Intelligent Manufacturing in the Context of Industry 4.0: A Review

With the developments and applications of the new information technologies, such as cloud computing, Internet of Things, big data, and artificial intelligence, a smart manufacturing era is coming. At the same time, various national manufacturing development strategies have been put forward, such as Industry 4.0 , Industrial Internet , manufacturing based on Cyber-Physical System , and Made in China 2025 . However, one of specific challenges to achieve smart manufacturing with these strategies is how to converge the manufacturing physical world and the virtual world, so as to realize a series of smart operations in the manufacturing process, including smart interconnection, smart interaction, smart control and management, etc. In this context, as a basic unit of manufacturing, shop-floor is required to reach the interaction and convergence between physical and virtual spaces, which is not only the imperative demand of smart manufacturing, but also the evolving trend of itself. Accordingly, a novel concept of digital twin shop-floor (DTS) based on digital twin is explored and its four key components are discussed, including physical shop-floor, virtual shop-floor, shop-floor service system, and shop-floor digital twin data. What is more, the operation mechanisms and implementing methods for DTS are studied and key technologies as well as challenges ahead are investigated, respectively.

Digital Twin Shop-Floor: A New Shop-Floor Paradigm Towards Smart Manufacturing

Due to the current structure of digital factory, it is necessary to build the smart factory to upgrade the manufacturing industry. Smart factory adopts the combination of physical technology and cyber technology and deeply integrates previously independent discrete systems making the involved technologies more complex and precise than they are now. In this paper, a hierarchical architecture of the smart factory was proposed first, and then the key technologies were analyzed from the aspects of the physical resource layer, the network layer, and the data application layer. In addition, we discussed the major issues and potential solutions to key emerging technologies, such as Internet of Things (IoT), big data, and cloud computing, which are embedded in the manufacturing process. Finally, a candy packing line was used to verify the key technologies of smart factory, which showed that the overall equipment effectiveness of the equipment is significantly improved.

Smart Factory of Industry 4.0: Key Technologies, Application Case, and Challenges

Information and communication technology is undergoing rapid development, and many disruptive technologies, such as cloud computing, Internet of Things, big data, and artificial intelligence, have emerged. These technologies are permeating the manufacturing industry and enable the fusion of physical and virtual worlds through cyber-physical systems (CPS), which mark the advent of the fourth stage of industrial production (i.e., Industry 4.0). The widespread application of CPS in manufacturing environments renders manufacturing systems increasingly smart. To advance research on the implementation of Industry 4.0, this study examines smart manufacturing systems for Industry 4.0. First, a conceptual framework of smart manufacturing systems for Industry 4.0 is presented. Second, demonstrative scenarios that pertain to smart design, smart machining, smart control, smart monitoring, and smart scheduling, are presented. Key technologies and their possible applications to Industry 4.0 smart manufacturing systems are reviewed based on these demonstrative scenarios. Finally, challenges and future perspectives are identified and discussed.

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Smart manufacturing systems for Industry 4.0: Conceptual framework, scenarios, and future perspectives

Recently, cloud manufacturing (CMfg) as a new service-oriented manufacturing mode has been paid wide attention around the world. However, one of the key technologies for implementing CMfg is how to realize manufacturing resource intelligent perception and access. In order to achieve intelligent perception and access of various manufacturing resources, the applications of IoT technologies in CMfg has been investigated in this paper. The classification of manufacturing resources and services, as well as their relationships, are presented. A five-layered structure (i.e., resource layer, perception layer, network layer, service layer, and application layer) resource intelligent perception and access system based on IoT is designed and presented. The key technologies for intelligent perception and access of various resources (i.e., hard manufacturing resources, computational resources, and intellectual resources) in CMfg are described. A prototype application system is developed to valid the proposed method.

IoT-Based Intelligent Perception and Access of Manufacturing Resource Toward Cloud Manufacturing

Mass-customization production (MCP) companies must fight with shop-floor uncertainty and complexity caused by wide variety of product components. The research is motivated by a typical MCP company that has experienced inefficient scheduling due to paper-based identification and manual data collection. This paper presents an RFID-enabled real-time manufacturing execution system (RT-MES). RFID devices are deployed systematically on the shop-floor to track and trace manufacturing objects and collect real-time production data. Disturbances are identified and controlled within RT-MES. Planning and scheduling decisions are more practically and precisely made and executed. Online facilities are provided to visualize and manage real-time dynamics of shop-floor WIP (work-in-progress) items. A case study is reported in a collaborating company which manufactures large-scale and heavy-duty machineries. The efficiency and effectiveness of the proposed RT-MES are evaluated with real-life industrial data for shop-floor production management in terms of workers, machines and materials.

RFID-enabled real-time manufacturing execution system for mass-customization production

Discrete manufacturing (DM) refers to produce products in non-sequential processes so as to respond to market and customer requirements quickly under limited lead-time. However, in shop-floor management, DM companies usually confront challenges such as information gaps between different manufacturing units, slow responsiveness to customer changes, and poor visualization. The main reasons are lacking of efficient manufacturing data collection manners and software to support shop-floor management. This paper introduces an RFID-enabled real-time manufacturing execution system (RT-MES) for improving DM shop-floor management level in the perspective of illustrating the RT-MES software design and implementation. Several contributions from this paper are significant. First, a framework of RFID-enabled RT-MES is proposed, which is generic and helpful for enterprise information system (EIS) construction. Second, a plug-universal database-aided design (PUDAD) concept and its realization are elaborated, which could reduce RT-MES development and implementation cycle. Third, an interface middleware is reported to enable RT-MES real-time intercommunication with other EISs such as SAP ERP. Fourth, a real-life case study describes how RT-MES to enhance a typical DM firm's shop-floor management, which can be referenced by other DM companies when they initiate and implement RFID-enabled solutions.

G. J. Hu

Papers

RFID-enabled real-time manufacturing execution system for mass-customization production

RFID-enabled real-time manufacturing execution system for discrete manufacturing: Software design and implementation