Energy-efficient through-life smart design, manufacturing and operation of ships in an industry 4.0 environment

Energy efficiency is an important factor in the marine industry to help reduce manufacturing and operational costs as well as the impact on the environment. In the face of global competition and cost-effectiveness, ship builders and operators today require a major overhaul in the entire ship design, manufacturing and operation process to achieve these goals. This paper highlights smart design, manufacturing and operation as the way forward in an industry 4.0 (i4) era from designing for better energy efficiency to more intelligent ships and smart operation through-life. The paper (i) draws parallels between ship design, manufacturing and operation processes, (ii) identifies key challenges facing such a temporal (lifecycle) as opposed to spatial (mass) products, (iii) proposes a closed-loop ship lifecycle framework and (iv) outlines potential future directions in smart design, manufacturing and operation of ships in an industry 4.0 value chain so as to achieve more energy-efficient vessels. Through computational intelligence and cyber-physical integration, we envision that industry 4.0 can revolutionise ship design, manufacturing and operations in a smart product through-life process in the near future

Design, modelling, simulation and integration of cyber physical systems: Methods and applications

The main drivers for the development and evolution of Cyber Physical Systems (CPS) are the reduction of development costs and time along with the enhancement of the designed products. The aim of this survey paper is to provide an overview of different types of system and the associated transition process from mechatronics to CPS and cloud-based (IoT) systems. It will further consider the requirement that methodologies for CPS-design should be part of a multi-disciplinary development process within which designers should focus not only on the separate physical and computational components, but also on their integration and interaction. Challenges related to CPS-design are therefore considered in the paper from the perspectives of the physical processes, computation and integration respectively. Illustrative case studies are selected from different system levels starting with the description of the overlaying concept of Cyber Physical Production Systems (CPPSs). The analysis and evaluation of the specific properties of a sub-system using a condition monitoring system, important for the maintenance purposes, is then given for a wind turbine

Food industry digitalization: from challenges and trends to opportunities and solutions

Over the last years, manufacturing companies have to face several challenges, mainly related to the volatility of the demand and to the continuously changing requirements, both from the customers and suppliers. In the meantime, new technological roadmaps and suggested interventions in manufacturing systems have been implemented. These solutions aim to exploit the high innovation and economic potential resulting from the continuing impact of rapidly advancing information and communication technology (ICT) in industry. This paper explores these topics focusing on the food sector. Indeed, companies belonging to this industry are facing global challenges, which can be met with the support of the information technologies (IT). The overall goal of this study is to help food companies toward digitalization, with a particular focus on the design and manufacturing processes. From the methodological point of view, Case Study has been used as research method. Furthermore, a questionnaire characterized by the different elements of the Manufacturing Value Modelling Methodology (MVMM) has been developed and used to gather information from companies. A framework for the digitalization process in the food industry has been developed basing on the results of a preliminary literature review and of different focus groups. On completion of the aforementioned framework, a list of enabling technologies has been discussed. These represent the technological solutions for the specific food issues highlighted by the framework. Finally, a case study has been accomplished in order to test and validate the contents\u2019 framework

Food industry digitalization: from challenges and trends to opportunities and solutions

Over the last years, manufacturing companies have to face several challenges, mainly related to the volatility of the demand and to the continuously changing requirements, both from the customers and suppliers. In the meantime, new technological roadmaps and suggested interventions in manufacturing systems have been implemented. These solutions aim to exploit the high innovation and economic potential resulting from the continuing impact of rapidly advancing information and communication technology (ICT) in industry. This paper explores these topics focusing on the food sector. Indeed, companies belonging to this industry are facing global challenges, which can be met with the support of the information technologies (IT). The overall goal of this study is to help food companies toward digitalization, with a particular focus on the design and manufacturing processes. From the methodological point of view, Case Study has been used as research method. Furthermore, a questionnaire characterized by the different elements of the Manufacturing Value Modelling Methodology (MVMM) has been developed and used to gather information from companies. A framework for the digitalization process in the food industry has been developed basing on the results of a preliminary literature review and of different focus groups. On completion of the aforementioned framework, a list of enabling technologies has been discussed. These represent the technological solutions for the specific food issues highlighted by the framework. Finally, a case study has been accomplished in order to test and validate the contents' framework. (C) 2018, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved

Quality by Design Procedure for Continuous Pharmaceutical Manufacturing: An Integrated Flowsheet Model Approach

