is becoming prominent along with data-driven methodologies to extract useful and hidden knowledge supporting the decision making process. This paper discusses the latest software technologies needed to collect, manage and elaborate all data generated through innovative IoT architectures deployed over the production line, with the aim of extracting useful knowledge for the orchestration of high-level control services that can generate added business value. This survey covers the entire data life-cycle in manufacturing environments, discussing key functional and methodological aspects along with a rich and properly classified set of technologies and tools, useful to add intelligence to data-driven services. Therefore, it serves both as a first guided step towards the rich landscape of literature for readers approaching this field, and as a global yet detailed overview of the current state-of-the-art in the Industry 4.0 domain for experts. As a case study, we discuss in detail the deployment of the proposed solutions for two research project demonstrators, showing their ability to mitigate manufacturing line interruptions and reduce the corresponding impacts and costs

Business analytics in industry 4.0: a systematic review

Recently, the term “Industry 4.0” has emerged to characterize several Information Technology and Communication (ICT) adoptions in production processes (e.g., Internet-of-Things, implementation of digital production support information technologies). Business Analytics is often used within the Industry 4.0, thus incorporating its data intelligence (e.g., statistical analysis, predictive modelling, optimization) expert system component. In this paper, we perform a Systematic Literature Review (SLR) on the usage of Business Analytics within the Industry 4.0 concept, covering a selection of 169 papers obtained from six major scientific publication sources from 2010 to March 2020. The selected papers were first classified in three major types, namely, Practical Application, Reviews and Framework Proposal. Then, we analysed with more detail the practical application studies which were further divided into three main categories of the Gartner analytical maturity model, Descriptive Analytics, Predictive Analytics and Prescriptive Analytics. In particular, we characterized the distinct analytics studies in terms of the industry application and data context used, impact (in terms of their Technology Readiness Level) and selected data modelling method. Our SLR analysis provides a mapping of how data-based Industry 4.0 expert systems are currently used, disclosing also research gaps and future research opportunities.The work of P. Cortez was supported by FCT - Fundação para a Ciência e Tecnologia within the R&D Units Project Scope: UIDB/00319/2020. We would like to thank to the three anonymous reviewers for their helpful suggestions

An integrative framework for cooperative production resources in smart manufacturing

