Towards a Cyber-Physical Manufacturing Cloud through Operable Digital Twins and Virtual Production Lines

In last decade, the paradigm of Cyber-Physical Systems (CPS) has integrated industrial manufacturing systems with Cloud Computing technologies for Cloud Manufacturing. Up to 2015, there were many CPS-based manufacturing systems that collected real-time machining data to perform remote monitoring, prognostics and health management, and predictive maintenance. However, these CPS-integrated and network ready machines were not directly connected to the elements of Cloud Manufacturing and required human-in-the-loop. Addressing this gap, we introduced a new paradigm of Cyber-Physical Manufacturing Cloud (CPMC) that bridges a gap between physical machines and virtual space in 2017. CPMC virtualizes machine tools in cloud through web services for direct monitoring and operations through Internet. Fundamentally, CPMC differs with contemporary modern manufacturing paradigms. For instance, CPMC virtualizes machining tools in cloud using remote services and establish direct Internet-based communication, which is overlooked in existing Cloud Manufacturing systems. Another contemporary, namely cyber-physical production systems enable networked access to machining tools. Nevertheless, CPMC virtualizes manufacturing resources in cloud and monitor and operate them over the Internet. This dissertation defines the fundamental concepts of CPMC and expands its horizon in different aspects of cloud-based virtual manufacturing such as Digital Twins and Virtual Production Lines. Digital Twin (DT) is another evolving concept since 2002 that creates as-is replicas of machining tools in cyber space. Up to 2018, many researchers proposed state-of-the-art DTs, which only focused on monitoring production lifecycle management through simulations and data driven analytics. But they overlooked executing manufacturing processes through DTs from virtual space. This dissertation identifies that DTs can be made more productive if they engage directly in direct execution of manufacturing operations besides monitoring. Towards this novel approach, this dissertation proposes a new operable DT model of CPMC that inherits the features of direct monitoring and operations from cloud. This research envisages and opens the door for future manufacturing systems where resources are developed as cloud-based DTs for remote and distributed manufacturing. Proposed concepts and visions of DTs have spawned the following fundamental researches. This dissertation proposes a novel concept of DT based Virtual Production Lines (VPL) in CPMC in 2019. It presents a design of a service-oriented architecture of DTs that virtualizes physical manufacturing resources in CPMC. Proposed DT architecture offers a more compact and integral service-oriented virtual representations of manufacturing resources. To re-configure a VPL, one requirement is to establish DT-to-DT collaborations in manufacturing clouds, which replicates to concurrent resource-to-resource collaborations in shop floors. Satisfying the above requirements, this research designs a novel framework to easily re-configure, monitor and operate VPLs using DTs of CPMC. CPMC publishes individual web services for machining tools, which is a traditional approach in the domain of service computing. But this approach overcrowds service registry databases. This dissertation introduces a novel fundamental service publication and discovery approach in 2020, OpenDT, which publishes DTs with collections of services. Experimental results show easier discovery and remote access of DTs while re-configuring VPLs. Proposed researches in this dissertation have received numerous citations both from industry and academia, clearly proving impacts of research contributions

Digital-Twins towards Cyber-Physical Systems: A Brief Survey

Cyber-Physical Systems (CPS) are integrations of computation and physical processes. Physical processes are monitored and controlled by embedded computers and networks, which frequently have feedback loops where physical processes affect computations and vice versa. To ease the analysis of a system, the costly physical plants can be replaced by the high-fidelity virtual models that provide a framework for Digital-Twins (DT). This paper aims to briefly review the state-of-the-art and recent developments in DT and CPS. Three main components in CPS, including communication, control, and computation, are reviewed. Besides, the main tools and methodologies required for implementing practical DT are discussed by following the main applications of DT in the fourth industrial revolution through aspects of smart manufacturing, sixth wireless generation (6G), health, production, energy, and so on. Finally, the main limitations and ideas for future remarks are talked about followed by a short guideline for real-world application of DT towards CPS

