This paper proposes a new integration method for cell formation, group scheduling, production, and preventive maintenance (PM) planning problems in a dynamic cellular manufacturing system (CMS). The cell formation sub-problem aims to form part families and machine groups, which minimizes the inter-cell material handling, under-utilization, and relocation costs. The production planning aspect is a multi-item

The prognostic study of the ball screw is critical to increase the reliability of manufacturing system, which has drawn great attention in the field of Prognostics and Health Management (PHM). The particle filters (PF) method is a powerful tool for prognostic study because of its capability of robustly predicting the future behavior. However, lack of analytical ball screw measurement model limits the

For many contemporary manufacturing processes, autonomous robotic operators have become ubiquitous. Despite this, the number of human operators within these processes remains high, and as a consequence, the number of interactions between humans and robots has increased in this context. This is a problem, as human beings introduce a source of disturbance and unpredictability into these processes in

Smart manufacturing is arriving. It promises a future of mass-producing highly personalized products via responsive autonomous manufacturing operations at a competitive cost. Of utmost importance, smart manufacturing requires end-to-end integration of intra-business and inter-business manufacturing processes and systems. Such end-to-end integration relies on standards-compliant and interoperable interfaces

Modeling complex systems as networks of interacting elements has gained increased attention in recent years. So far, network modeling in manufacturing and logistics has often focused on the description of system properties. In the data-driven world of smart manufacturing, creating material flow network models becomes a lot easier due to the ubiquitous availability of shop floor and transportation data

Pharmaceutical product customization, a prerequisite for personalized medicines, is currently a widely researched topic. Patient characteristics can be mapped and translated into parameters for designing patients’ individual treatment, i.e., the dosage form. However, current pharmaceutical manufacturing is dominated by mass production and lacks the capability and flexibility required to produce customized

To reduce waste during disassembly production and improve disassembly efficiency, this study investigates a type of partial parallel disassembly line applicable for the simultaneous disassembly of different products. A multi-objective mathematical model for a partial parallel disassembly line balancing problem is built considering four optimisation goals, namely, the minimisation of the cycle time

Every time a component’s design is changed, the corresponding manufacturing has to be changed as well. Due to several recent developments such as increasing market dynamics or ever-shorter product life cycles, the amount of component changes is rising sharply. Therefore, the number of manufacturing changes is increasing at a fast pace. Particularly for safety-critical components, the implementation

With the Internet of Things, it is now possible to sense the real-time status of manufacturing objects and processes. For complex Service Selection (SS) in Cloud Manufacturing, real-time information can be utilized to deal with uncertainties emerging during task execution. Moreover, in the face of diversified demands, multiple manufacturing clouds (MCs) can provide a much wider range of choices of

Feature extraction plays an important role in industrial process monitoring. Autoencoder and its deep framework, deep autoencoder, are used to extract latent features from complex data. However, the latent features extracted by autoencoder through unsupervised learning may not be useful for discriminative tasks. Fisher discriminant analysis (FDA) is another widely used supervised feature extraction

Cyber-physical security is a major concern in the modern environment of digital manufacturing, wherein a cyber-attack has the potential to result in the production of defective parts, theft of IP, or damage to infrastructure or the operator have become a real threat that have the potential to create bad parts. Current cyber only solutions are insufficient due to the nature of manufacturing environments

In automotive paint shops, changes of colors between consecutive production orders cause costs for cleaning the painting robots. It is a significant task to re-sequence orders and group orders with identical color as a color batch to minimize the color changeover costs. In this paper, a Color-batching Resequencing Problem (CRP) with mix bank buffer systems is considered. We propose a Color-Histogram

Computer Numerical Control Machine Tool (CNCMT) Digital Twin (DT) model is a carrier for complex, time-varying, coupled data of CNCMT, which can theoretically provide a time-varying high-fidelity model. However, there are still many difficulties in its implementation process. And the key issue is how to realize the updated DT model with performance attenuation and validate it. In order to solve this

When a mission arrives at a random time and lasts for a duration, it becomes an interesting problem to plan replacement policies according to the health condition and repair history of the operating unit, as the reliability is required at mission time and no replacement can be done preventively during the mission duration. From this viewpoint, this paper proposes that effective replacement policies