Under the push of Industry 4.0 paradigm modern manufacturing companies are dealing with a significant digital transition, with the aim to better address the challenges posed by the growing complexity of globalized businesses (Hermann, Pentek, & Otto, Design principles for industrie 4.0 scenarios, 2016). One basic principle of this paradigm is that products, machines, systems and business are always connected to create an intelligent network along the entire factory\u2019s value chain. According to this vision, manufacturing resources are being transformed from monolithic entities into distributed components, which are loosely coupled and autonomous but nevertheless provided of the networking and connectivity capabilities enabled by the increasingly widespread Industrial Internet of Things technology. Under these conditions, they become capable of working together in a reliable and predictable manner, collaborating among themselves in a highly efficient way. Such a mechanism of synergistic collaboration is crucial for the correct evolution of any organization ranging from a multi-cellular organism to a complex modern manufacturing system (Moghaddam & Nof, 2017). Specifically of the last scenario, which is the field of our study, collaboration enables involved resources to exchange relevant information about the evolution of their context. These information can be in turn elaborated to make some decisions, and trigger some actions. In this way connected resources can modify their structure and configuration in response to specific business or operational variations (Alexopoulos, Makris, Xanthakis, Sipsas, & Chryssolouris, 2016). Such a model of \u201csocial\u201d and context-aware resources can contribute to the realization of a highly flexible, robust and responsive manufacturing system, which is an objective particularly relevant in the modern factories, as its inclusion in the scope of the priority research lines for the H2020 three-year period 2018-2020 can demonstrate (EFFRA, 2016). Interesting examples of these resources are self-organized logistics which can react to unexpected changes occurred in production or machines capable to predict failures on the basis of the contextual information and then trigger adjustments processes autonomously. This vision of collaborative and cooperative resources can be realized with the support of several studies in various fields ranging from information and communication technologies to artificial intelligence. An update state of the art highlights significant recent achievements that have been making these resources more intelligent and closer to the user needs. However, we are still far from an overall implementation of the vision, which is hindered by three major issues. The first one is the limited capability of a large part of the resources distributed within the shop floor to automatically interpret the exchanged information in a meaningful manner (semantic interoperability) (Atzori, Iera, & Morabito, 2010). This issue is mainly due to the high heterogeneity of data model formats adopted by the different resources used within the shop floor (Modoni, Doukas, Terkaj, Sacco, & Mourtzis, 2016). Another open issue is the lack of efficient methods to fully virtualize the physical resources (Rosen, von Wichert, Lo, & Bettenhausen, 2015), since only pairing physical resource with its digital counterpart that abstracts the complexity of the real world, it is possible to augment communication and collaboration capabilities of the physical component. The third issue is a side effect of the ongoing technological ICT evolutions affecting all the manufacturing companies and consists in the continuous growth of the number of threats and vulnerabilities, which can both jeopardize the cybersecurity of the overall manufacturing system (Wells, Camelio, Williams, & White, 2014). For this reason, aspects related with cyber-security should be considered at the early stage of the design of any ICT solution, in order to prevent potential threats and vulnerabilities. All three of the above mentioned open issues have been addressed in this research work with the aim to explore and identify a precise, secure and efficient model of collaboration among the production resources distributed within the shop floor. This document illustrates main outcomes of the research, focusing mainly on the Virtual Integrative Manufacturing Framework for resources Interaction (VICKI), a potential reference architecture for a middleware application enabling semantic-based cooperation among manufacturing resources. Specifically, this framework provides a technological and service-oriented infrastructure offering an event-driven mechanism that dynamically propagates the changing factors to the interested devices. The proposed system supports the coexistence and combination of physical components and their virtual counterparts in a network of interacting collaborative elements in constant connection, thus allowing to bring back the manufacturing system to a cooperative Cyber-physical Production System (CPPS) (Monostori, 2014). Within this network, the information coming from the productive chain can be promptly and seamlessly shared, distributed and understood by any actor operating in such a context. In order to overcome the problem of the limited interoperability among the connected resources, the framework leverages a common data model based on the Semantic Web technologies (SWT) (Berners-Lee, Hendler, & Lassila, 2001). The model provides a shared understanding on the vocabulary adopted by the distributed resources during their knowledge exchange. In this way, this model allows to integrate heterogeneous data streams into a coherent semantically enriched scheme that represents the evolution of the factory objects, their context and their smart reactions to all kind of situations. The semantic model is also machine-interpretable and re-usable. In addition to modeling, the virtualization of the overall manufacturing system is empowered by the adoption of an agent-based modeling, which contributes to hide and abstract the control functions complexity of the cooperating entities, thus providing the foundations to achieve a flexible and reconfigurable system. Finally, in order to mitigate the risk of internal and external attacks against the proposed infrastructure, it is explored the potential of a strategy based on the analysis and assessment of the manufacturing systems cyber-security aspects integrated into the context of the organization\u2019s business model. To test and validate the proposed framework, a demonstration scenarios has been identified, which are thought to represent different significant case studies of the factory\u2019s life cycle. To prove the correctness of the approach, the validation of an instance of the framework is carried out within a real case study. Moreover, as for data intensive systems such as the manufacturing system, the quality of service (QoS) requirements in terms of latency, efficiency, and scalability are stringent, an evaluation of these requirements is needed in a real case study by means of a defined benchmark, thus showing the impact of the data storage, of the connected resources and of their requests

An integrative framework for cooperative production resources in smart manufacturing

