Report on a smart manufacturing factory with intelligent assembly technology and systems in phased Implementations

Figure 1: Pick to Light Technology

Figure 2: Arkite Human Interface Mate (HIM)

5. The Digitalized Lean Assembly line of a smart manufacturing factory with intelligent assembly technology and systems in phased Implementations

The next technology used in the smart manufacturing factory is related to the digital lean assembly line. It is shown in the given figure below. It has consisted of three main stations that include the shaft assembly, gearbox assembly, and final assembly. For that case, operators are involved in using each of the stations and it contains only one material handler and he is the charge of inspected the inventories and gear parts.

Figure 3: Digitalized Assembly Line

5.1. Shaft assembly  

Figure 4: Manual Workstation Shaft assembly

It is the first station and shown in the figure 4. In this station, the operator is required to deal with some hot and heavy parts that will increase safety risk. The next thing is that time required for assembling the sub-assembly parts by using a hydraulic press and the induction heater is about 20 minutes. It can be observed that when a collaborative robot is placed at the station then the operator has to play a supervisory role by performing some value-added tasks properly. Moreover, the whole system will increase work efficiency and also enhancing workshop safety.

Figure 5: Solution for Manual Setup

Figure 6: Cobot Station with cobot arm

The next point is related to the implementation of the 3D scanner and it is implemented with a part recognition algorithm in the cobot’ station. This 3D scanner will improve the efficiency of the assembly process by capturing imaging and analyzing its position of related parts. Then cobot will assemble these parts correctly. There is a need for image data from the vision controller and it will transmit through OPCUA to industry PC. Then after this, for obtaining the correct coordination of the parts of the controller there is a need for analysis. According to these coordinates, the cobot can easily pick and place the required parts properly from the trolley. There is also a smart safety projector and it is assembled at the cobot station and it is implemented with the idea of projecting the wellbeing operators in assembly workstations. Moreover, the next fact is that a Smart safety projector will project safety barrage with an efficient warning sign and it will allow the operator to check the problem present in the workstations.

Figure 7: Scanner to Cobot

5.2. Station 2 gear assembly

In that station, the operator will check the gear assembly process and also shafts sub-assembly produced from station 1. Moreover, at the start of station 2 the main parts of gears like bearing cups, and covers are placed on the normal bins for the operator to use. Despite this, when inventory is low then the operator is required to travel towards the warehouse and replenish the parts required and applied them to the work station 2. Moreover, if they wanted to reduce the operator effort and time then they applied an automated transportation system and it is implemented with (Mobile industrial robot) MIR technology as shown in the given figure. It will provide ease to the operator to carry out materials from one place to another in the workstation. Moreover, MIR will allow the user to install maps into its software so it will become simple to move around the workplace without the involvement of human efforts. Another thing is that MIR will safely control the people and other obstacles on the shop floor because it contains high-speed cameras and sensors. Moreover, MIR is also smart it can easily identify its surroundings and take the most efficient route towards its destination. If its route is blocked then it can easily find another shortest route towards its destination. Another fact is that its structure part of the transportation module is extremely versatile. It also contains the trolley system and it will customize the top module of the system with bins and racks

Figure 8: Mobile Industrial Robot (MiR)

We also realised that an operator requires carrying a heavy load such as a gear box around the lean assembly line. Thus, another alternative of helping operator carry heavy workloads around the shopfloor would be the “THOUZER” (as shown in Figure 9). At our shopfloor, we apply the “THOUZER” to carry heavy objects such as gearboxes which weigh about 20kg. It has a maximum payload of 120kg. The operator can either use the vehicle to follow them or manoeuvre it using the joystick to navigate around the workshop. Thus, this method prevents the need for the operator to carry heavy loads and increases workplace safety.

Figure 9: THOUZER with complete parts

Moreover, in station 2 there is a manual check of the stock. It is considered an extremely time-consuming process and also tedious for the operator. This problem can be solved through the new system and software named as Bossard Smart bin  Bossard smartbin powered by Bossard Armis software. It shown in the given figures. The main aim of the system to help the operator by identifying the stock levels by just looking at the color level on the display screen. It shows that if it is displaying green color its means it is completely full. On the other hand, blue is showing sufficient inventory, yellow is showing low and red is showing empty. Moreover, this screen will also show the name and serial number and its estimated quantity. The next point is that in Smart bin there is only the requirement of remote wireless connections for monitoring stock by weight sensors. This means that whenever the inventory is low then it will be reflected in the dashboard of the Bossard ARMIS software and it is connected with Smart bin. Due to the low stock level, this software will trigger the MIR system by IIOT platform to carry parts towards the station 2.