Smart manufacturing: role of Internet of Things in process optimization

This research is primarily focused on process optimization in manufacturing field in business-to-business context. The study is an effort to point out the issues manufacturers face at their shop floor and it provides solutions for dealing with those issues. During the last decade the Internet of Things (IoT) has gained a lot of attention from both academia and practitioners. IoT emphasizes on the importance of physical objects transferring information by using both software and the Internet. Based on the global trends, nowadays, there is a clear requirement for companies to focus on how they can implement IoT in order to facilitate their businesses and create new business and market opportunities. IoT is able to connect various things and objects around us which are able to interact with each other. In other words, IoT technologies not only connect a particular industrial system or supply chain, but also connects stakeholders and end-customers. The goal of the thesis is to discuss IoT technologies and elaborate on how they are implemented in manufacturing processes. One empirical case study on IoT applications in shop floors and production lines carried out. Two cases were selected based on being a pioneer in implementing IoT technologies into manufacturing and highly optimized production at targeted factories. The cases represent next generation of smart factories which IoT technologies and in particular RFID solutions play an important role. A qualitative document analysis was conducted. The topic of this research is relatively new and therefore majority of references used for this paper are from 2014 onwards. Data were collected from public, non-confidential information sources including press releases, newspapers, articles and journals. The research approach was primarily descriptive with the focus on differences between previous production optimization technologies and IoT applications in use today. The results of thesis demonstrates that IoT technologies bring transparency, traceability, adaptability, scalability and flexibility to the system. Therefore, the adoption of IoT has quite a few potential benefits, including improvement in cost and risk reduction, operational processes and value creation. This research also shows that using IoT technologies for their benefits is not an easy task for enterprises. Companies face many challenges on the way including layout changes in the factory’s shop floor, changes in the design of the products, security concerns and consumer privacy. Moreover, since the IoT is a recent development, different aspects of the IoT such as economical, managerial and industrial aspects need to be studied. And this makes companies hesitant to make decisions regarding the adoption of IoT

Sistemas de informação na indústria 4.0 : mecanismos de apoio à transferência de dados para conhecimento em ambientes Lean

The paradigm that presently emerges in the organizational context, known as Industry 4.0 (I4.0) or Fourth Industrial Revolution, promises to bring principles of connectivity and flexibility to the companies that embrace it. Industry 4.0 enhances the efficiency in adapting in real time to the customers’ requirements, through the establishment of an intelligent shop floor capable of answering in a flexible and customized way to market changes. However, during the last three decades, it is known that the adoption of the Lean philosophy was absorbed by the industrial environment, with results that proved to be exuberant, considering the simplicity of the tools. In this way, the I4.0 implementation must be prepared to preserve the existing manufacturing systems, proceeding, whenever possible, to upgrade them on a Lean excellence basis. It is said that information systems will be decisive in the foundation of the I4.0 paradigm. Of these, MES systems, with greater connection to the shop floor, will tend to be aligned with existing practices, contributing, through their connectivity, to the introduction of knowledge management practices and data visualization mechanisms. In the specification and architecture phase of these systems, understanding the processes will be crucial. Thus, their documentation is an organizational pillar, with BPMN and UML being able to guide it. However, and in addition to its usefulness in the processes’ mapping, BPMN is also likely to be applied in capturing tacit knowledge, which can be a foundation for the constitution of knowledge repositories, impacting organizational excellence. It is in this context that the present work is implanted, aiming at the creation of guidelines and mechanisms that facilitate the implementation of I4.0 strategies in Lean industrial environments. The adopted methodology first went through an exhaustive literature review, in order to find possible bilateral effects between I4.0 technologies and lean tools. Then, the development of some applications aligned with the I4.0 paradigm, as a technological engine, and the Lean philosophy, as a tool for eliminating waste and / or creating value, was contemplated. From the various development experiences in an industrial context and considering the evidence reported in the literature, this study proposes a Lean 4.0 framework oriented to the shop floor.O paradigma que atualmente emerge no contexto organizacional, conhecido como Indústria 4.0 (I4.0) ou Quarta Revolução Industrial, promete trazer princípios de conectividade e flexibilidade às empresas que a adotam. A Indústria 4.0 potencia a eficácia no ajuste em tempo real aos requisitos dos clientes, através da constituição de um chão de fábrica inteligente e capaz de responder de forma flexível e customizada às mudanças do mercado. Contudo, durante as últimas três décadas, sabe-se que a adoção da filosofia Lean foi absorvida pelo meio industrial, com resultados que se demonstraram exuberantes, tendo em conta a simplicidade das ferramentas. Deste modo, a implementação I4.0 deve ser feita no sentido da preservação dos sistemas de manufatura já existentes, procedendo, desde que possível, ao seu upgrade numa base de excelência Lean. Conta-se que os sistemas de informação serão decisivos na fundação do paradigma I4.0. Destes, os sistemas MES, com maior conexão ao chão de fábrica, tenderão a ser alinhados com as práticas já existentes, contribuindo, através da sua conectividade, para a introdução de práticas de gestão do conhecimento e mecanismos de visualização de dados. Na fase de especificação e arquitetura destes sistemas, o entendimento dos processos será crucial. Assim, a documentação dos mesmos é um pilar organizacional, estando o BPMN e a UML capazes de a orientar. Porém, e a somar à sua utilidade na ilustração de processos, o BPMN está igualmente passível de ser aplicado na captação de conhecimento tácito, o que por si pode ser uma base para a constituição de repositórios de conhecimento, contribuindo para a excelência organizacional. É neste contexto que o presente trabalho se insere, tendo como objetivo a criação de linhas orientadoras e mecanismos que facilitem a implementação de estratégias I4.0 em ambientes industriais Lean. A metodologia adotada passou, primeiramente, por uma exaustiva revisão da literatura, por forma a encontrar possíveis efeitos bilaterais entre tecnologias I4.0 e ferramentas lean. De seguida, contemplou-se o desenvolvimento de alguns aplicativos alinhados ao paradigma I4.0, enquanto motor tecnológico, e à filosofia Lean, enquanto ferramenta de eliminação de desperdícios e/ou criação de valor. Das diversas experiências de desenvolvimento em contexto industrial e considerando as evidências reportadas na literatura o presente estudo propõe uma framework Lean 4.0 orientado ao chão de fábrica.Mestrado em Engenharia e Gestão Industria