The business world is continually changing. Dynamic environments, full of uncertainties, complexities, and ambiguities, demand faster and more confident decisions. To compete in this environment, Industry 4.0 emerges as an essential alternative. In this context, the reliability of manufacturing is an essential aspect for companies to make successful decisions. In the literature, several technologies

Complex products such as satellites, missiles, and aircraft typically have demanding requirements for dynamic data management and process traceability. The assembly process for these complex products involves high complexity, strong dynamics, many uncertainties, and frequent rework and repair, especially in the model development stage. Achieving assembly data management and process traceability for

Anomaly detection is a crucial aspect for both safety and efficiency of modern process industries. This paper proposes a two-steps methodology for anomaly detection in industrial processes, adopting machine learning classification algorithms. Starting from a real-time collection of process data, the first step identifies the ongoing process phase, the second step classifies the input data as “Expected”

The manufacturing industry is shifting towards smart manufacturing, in which both energy efficiency and flexibility are some of the main objectives of this digital transformation. In this regard, the control strategies for manufacturing systems should be able to support the requirements of this transformation with a low computational burden towards their implementation in real time. To this end, in

Ultra-precision machining (UPM) technology is extensively applied to manufacture top quality products with high precision level and complicated geometry. As complicated machining factors affect the surface quality of machined components in UPM, large numbers of experiments for understanding the influences from particular machining factors are needed, leading overestimate or underestimate of significance

Structural dimensional inspection is vital for the process monitoring, quality control, and fault diagnosis in the mass production of auto bodies. Comparing with the non-contact measurement, the high-precision five-axis measuring machine with the touch-trigger probe is a preferred choice for data collection. It can assist manufacturers in making accurate inspection quickly. As the increase of free-form

Fault diagnosis of rotary machinery plays a significant role in the prognostic and health management system, which aims to identify the root causes of system failures and provide effective information for prognostics and maintenance. Recently, Lempel–Ziv complexity (LZC) method has been employed for fault diagnosis of rotary machinery. However, one actual problem is that LZC fails to account for the

Open product architecture is a key enabler for product personalization, as it allows the integration of personalized modules in a product architecture to satisfy individual customer needs and preference. A critical challenge for integrating personalized modules into a product architecture is determining the optimal assembly architecture when considering market expectations and manufacturing constraints

Digital twin (DT) is a virtual mirror (representation) of a physical world or a system along its lifecycle. As for a complex discrete manufacturing system (DMS), it is a digital model for emulating or reproducing the functions or actions of a real manufacturing system by giving the system simulation information or directly driven by a real system with proper connections between the DT model and the

Metal Additive Manufacturing (AM) has been attracting a continuously increasing attention due to its great advantages compared to traditional subtractive manufacturing in terms of higher design flexibility, shorter development time, lower tooling cost, and fewer production wastes. However, the lack of process robustness, stability and repeatability caused by the unsolved complex relationships between

Cyber-physical production systems enable adaptivity and flexibility when manufacturing customized products in small batches. Due to varying routes and a high variance of workpieces, material flows in cyber-physical production systems can get highly complex, which can lead to physically induced disturbances that can result in accidents or decreased throughput and high costs. This issue can be addressed

Industry 4.0-based manufacturing systems are equipped with Cyber-Physical Systems that are characterized by a strong interlinkage between the real world and the digital one: actions in one world have an impact on the other. In this paradigm, Digital Twins (DT) are defined as simulation models that are both getting data from the field and triggering actions on the physical equipment. However, most of

Two-dimensional (2D) irregular layout is widely applied in various manufacturing processes, such as sheet metal cutting, shipbuilding, and electronic component placement. An efficient layout algorithm can effectively improve the material utilization, thereby reducing manufacturing cost. But the free-form shape layout problem is very challenge as it is difficult to exactly represent a free-form shape

The disassembly process has attracted mounting interest due to growing green concerns. This paper addresses the capacitated dynamic lot-sizing problem with external procurement, defective and backordered items, setup times, and extra capacity. The problem is to determine how many end-of-life products to disassemble during each period. We propose a new mixed-integer programming (MIP) approach to formulate

