Part 1:
A Big Picture of Production
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
2
Vad är “Produktion”?
What Is Production?
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
3
Paradigmskift
Paradigms Shift
(Adapted from Jovane et al., CIRP Annals, 2003)
Paradigm
Mass
Production
Flexible
Production
Mass
Customization /
Personalization
Cyber - Physical
System
Paradigm
Started
~1850
1913
~1980
2000
2025
Society
Needs
Customized
products
Low cost
products
Variety of
products
Customized
products
Clean & smart
products
Market
Very small
volume per
product
Demand >
supply
Supply >
demand
Smaller volume
per product
Globalization
Distributed &
Dynamic
Circular
Economy
Flow Control
Model
2014-11-07
Craft
Production
Steady demand
Pull
Push
Push-Pull
Fluctuating
demand
Pull
Pull
sell-designmake-assemble
design-makeassemble-sell
design-makesell-assemble
design-sellmake-assemble
Technology
Enabler
Electricity
Interchangeable
parts
Computers
Information
Technology
Smart Sensor
Process
Enabler
Machine Tools
Moving
Assembly Line
& DML
FMS Robots
Reconfigurable
Manufacturing
Systems
Adaptive
Manufacturin
g Systems
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
Design for
environment-sellmake-assemble
6
Part 2:
Production Automation
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
10
Utmaningar
Existing Problems
Monitoring
Systems
Production Plans
and Schedules
• Camera based
• real-time apps
Planning and
Control Systems
• Created in advance
• Not adaptable to changes
Design and
Manufacturing
• Platform dependent
• Expensive and not portable
• Not well integrated in
terms of design for mfg
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
11
Takt tid - genomloppstid-cykeltidvänttid.
Why Automation?
Percentage of time spending of a typical part on a shop floor:
On machine
Time on shop floor
Moving and waiting
5%
95%
waste ?
Time on machine
2014-11-07
30%
70%
Cutting
Loading/unloading,
positioning (setup)
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
14
Produktion - Automation - Maskin
Production
Automation
Machine
A system in which a process is performed by a machine without the
direct participation of a human worker.
Automation is implemented using a program of instructions
combined with a control system that executes the instructions.
Fully automated system vs. semi-automated system.
Controller
Program
Automated
Machine
Raw
Material
Worker’s
Attention
Process
Finished
Part
Scrap or Waste
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
15
Part 4:
Impact of Production in Society
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
26
Hållbarhet
och
inverkan
på samhälleImpact
Societal
and
Environmental
Five Typical Drivers:
Shortage of natural resources
Dramatic increase of world population
Global warming
Pollution
Unstoppable global economy
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
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Trender
Production Trends
Volume
1955
Mass
Production
1980
Sustainable Manufacturing
(6R-based)
2000
1913
1850
Increased value of products
Innovation elements
•
•
•
•
•
•
Variety
Remanufacture
Redesign
Recover
Reuse
Recycle
Reduce
Green Manufacturing
(3R-based)
Lean
Manufacturing
(reduce wastes)
Traditional
Manufacturing
1980
1990
2000
2010
2020
2030
2040
2050
(Adapted from Jayal, Badurdeen, Dillon and Jawahir, “Sustainable manufacturing: modeling and optimization challenges at the
product, process and system levels,” CIRP Journal of Manufacturing Science and Technology, 2, pp. 144–152, 2010)
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
28
Traditionell vs Hållbar
Traditional vs. Sustainable Manuf.
Energy
Use
Recycled materials/parts
Customers’ requirements
Raw materials
Design
Manufacturing
Assembly
Lease
Natural resources
Customers’
requirements
Raw
materials
Redesign
Reconfiguration
Design
Manufacturing
Manufacturing
Use
Assembly
Customers’
products
Wastes
Reconfiguration
Reuse
Recycle
Wastes
Collection and
assessment
Disassembly
Environmental impact
Natural resources
Disposal
Remanufacturing
Non-recoverable wastes
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
32
Part 5:
Production in Factories of the Future
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
41
CPS: Cyber-Physical Systems
CPS: Cyber-Physical Systems
Unit process modelling
Process-feature mapping
Adaptive machining process planning
Reconfigurable assembly planning
Intelligent algorithm embedding
Process
Planning
Wireless Shop Floor
Adaptive
Decision
Making
Execution
Control
Machine Status
Monitoring
Status monitoring
Machine availability
checking
Abnormal event
detection
Cyber-Physical Link
Resource selection
Job dispatching
Remote machining
Remote assembly
Execution control
Sensor Network
Real-time data acquisition
Data analysis and feature extraction
Distributed and Dynamic Manufacturing Processes
2014-11-07
KTH Sustainable Manufacturing • www.kth.se • © Lihui Wang
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