A Complex Event Processing System for Monitoring of Manufacturing Systems

Future manufacturing systems will require to process large amounts of complex data due to a rising demand on visibility and vertical integration of factory floor devices with higher level systems. Systems contained in higher layers of the business model are rapidly moving towards a Service Oriented Architecture, inducing a tendency to push Web Technologies down to the factory floor level. Evidence of this trend is the addition of Web Services at the device level with Device Profile for Web Services and the transition of OPC based on COM/DCOM communication to OPC-UA based on Web Services. DPWS and OPC-UA are becoming nowadays the preferred options to provide on a device level, service-oriented solutions capable to extend with an Event Driven Architecture into manufacturing systems. This thesis provides an implementation of a factory shop floor monitor based on Complex Event Processing for event-driven manufacturing processes. Factory shop monitors are particularly used to inform the workshop personnel via alarms, notifications and, visual aids about the performance and status of a manufacturing process. This work abstracts the informative value of the event-cloud surrounding the factory shop floor by processing its content against rules and formulas to convert it to valuable pieces of information that can be exposed to business monitors and dashboards. As a result, a system with a generic framework for integrating heterogeneous sources was reached, transforming simple data into alarms and complex events containing a specific context within the manufacturing process

PLATFORM-DRIVEN CROWDSOURCED MANUFACTURING FOR MANUFACTURING AS A SERVICE

Platform-driven crowdsourced manufacturing is an emerging manufacturing paradigm to instantiate the adoption of the open business model in the context of achieving Manufacturing-as-a-Service (MaaS). It has attracted attention from both industries and academia as a powerful way of searching for manufacturing solutions extensively in a smart manufacturing era. In this regard, this work examines the origination and evolution of the open business model and highlights the trends towards platform-driven crowdsourced manufacturing as a solution for MaaS. Platform-driven crowdsourced manufacturing has a full function of value capturing, creation, and delivery approach, which is fulfilled by the cooperation among manufacturers, open innovators, and platforms. The platform-driven crowdsourced manufacturing workflow is proposed to organize these three decision agents by specifying the domains and interactions, following a functional, behavioral, and structural mapping model. A MaaS reference model is proposed to outline the critical functions and inter-relationships. A series of quantitative, qualitative, and computational solutions are developed for fulfilling the outlined functions. The case studies demonstrate the proposed methodologies and can pace the way towards a service-oriented product fulfillment process. This dissertation initially proposes a manufacturing theory and decision models by integrating manufacturer crowds through a cyber platform. This dissertation reveals the elementary conceptual framework based on stakeholder analysis, including dichotomy analysis of industrial applicability, decision agent identification, workflow, and holistic framework of platform-driven crowdsourced manufacturing. Three stakeholders require three essential service fields, and their cooperation requires an information service system as a kernel. These essential functions include contracting evaluation services for open innovators, manufacturers' task execution services, and platforms' management services. This research tackles these research challenges to provide a technology implementation roadmap and transition guidebook for industries towards crowdsourcing.Ph.D

