A framework for manufacturing system reconfiguration and optimisation utilising digital twins and modular artificial intelligence

Digital twins and artificial intelligence have shown promise for improving the robustness, responsiveness, and productivity of industrial systems. However, traditional digital twin approaches are often only employed to augment single, static systems to optimise a particular process. This article presents a paradigm for combining digital twins and modular artificial intelligence algorithms to dynamically reconfigure manufacturing systems, including the layout, process parameters, and operation times of numerous assets to allow system decision-making in response to changing customer or market needs. A knowledge graph has been used as the enabler for this system-level decision-making. A simulation environment has been constructed to replicate the manufacturing process, with the example here of an industrial robotic manufacturing cell. The simulation environment is connected to a data pipeline and an application programming interface to assist the integration of multiple artificial intelligence methods. These methods are used to improve system decision-making and optimise the configuration of a manufacturing system to maximise user-selectable key performance indicators. In contrast to previous research, this framework incorporates artificial intelligence for decision-making and production line optimisation to provide a framework that can be used for a wide variety of manufacturing applications. The framework has been applied and validated in a real use case, with the automatic reconfiguration resulting in a process time improvement of approximately 10%

A maturity model for the autonomy of manufacturing systems

Modern manufacturing has to cope with dynamic and changing circumstances. Market fluctuations, the effects caused by unpredictable material shortages, highly variable product demand, and worker availability all require system robustness, flexibility, and resilience. To adapt to these new requirements, manufacturers should consider investigating, investing in, and implementing system autonomy. Autonomy is being adopted in multiple industrial contexts, but divergences arise when formalizing the concept of autonomous systems. To develop an implementation of autonomous manufacturing systems, it is essential to specify what autonomy means, how autonomous manufacturing systems are different from other autonomous systems, and how autonomous manufacturing systems are identified and achieved through the main features and enabling technologies. With a comprehensive literature review, this paper provides a definition of autonomy in the manufacturing context, infers the features of autonomy from different engineering domains, and presents a five-level model of autonomy — associated with maturity levels for the features — to ensure the complete identification and evaluation of autonomous manufacturing systems. The paper also presents the evaluation of a real autonomous system that serves as a use-case and a validation of the model

Industrial transformation and assembly technology: context and research trends

The fourth industrial revolution is based on a few technological advancements that promise an industrial transformation based on achieving sharing and circular economies. Selecting and applying these advancements correctly, i.e., following relevant value drivers, is a key to the success of manufacturing firms. This results in an increasing body of knowledge from academy and practitioners in the domain of the adoption of digital technology in industry. Given the breadth of the topic, the literature deals with both a vast amount of promising technologies and related existing and prospect industrial application. This work focuses on the contributions in the production sub-domain of assembly systems and technology. In detail, relevant high-impact scientific and engineering works have been identified and analyzed with the purpose of highlighting the innovation patterns in term of the prominent technological advancement (push) and related application (pull). The results of the present study show that the most relevant areas of research are: (1) the Industrial Internet of Things, (2) Augmented and Virtual Reality as assistance to the assembly and applied to the training of operators, and (3) the horizontal and vertical system integration through Digital Twins (DT) and Cyber Physical Systems (CPS). The prominent value drivers are the improvement of resources and processes as well as asset utilization and labor. Moreover, this work represents a first step towards a unitary framework to synchronize different research efforts in the domain of assembly and support the envisaged green industrial transformation.QC 20221123</p

The Impact of Learning Factories on Teaching Lean Principles in an Assembly Environment

Learning factories are realistic manufacturing environments built for education; many universities have recently introduced learning factories in engineering programs to tackle real industrial problems; however, statistical studies on its effectiveness are still scarce. This paper presents a statistical study on the impact of learning factories on the students’ learning process, when teaching the lean manufacturing concepts in an assembly environment. The analysis is carried out through the Lean Manufacturing Lab at KTH, a learning factory supporting the traditional educational activities. In the lab, the students assemble a product on an assembly line; during three rounds, they identify problems on the line, apply the appropriate lean tools to overcome the problems, and try to achieve a higher productivity. The study is based on the analysis of the times recorded during the sessions of the lab. A questionnaire submitted to the students after the course evaluates the level of knowledge of lean production principles that the students achieved. The results are twofold: the improvement of the assembly times through the implementation of the lean tools and the positive effect of a hands-on experience on the students’ understanding of the lean principles, highlighted by the answers to the questionnaire. The main contributions are that applying the lean tools on an assembly line improves the productivity even with inexperienced operators, implementing a learning factory is effective in enhancing the learning process, and, lastly, that a first-hand experience applying the lean tools in a real assembly environment is an added value to the students’ education.QC 20221123Part of proceedings: ISBN 978-3-031-18325-6</p