Pharmaceutical manufacturing is crucial to global healthcare and requires a higher, more consistent level of quality than any other industry. Yet, the traditional pharmaceutical batch manufacturing has remained largely unchanged in the last fifty years due to high R&D costs, shorter patent durations, and regulatory uncertainty. This has led regulatory bodies to promote modernization of manufacturing process to continuous pharmaceutical manufacturing (CPM) by introducing new methodologies including quality by design, design space, and process analytical technology (PAT). This represents a shift away from the traditional pharmaceutical manufacturing way of thinking towards a risk based approach that promotes increased product and process knowledge through a data-rich environment. While both literature and regulatory bodies acknowledge the need for modernization, manufacturers have been slow to modernize due to uncertainty and lack of confidence in the applications of these methodologies. This paper aims to describe the current applications of QbD principles in literature and the current regulatory environment to identify gaps in literature through leveraging regulatory guidelines and CPM literature. To aid in closing the gap between QbD theory and QbD application, a QbD algorithm for CPM using an integrated flowsheet models is also developed and analyzed. This will help to increase manufacturing confidence in CPM by providing answers to questions about the CPM business case, applications of QbD tools, process validation and sensitivity, and process and equipment characteristics. An integrated flowsheet model will aid in the decision-making process and process optimization, breaking away from ex silico methods extensively covered in literature

Articulation of Quality By Design Elements for Product Development and its Unique Applications

Quality by Design (QbD) is a methodical approach to pharmaceutical product development that begins with predefined objectives and emphasizes product and process comprehension and process control based on sound science and quality risk management. Pharmaceutical development should lead to the design a quality product and its manufacturing process to meet the QTPP and CQA parameters. To arrive at the robust product development QbD articulation is important which is missing in most of the reviews. This review articulates the QbD elements in the product development. QbD process stars with identification of QTPP and source CQA from QTPP. CMAs and CPPs are derived with risk assessment from the product ingredients and process. Their impact on the CQAs can be studies with DoE tools. The information and knowledge gained from pharmaceutical development studies and manufacturing experience provide scientific understanding to support the design space and control strategy. Product process follows life cycle management approach with continuous improvement. PAT tools are utilized for the online monitoring of the processes. This review paper is dedicated to provide QbD element articulation in product development and its unique applications in the various areas of the product development such as Biotechnology, Nanotechnology products, Nasal products, Inhalation, Injectable products, Targeted drug delivery, complex Solid oral, Transdermal and topical products, Bioavailability and dissolution enhancement, Analytical processes and API manufacturing etc. Current trends in the technical application of the PAT tools are discussed. Keywords: Quality by Design (QbD), Quality Target Product Profile (QTPP), Critical Quality Attributes (CQA) and Design of Experiment (DoE): Product development application of Qb

Toward the Development of a Maturity Model for Digitalization within the Manufacturing Industry’s Supply Chain

The aim of this paper is the scientific development of a maturity model concerning the digital transformation of companies within the manufacturing industry’s supply chain. The rather “broad” and dispersed “mega-trend” of digitalization is expected to play an increasingly important role for companies as well as for the (digital) supply chain of the future. Such a model comprises the objective of addressing fundamental components, complementary innovations and relevant terminologies, like smart products, Cyber-Physical Systems (CPS) and Big Data Analytics. Scientific rigor is achieved through conducting grounded theory research and in-depth interviews as methods of data collection and evaluation. Furthermore, relevant aspects concerning the development and construction of maturity models are discussed, before a suitable and scientifically elaborated maturity model concerning digitalization emerges from the course of investigation and its value for economic practice as well as for the scientific community is specified

Quality management in the industry 4.0 era

In the current competitive scenario, manufacturing companies are facing various challenges related to an increasing level of variability. This variability means different sets of dimensions such as demand, volume, process, technology, quality, customer behavior and supplier attitude, and transform the industrial systems engineering domain. A new paradigm tries to solve these challenges and solutions such as "the fourth industrial revolution" or "Industry 4.0" refers to new production patterns, including new technologies, productive factors and labor organizations, which are completely changing the production processes and developing high-efficiency production systems that make it possible to minimize production costs and improve production and product quality. Manufacturing companies need to achieve a substantial improvement in performance by manufacturing high-quality products and creating highly flexible systems that make it possible to maintain their efficiency even when demand varies dramatically. Tools for the management and optimization of quality are vitally important. In this way the adoption of highly flexible cyber physical production units permits the implementation of production processes capable of guaranteeing high-quality standards in the finished product, even in the case of small production lots. Industry 4.0 provides promising opportunities for quality management therefore, the purpose of this paper is to focus on the quality management and industry 4.0 concepts and analyze the current state of literature trying to understand the implications and opportunities for quality management in the industry 4.0 era

Challenges of digital twin in high value manufacturing

Digital Twin (DT) is a dynamic digital representation of a real-world asset, process or system. Industry 4.0 has recognised DT as the game changer for manufacturing industries in their digital transformation journey. DT will play a significant role in improving consistency, seamless process development and the possibility of reuse in subsequent stages across the complete lifecycle of the product. As the concept of DT is novel, there are several challenges that exist related to its phase of development and implementation, especially in high value manufacturing sector. The paper presents a thematic analysis of current academic literature and industrial knowledge. Based on this, eleven key challenges of DT were identified and further discussed. This work is intended to provide an understanding of the current state of knowledge around DT and formulate the future research directions