Figure 10: Normal Bin To Smart Bin

Figure 11: Smart Bin colour indicator

Moreover, in station 2 there is also a digital Standard Procedure (SOP). It is shown in figure 12. This system is used for guiding the operator for following certain steps by video. It will become extremely simple and clear for the new operators working in a particular environment. It will also help the operator during the work environment so they can easily update the SOP according to the requirement of the system.

Figure 12: Digital Standard Operating Procedure (SOP) Used in Lean Assembly Line

5.3. Station 3

It deals with the final assembly stage. In that particular state, the operator will qualify the inspection on the gearbox and complete its final assembly. It can be noted that the final assembly is extremely important to process for the implementation of the gearbox assurance and its quality. Moreover, it is no easy for the new operator to follow. Due to this, there is a need to implement the Arkite Human interface for guiding new operators for the final assembly process. Due to this system, the new operators can handle tough tasks in the final assembly. It will also help the operator to follow the required steps to assemble the gearbox and also minimize the important errors of the system like implementing the wrong parts for the assembly.

6. Methodology

This research is based on secondary data and collected data from different manufacturing factories. The data is collected from smart manufacturing and ordinary manufacturing factory. In smart manufacturing, there is the implementation of efficient assembly technology and system. On the other hand, ordinary manufacturing is operated with a human. Moreover, in this survey, all main assembly operations are analyzed properly. Moreover, all of these industries are located in Singapore. It will analyze the productivity and also inventory controlling of the smart and ordinary manufacturing companies.

7. Discussion of a smart manufacturing factory with intelligent assembly technology and systems in phased Implementations

It can be noted that smart manufacturing factories will be the future of the industrial revolution. This is because all of these technologies will lower the human efforts and time. Moreover, due to these technologies, the efficiency of the system is increased and also there will be quite a low risk of any error in the system. Another important point is that due to the implementation of these technologies the workload on the human will be reduced. From these technologies, the Digitalized Lean Assembly line is considered one of the most efficient ones used in the smart inventory system. This is because it contains three work stations and every work station is efficient in reducing human efforts. This shows that due to such technologies humans will only play a supervisory and maintenance role in the workstations. If there is any problem is present in the workstation they will solve it.

 But all operations at the workspace will be carried out through these technologies. The results of these technologies are extremely efficient. The results are obtained from the survey and secondary data conducting from smart manufacturing factory and ordinary factory. The results are showing that these technologies become a new revolution for the manufacturing industries. This is because it is reducing the human efforts and also increasing efficiency and productivity in the workplace. The main reason is that such robots are fast and robust in action. It contains the latest and premium software applications operated with artificial intelligence technology so they can easily sense the problem and solve it properly. It is showing that it is considered an advanced technological future for the manufacturing factors around the world. 

8. Conclusion of a smart manufacturing factory with intelligent assembly technology and systems in phased Implementations

Summing up all the discussion from above, it is concluded that smart manufacturing factories are the future of industries. In this paper, there is complete information on the different technologies used for the assembly system of the factory. All of these technologies are explained with proper information and figures. For methodology, a complete survey is conducted between smart and ordinary manufacturing factories. It will highlight some important advantages of smart technologies in the workplace. 

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A*STAR’s Model Factory initiative brings you real-time manufacturing environments that will allow companies to learn from, and test newer Industry 4.0 technologies within a collaborative ecosystem of partners. The industry partners will work with ARTC to develop Industry 4.0 technologies to improve performance and efficiency in shop floor production. The results of these technologies are extremely efficient. The results are obtained from the survey and secondary data conducting from smart manufacturing factory and ordinary factory.

Acknowledgements of a smart manufacturing factory with intelligent assembly technology and systems in phased Implementations

This research is supported by the Agency for Science, Technology and Research (A*STAR) under its Advanced Manufacturing & Engineering (AME) Industry Alignment Funding. – Pre-positioning funding scheme (Project No: A1723a0035)

9. References of a smart manufacturing factory with intelligent assembly technology and systems in phased Implementations:

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[4]   Luo, W., Hu, T., Zhang, C., & Wei, Y. (2019). Digital twin for CNC machine tool: modeling and using strategy. Journal of Ambient Intelligence and Humanized Computing, 10(3), 1129-1140.

[5]   Zhao, R., Yan, D., Liu, Q., Leng, J., Wan, J., Chen, X., & Zhang, X. (2019). Digital Twin-Driven Cyber-Physical System for Autonomously Controlling of Micro Punching System. IEEE Access, 7, 9459-9469.

[6]   ElProCus - Electronic Projects for Engineering Students. (2019). Introduction to Wireless Sensor Networks Types and Applications.

https://www.elprocus.com/introduction-to-wireless-sensor-networks-types-and-applications

[7]   Arkite. (2019). Arkite - Helping Operators Excel

https://www.arkite.be/tag/helping-operators-excel.