Dynamic Mixed Reality Assembly Guidance Using Optical Recognition Methods

Augmented (AR) and Mixed Reality (MR) technologies are enablers of the Industry 4.0 paradigm and are spreading at high speed in production. Main applications include design, training, and assembly guidance. The latter is a pressing concern, because assembly is the process that accounts for the biggest portion of total cost within production. Teaching and guiding operators to assemble with minimal effort and error rates is pivotal. This work presents the development of a comprehensive MR application for guiding novice operators in following simple assembly instructions. The app follows innovative programming logic and component tracking in a dynamic environment, providing an immersive experience that includes different guidance aids. The application was tested by experienced and novice users, data were drawn from the performed experiments, and a questionnaire was submitted to collect the users’ perception. Results indicate that the MR application was easy to follow and even gave confidence to inexperienced subjects. The guidance support was perceived as useful by the users, though at times invasive in the field of view. Further development effort is required to draw from this work a complete and usable architecture for MR application in assembly, but this research forms the basis to achieve better, more consistent instructions for assembly guidance based on component tracking

An experimental study of the impact of virtual reality training on manufacturing operators on industrial robotic tasks

Despite the recent increase in Virtual Reality (VR) technologies employed for training manufacturing operators on industrial robotic tasks, the impact of VR methods compared to traditional ones is still unclear. This paper presents an experimental comparison of the two training approaches, with novice operators performing the same manufacturing tasks with a VR robot and with a real robot. The hardware selected is an ABB IRB 120 industrial robot, a HTC Vive head mounted display to operate it, besides a corresponding VR model developed in Unity. Twenty-four students performed two actions — drawing and “pick and place” -– in tasks with increasing difficulty, with both the VR model and the real robot. Completion time and task pass rate are adopted to estimate the learning efficiency, while a questionnaire evaluates the users’ satisfaction. The results show that students using VR overall need less elapsed time to complete all tasks, and they record a higher pass rate. The questionnaire answers show that 83% of participants find the VR model helpful in familiarizing with the real robot, and 75% are in favor of using the virtual tool for training novice operators. Users also report that moving the real robot is more complex than the virtual one; adjusting the speed is harder and the possibility of causing damage is worrisome, whereas the VR robot feels safer to operate and easier to drive. The majority of students are satisfied with the design of the tasks, and feel content with the experience. The main finding is that learning from a VR model allows to master driving a real robot quickly and easily. VR training is more useful than conventional methods because it reduces the learning time, allows for training without hindering production, lowers the risk perception, and improves safety for operators and industrial equipment.QC 20221116</p

Adopting extended reality? A systematic review of manufacturing training and teaching applications

The training of future experts and operators in manufacturing engineering relies on understanding procedural processes that require applied practice. Yet, current manufacturing education and training overwhelmingly continues to depend on traditional pedagogical methods that segregate theoretical studies and practical training. While educational institutes have generally improved theoretical studies, they often lack facilities and labs to properly reproduce the working environments necessary for practice. Even in industrial settings, it is difficult, if not impossible, to halt the actual production lines to train new operators. Recently, applications with extended reality (XR) technologies, such as virtual, augmented, or mixed reality, reached a mature technology readiness level. With this technological advancement, we can envision a transition to a new teaching paradigm that exploits simulated learning environments. Thus, it becomes possible to bridge the gap between theory and practice for both students and industrial trainees. This article presents a systematic literature review of the main applications of XR technologies in manufacturing education, their goals and technology readiness levels, and a comprehensive overview of the development tools and experimental strategies deployed. This review contributes: (1) a state-of-the-art description of current research in XR education for manufacturing systems, and (2) a comprehensive analysis of the technological platforms, the experimental procedures and the analytical methodologies deployed in the body of literature examined. It serves as a guide for setting up and executing experimental designs for evaluating interventions of XR in manufacturing education and training.QC 20231204</p