Under the push of Industry 4.0 paradigm modern manufacturing companies are dealing with a significant digital transition, with the aim to better address the challenges posed by the growing complexity of globalized businesses (Hermann, Pentek, & Otto, Design principles for industrie 4.0 scenarios, 2016). One basic principle of this paradigm is that products, machines, systems and business are always connected to create an intelligent network along the entire factory’s value chain. According to this vision, manufacturing resources are being transformed from monolithic entities into distributed components, which are loosely coupled and autonomous but nevertheless provided of the networking and connectivity capabilities enabled by the increasingly widespread Industrial Internet of Things technology. Under these conditions, they become capable of working together in a reliable and predictable manner, collaborating among themselves in a highly efficient way. Such a mechanism of synergistic collaboration is crucial for the correct evolution of any organization ranging from a multi-cellular organism to a complex modern manufacturing system (Moghaddam & Nof, 2017). Specifically of the last scenario, which is the field of our study, collaboration enables involved resources to exchange relevant information about the evolution of their context. These information can be in turn elaborated to make some decisions, and trigger some actions. In this way connected resources can modify their structure and configuration in response to specific business or operational variations (Alexopoulos, Makris, Xanthakis, Sipsas, & Chryssolouris, 2016). Such a model of “social” and context-aware resources can contribute to the realization of a highly flexible, robust and responsive manufacturing system, which is an objective particularly relevant in the modern factories, as its inclusion in the scope of the priority research lines for the H2020 three-year period 2018-2020 can demonstrate (EFFRA, 2016). Interesting examples of these resources are self-organized logistics which can react to unexpected changes occurred in production or machines capable to predict failures on the basis of the contextual information and then trigger adjustments processes autonomously. This vision of collaborative and cooperative resources can be realized with the support of several studies in various fields ranging from information and communication technologies to artificial intelligence. An update state of the art highlights significant recent achievements that have been making these resources more intelligent and closer to the user needs. However, we are still far from an overall implementation of the vision, which is hindered by three major issues. The first one is the limited capability of a large part of the resources distributed within the shop floor to automatically interpret the exchanged information in a meaningful manner (semantic interoperability) (Atzori, Iera, & Morabito, 2010). This issue is mainly due to the high heterogeneity of data model formats adopted by the different resources used within the shop floor (Modoni, Doukas, Terkaj, Sacco, & Mourtzis, 2016). Another open issue is the lack of efficient methods to fully virtualize the physical resources (Rosen, von Wichert, Lo, & Bettenhausen, 2015), since only pairing physical resource with its digital counterpart that abstracts the complexity of the real world, it is possible to augment communication and collaboration capabilities of the physical component. The third issue is a side effect of the ongoing technological ICT evolutions affecting all the manufacturing companies and consists in the continuous growth of the number of threats and vulnerabilities, which can both jeopardize the cybersecurity of the overall manufacturing system (Wells, Camelio, Williams, & White, 2014). For this reason, aspects related with cyber-security should be considered at the early stage of the design of any ICT solution, in order to prevent potential threats and vulnerabilities. All three of the above mentioned open issues have been addressed in this research work with the aim to explore and identify a precise, secure and efficient model of collaboration among the production resources distributed within the shop floor. This document illustrates main outcomes of the research, focusing mainly on the Virtual Integrative Manufacturing Framework for resources Interaction (VICKI), a potential reference architecture for a middleware application enabling semantic-based cooperation among manufacturing resources. Specifically, this framework provides a technological and service-oriented infrastructure offering an event-driven mechanism that dynamically propagates the changing factors to the interested devices. The proposed system supports the coexistence and combination of physical components and their virtual counterparts in a network of interacting collaborative elements in constant connection, thus allowing to bring back the manufacturing system to a cooperative Cyber-physical Production System (CPPS) (Monostori, 2014). Within this network, the information coming from the productive chain can be promptly and seamlessly shared, distributed and understood by any actor operating in such a context. In order to overcome the problem of the limited interoperability among the connected resources, the framework leverages a common data model based on the Semantic Web technologies (SWT) (Berners-Lee, Hendler, & Lassila, 2001). The model provides a shared understanding on the vocabulary adopted by the distributed resources during their knowledge exchange. In this way, this model allows to integrate heterogeneous data streams into a coherent semantically enriched scheme that represents the evolution of the factory objects, their context and their smart reactions to all kind of situations. The semantic model is also machine-interpretable and re-usable. In addition to modeling, the virtualization of the overall manufacturing system is empowered by the adoption of an agent-based modeling, which contributes to hide and abstract the control functions complexity of the cooperating entities, thus providing the foundations to achieve a flexible and reconfigurable system. Finally, in order to mitigate the risk of internal and external attacks against the proposed infrastructure, it is explored the potential of a strategy based on the analysis and assessment of the manufacturing systems cyber-security aspects integrated into the context of the organization’s business model. To test and validate the proposed framework, a demonstration scenarios has been identified, which are thought to represent different significant case studies of the factory’s life cycle. To prove the correctness of the approach, the validation of an instance of the framework is carried out within a real case study. Moreover, as for data intensive systems such as the manufacturing system, the quality of service (QoS) requirements in terms of latency, efficiency, and scalability are stringent, an evaluation of these requirements is needed in a real case study by means of a defined benchmark, thus showing the impact of the data storage, of the connected resources and of their requests