Landscape of logistics and the time present

Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Architecture, 2011.Cataloged from PDF version of thesis.Includes bibliographical references (p. 152-155).Upon arrival in Memphis by air, a sign welcomes passengers to "Memphis - America's Distribution Center", a reflection of one's place in the city, and the country. Rather than a romantic reflection of the cultural heritage of the city with Elvis Presley and B.B. King, the statement places passengers not at the destination of their travels, vis a vis a "welcome to", but en route somewhere else. Memphis International Airport, identified via its aviation code "MEM", is not a place of arrival-a terminal, from "terminus", the end-but a location to be passed through-a state of being in transit or colloquially "passing through". Few passengers and goods conclude their travel here; MEM's raison d'etre is as a layover, as travelers are being distributed elsewhere as a result of the efficiency of the hub-and-spoke model of aviation. As a result, MEM is the world's busiest cargo airport. At its peak, an upwards of six flights arriving a minute carrying Apple computers, Mickey Mouse plush toys, cooking items from William-Sonoma, and the variety of other goods to and from all corners of the world destined for FedEx's so-called SuperHub. Because of the presence of such a facility, MEM has arisen as an economic capital in an improbably location within the interior of the United States replete with its own sprawling developments. MEM, as an airport city, challenges the social and cultural norms of what one considers a traditional city, as its reasons for being is the economy of moving goods and founded on the way we do business and not the way we live. This thesis proposes an urban form for MEM's surrounding city that serves as a means of regeneration of the surrounding, decaying area as well as accepts the condition of being in transit for goods and people as a primary condition of existence. In Brophy's character's words, it is an urbanism that "[perpetually remains] in the present moment, in at least semi-sempiternal transit between departure from the past and arrival in the future" and is more appropriate than the status quo within the context of MEM with regard to the transitory nature of goods, passengers and employees. The urban logic is thus a metaphor of FedEx in the transposition of technological logics, such as the flow of bodies and the interface of machine, the parcel, and the human occupant.by Anthony P. Vanky.S.M

Fractal architecture for 'leagile' networked enterprises.

The manufacturing environment and markets in recent times are becoming increasingly dynamic, diverse and unpredictable, due mainly to fast evolution of products and technology, erratic customer behaviour and high consumerism and an increasingly shorter lead-time. The burden of the impact falls on organisational structures built on centralized, rigid manufacturing architecture, because they cannot cope or adapt to the highly uncertain or unpredictable nature of the market. Enterprises who wish to survive these challenges need to rethink their business and manufacturing models, and most importantly reinvent their tactical, operational and organizational formulas to leverage their strategic long term visions.Newer manufacturing systems to curb the effects of this upheaval have to promote an entirely decentralised, flexible, distributed, configurable and adaptable architecture to ameliorate this condition. Many philosophies are proposed and studied towards planning, monitoring, and controlling the 21st century manufacturing system. These include - Bionic manufacturing system (BMS), Holonic manufacturing system (HMS), Fractal manufacturing system (FrMS), Responsive manufacturing etc.This research program focuses on the FrMS, which has vast conceptual advantageous features among these new philosophies, but its implementation has proved very difficult. FrMS is based on autonomous, cooperating, self-similar agent called fractal that has the capability of perceiving, adapting and evolving with respect to its partners and environment. The fractal manufacturing configuration uses self regulating, organisational work groups, each with identical goals and within its own area of competence to build up an integrated, holistic network system of companies. This network yields constant improvement as well as continuous checks and balances through self-organising control loops. The study investigates and identifies the nature, characteristic features and feasibility of this system in comparison to traditional approaches with a detailed view to maximising the logistical attribute of lean manufacturing system and building a framework for 'leagile' (an integration of lean and agile solutions) networked capabilities. It explores and establishes the structural characteristic potentials of Fractal Manufacturing Partnership (FMP), a hands-on collaboration between enterprises and their key suppliers, where the latter become assemblers of their components while co-owning the enterprise's facility, to create and achieve high level of responsiveness. It is hoped that this architecture will drive and harness the evolution from a vertically integrated company, to a network of integrated, leaner core competencies needed to tackle and weather the storm of the 21st century manufacturing system

Smart Manufacturing

This book is a collection of 11 articles that are published in the corresponding Machines Special Issue “Smart Manufacturing”. It represents the quality, breadth and depth of the most updated study in smart manufacturing (SM); in particular, digital technologies are deployed to enhance system smartness by (1) empowering physical resources in production, (2) utilizing virtual and dynamic assets over the Internet to expand system capabilities, (3) supporting data-driven decision-making activities at various domains and levels of businesses, or (4) reconfiguring systems to adapt to changes and uncertainties. System smartness can be evaluated by one or a combination of performance metrics such as degree of automation, cost-effectiveness, leanness, robustness, flexibility, adaptability, sustainability, and resilience. This book features, firstly, the concepts digital triad (DT-II) and Internet of digital triad things (IoDTT), proposed to deal with the complexity, dynamics, and scalability of complex systems simultaneously. This book also features a comprehensive survey of the applications of digital technologies in space instruments; a systematic literature search method is used to investigate the impact of product design and innovation on the development of space instruments. In addition, the survey provides important information and critical considerations for using cutting edge digital technologies in designing and manufacturing space instruments