A Framework for Manufacturing System Reconfiguration Based on Artificial Intelligence and Digital Twin

The application of digital twins and artificial intelligence to manufacturing has shown potential in improving system resilience, responsiveness, and productivity. Traditional digital twin approaches are generally applied to single, static systems to enhance a specific process. This paper proposes a framework that applies digital twins and artificial intelligence to manufacturing system reconfiguration, i.e., the layout, process parameters, and operation time of multiple assets, to enable system decision making based on varying demands from the customer or market. A digital twin environment has been developed to simulate the manufacturing process with multiple industrial robots performing various tasks. A data pipeline is built in the digital twin with an API (application programming interface) to enable the integration of artificial intelligence. Artificial intelligence methods are used to optimise the digital twin environment and improve system decision-making. Finally, a multi-agent program approach shows the communication and negotiation status between different agents to determine the optimal configuration for a manufacturing system to solve varying problems. Compared with previous research, this framework combines distributed intelligence, artificial intelligence for decision making, and production line optimisation that can be widely applied in modern reactive manufacturing applications.QC 20221123Part of proceedings: ISBN 978-3-031-18325-6</p

Incidence trends of colorectal cancer in the early 2000s in Italy. Figures from the IMPATTO study on colorectal cancer screening

We utilised the IMPATTO study's archives to describe the 2000-2008 colorectal cancer (CRC) incidence rate trends in Italy, once screening programmes based on the faecal immunochemical test were implemented in different areas. Data on CRCs diagnosed in Italy from 2000 to 2008 in subjects aged 40-79 years were collected by 23 cancer registries. Incidence rate trends were evaluated as a whole and by macro-area (North-Centre and South-Islands), presence of a screening programme, sex, ten-year age class, anatomic site, stage at diagnosis, and pattern of diagnosis (screen-detected, non-screen-detected). The annual percent change (APC) of incidence rate trends, with 95% confidence intervals (95%CI), were computed. The study included 46,857 CRCs diagnosed in subjects aged 40-79 years, of which 2,806 were screendetected. The incidence rates in the North-Centre were higher than in the South and on the Islands. During the study period, screening programmes had been implemented only in the North-Centre and had a significant effect on incidence rates, with an initial sharp increase in incidence, followed by a decrease that started in the 3rd-4th years of screening. These incidence rate trends were exclusively due to modifications in the rates of stage I cases. After screening programmes started, incidence increased in all anatomic sites, particularly in the distal colon. The differential figures introduced by the implementation of screening programmes warrant a continuous surveillance of CRC incidence and mortality trends to monitor the impact of screening at a national level

Global attitudes in the management of acute appendicitis during COVID-19 pandemic: ACIE Appy Study

Background: Surgical strategies are being adapted to face the COVID-19 pandemic. Recommendations on the management of acute appendicitis have been based on expert opinion, but very little evidence is available. This study addressed that dearth with a snapshot of worldwide approaches to appendicitis. Methods: The Association of Italian Surgeons in Europe designed an online survey to assess the current attitude of surgeons globally regarding the management of patients with acute appendicitis during the pandemic. Questions were divided into baseline information, hospital organization and screening, personal protective equipment, management and surgical approach, and patient presentation before versus during the pandemic. Results: Of 744 answers, 709 (from 66 countries) were complete and were included in the analysis. Most hospitals were treating both patients with and those without COVID. There was variation in screening indications and modality used, with chest X-ray plus molecular testing (PCR) being the commonest (19\ub78 per cent). Conservative management of complicated and uncomplicated appendicitis was used by 6\ub76 and 2\ub74 per cent respectively before, but 23\ub77 and 5\ub73 per cent, during the pandemic (both P < 0\ub7001). One-third changed their approach from laparoscopic to open surgery owing to the popular (but evidence-lacking) advice from expert groups during the initial phase of the pandemic. No agreement on how to filter surgical smoke plume during laparoscopy was identified. There was an overall reduction in the number of patients admitted with appendicitis and one-third felt that patients who did present had more severe appendicitis than they usually observe. Conclusion: Conservative management of mild appendicitis has been possible during the pandemic. The fact that some surgeons switched to open appendicectomy may reflect the poor guidelines that emanated in the early phase of SARS-CoV-2