A Systematic Review of Data Quality in CPS and IoT for Industry 4.0

The Internet of Things (IoT) and Cyber-Physical Systems (CPS) are the backbones of Industry 4.0, where data quality is crucial for decision support. Data quality in these systems can deteriorate due to sensor failures or uncertain operating environments. Our objective is to summarize and assess the research efforts that address data quality in data-centric CPS/IoT industrial applications. We systematically review the state-of-the-art data quality techniques for CPS and IoT in Industry 4.0 through a systematic literature review (SLR) study. We pose three research questions, define selection and exclusion criteria for primary studies, and extract and synthesize data from these studies to answer our research questions. Our most significant results are (i) the list of data quality issues, their sources, and application domains, (ii) the best practices and metrics for managing data quality, (iii) the software engineering solutions employed to manage data quality, and (iv) the state of the data quality techniques (data repair, cleaning, and monitoring) in the application domains. The results of our SLR can help researchers obtain an overview of existing data quality issues, techniques, metrics, and best practices. We suggest research directions that require attention from the research community for follow-up work.acceptedVersio

Cyber-Physical Threat Intelligence for Critical Infrastructures Security

Modern critical infrastructures can be considered as large scale Cyber Physical Systems (CPS). Therefore, when designing, implementing, and operating systems for Critical Infrastructure Protection (CIP), the boundaries between physical security and cybersecurity are blurred. Emerging systems for Critical Infrastructures Security and Protection must therefore consider integrated approaches that emphasize the interplay between cybersecurity and physical security techniques. Hence, there is a need for a new type of integrated security intelligence i.e., Cyber-Physical Threat Intelligence (CPTI). This book presents novel solutions for integrated Cyber-Physical Threat Intelligence for infrastructures in various sectors, such as Industrial Sites and Plants, Air Transport, Gas, Healthcare, and Finance. The solutions rely on novel methods and technologies, such as integrated modelling for cyber-physical systems, novel reliance indicators, and data driven approaches including BigData analytics and Artificial Intelligence (AI). Some of the presented approaches are sector agnostic i.e., applicable to different sectors with a fair customization effort. Nevertheless, the book presents also peculiar challenges of specific sectors and how they can be addressed. The presented solutions consider the European policy context for Security, Cyber security, and Critical Infrastructure protection, as laid out by the European Commission (EC) to support its Member States to protect and ensure the resilience of their critical infrastructures. Most of the co-authors and contributors are from European Research and Technology Organizations, as well as from European Critical Infrastructure Operators. Hence, the presented solutions respect the European approach to CIP, as reflected in the pillars of the European policy framework. The latter includes for example the Directive on security of network and information systems (NIS Directive), the Directive on protecting European Critical Infrastructures, the General Data Protection Regulation (GDPR), and the Cybersecurity Act Regulation. The sector specific solutions that are described in the book have been developed and validated in the scope of several European Commission (EC) co-funded projects on Critical Infrastructure Protection (CIP), which focus on the listed sectors. Overall, the book illustrates a rich set of systems, technologies, and applications that critical infrastructure operators could consult to shape their future strategies. It also provides a catalogue of CPTI case studies in different sectors, which could be useful for security consultants and practitioners as well