The fourth industrial revolution is derived from advances in digitization and prognostic and health management (PHM) disciplines to make plants smarter and more efficient. However, an adapted approach for data-driven PHM process implementation in small and medium-sized enterprises (SMEs) has not been yet discussed. This research gap is due to the specificities of SMEs and the lack of documentation

With the extensive application of mass customization, fast and accurate responses to customer inquiries can not only improve the competitive advantage of an enterprise but also reduce the cost of parts at the design stage. Most cost estimation methods establish a regression relationship between features and cost based on the processing features of parts. Traditional methods, however, encounter certain

The recent transformation in the aeronautical industry gives new prospects in the field of product geometry assurance. These include, in particular the creation of sophisticated virtual models, or digital twins, which can reflect the as-built geometry of physical products and optimize the assembly operations consequently. One of the current obstacles to the implementation of such digital twins is linked

Manufacturers are poorly equipped to manage product transition scenarios, when moving from one product to another. Most tools consider a mature system, yet during transition and ramp up disturbances and inefficiency are common. The traditional methods, using centralised planning and control structures are too rigid and often resort to simple dispatch heuristics in this highly dynamic environment. Distributed

The present study employs deep learning methods to recognize repetitive assembly actions and estimate their operating times. It is intended to monitor the assembly process of workers and prevent assembly quality problems caused by the lack of key operational steps and the irregular operation of workers. Based on the characteristics of the repeatability and tool dependence of the assembly action, the

Despite the recent success in data-driven machinery fault diagnosis, cross-domain diagnostic tasks still remain challenging where the supervised training data and unsupervised testing data are collected under different operating conditions. In order to address the domain shift problem, minimizing the marginal domain distribution discrepancy is considered in most of the existing studies. While improvements

Recent efforts to create a smart factory have inspired research that analyzes process data collected from Internet of Things (IOT) sensors, to predict product quality in real time. This requires an automatic defect inspection system that quantifies product quality data by detecting and classifying defects in real time. In this study, we propose a vision-based defect inspection system to inspect metal

In highly flexible and integrated manufacturing systems, such as semiconductor fabs, strong interactions between the equipment condition, operations executed on the various machines and the outgoing product quality necessitate integrated decision making in the domains of maintenance scheduling and production operations. Furthermore, in highly complex manufacturing equipment, the underlying condition

Flexible assembly tooling is an important manufacturing equipment for aircraft products, the positioning error of its end locating effectors determines the final assembly precision directly. To realize its accurate positioning, a precise and effective error compensation method based on two-stage strategy, is proposed. Based on the structure and working conditions of locating unit, an assembly measuring

High-performance aerospace component manufacturing requires stringent in-process geometrical and performance-based quality control. Real-time observation, understanding and control of machining processes are integral to optimizing the machining strategies of aerospace component manufacturing. Digital Twin can be used to model, monitor and control the machining process by fusing multi-dimensional in-context

Considering all the monitoring data of bearings until failure, very few data are acquired when the bearings are faulty. Such circumstance leads to small faulty sample problem when an intelligent fault diagnosis method is applied. A deep neural network trained with small samples cannot be trained completely, and tends to overfit, which results in poor performance in practical application. To solve this

Accurate identification of the model parameters of the machining process based on on-line process data is a crucial prerequisite for its model-based control and diagnostics. A typical machining process generates multi-output and multirate data streams. Whereas various sensors provide in-process information about the process, many important process outcomes including product qualities can be only measured

Induction motor is the main drive power in modern manufacturing, and timely fault diagnosis of induction motor is of significance to production safety, part quality and maintenance cost control. Data fusion-based diagnosis is attractive for effective utilization of multi-source monitoring information of motors with the development of industrial internet of things. A new multi-sensory fusion model is

The extrusion-based additive manufacturing (AM) processes are those where one or multiple tools (usually nozzles) are driven along predefined paths to deposit fabrication materials. They are usually inherently slow because solid contours have to be filled with mere single deposition lines of material. An intuitive way to improve the fabrication speed is to introduce multiple independent actuators for

For dynamic scheduling, which is daily decision-making in a job-shop, machine availability prediction, disturbance detection and performance evaluation are always common bottlenecks. Previous research efforts on addressing the bottlenecks primarily emphasize on the analysis of data from the physical job-shop, but with little connection and convergence with its virtual models and simulated data. By

Human-Robot Collaboration (HRC), which enables a workspace where human and robot can dynamically and safely collaborate for improved operational efficiency, has been identified as a key element in smart manufacturing. Human action recognition plays a key role in the realization of HRC, as it helps identify current human action and provides the basis for future action prediction and robot planning.

Digital twins can achieve hardware-in-the-loop simulation of both physical equipment and cyber model, which could be used to avoid the considerable cost of manufacturing system reconfiguration if the design deficiencies are found in the deployment process of the traditional irreversible design approach. Based on the digital twin technology, a quad-play CMCO (i.e., Configuration design-Motion planning-Control

With rapid advances in new generation information technologies, digital twin (DT), and cyber-physical system, smart assembly has become a core focus for intelligent manufacturing in the fourth industrial evolution. Deep integration between information and physical worlds is a key phase to develop smart assembly process design that bridge the gap between product assembly design and manufacturing. This

To benefit from the accurate simulation and high-throughput data contributed by advanced digital twin technologies in modern smart plants, the deep reinforcement learning (DRL) method is an appropriate choice to generate a self-optimizing scheduling policy. This study employs the deep Q-network (DQN), which is a successful DRL method, to solve the dynamic scheduling problem of flexible manufacturing

Deformation due to residual stress is a significant issue during the machining of thin-walled parts with low rigidity. If there are multiple processes with deformation during machining, some process suitability issues will appear. On this occasion, the actual geometric state of the deformed workpiece is needed for process adjustment. However, it is still a challenge to obtain the complete geometry

Due to the increasing greenhouse gas emissions and the energy crisis, the manufacturing industry which is one of the most energy intensive sector is paying close attention to the improvement of environmental performance efficiency. Therefore, in this paper the automated assembly line is balanced in a sustainable way which aims to optimize a green manufacturing objective (the total energy consumption)

To detect and evaluate weld defects, the skin depth and detection ability of magneto-optical imaging (MOI) for weld defects in alternating magnetic field were studied, and the application scope of MOI in alternating magnetic field was determined. A model of magnetic flux leakage testing (MFL) for weld defects is established by finite element method, and the reliability of the model is determined by

An advanced control of manufacturing and transportation systems forms a prominent research field with powerful algorithms developed in the last decades. Challenges still arise, if several automated guide vehicles (AGV) have to be coordinated. This paper focuses on the modelling and fault-tolerant control of multiple AGVs. The considered application concerns a highly flexible AGV transportation system

Quality and efficiency are crucial indicators of any manufacturing company. Many companies are suffering from a shortage of experienced workers across the production line to perform complex assembly tasks. To reduce time and error in an assembly task, a worker-centered system consisting of multi-modal Augmented Reality (AR) instructions with the support of a deep learning network for tool detection

Competitors stand out through commitment to providing excellent customer service. Many organizations strive to promote their order promising system to generate more reliable quotes with quantity and due date constraints. This paper develops a Capable-to-Promise (CTP) based Order Acceptance Model (OAM) for a Hybrid Production Strategy (HPS) based on the positioning of the Customer Order Decoupling Points

Performance analysis of flexible manufacturing cells (FMCs) can help companies find the pros and cons of production processes. However, the emphasis has been on issues like cell formation, layout design and scheduling optimization. Little seems to have been done to assess the reliability of an FMC. In this paper, we develop the stochastic models for the performance analysis mainly on the reliability

Decision making is an essential activity in manufacturing systems when designing production lines, scheduling, etc. Many decision making problems are characterized by multiple conflicting criteria and a large number of alternatives. For these complex decision making problems, it is rational to involve a group of decision makers (DM) for considering different aspects of the problem. This paper proposes

A novel system for performing in-situ micro-machining of aero-engines for repair applications is proposed in this paper. Using Pulsed Laser Ablation (PLA) as material removal technique, surface cracks caused by foreign objects colliding with airfoils are removed by performing a layer-by-layer micro-machining in the area surrounding the damaged zone. Compared to conventional repair performed by micro-grinding