Virtual Commissioning as the Main Core of Industry 4.0 – Case Study in the Automotive Paint Shop

Krystek, Jolanta; Alszer, Sara; Bysko, Szymon

doi:10.1007/978-3-319-97490-3_36

Cited by 11 publications

(6 citation statements)

References 11 publications

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“…2). The main purpose of the buffers is to ensure continuity of production, but from a wider point of view, they have a great significance in changing the input sequences independently for each shop and depending on their individual needs [32]. This is the reason, why in some works e.g.…”

Section: Background Of New Problemmentioning

confidence: 99%

Archives of Control Sciences

Bysko¹,

Krystek²,

Bysko³

et al. 2019

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Buffer management in solving a real sequencing problem in the automotive industry -Paint Shop 4.0 concept SARA BYSKO, JOLANTA KRYSTEK, SZYMON BYSKO and RADIM LENORTThe paper presents a Car Sequencing Problem, widely considered in the literature. The issue considered by the researchers is only a reduced problem in comparison with the problem in real automotive production. Consequently, a new concept, called Paint Shop 4.0., is considered from the viewpoint of a sequencing problem. The paper is a part of the previously conducted research, identified as Car Sequencing Problem with Buffers (CSPwB), which extended the original problem to a problem in a production line equipped with buffers. The new innovative approach is based on the ideas of Industry 4.0 and the buffer management system. In the paper, sequencing algorithms that have been developed so far are discussed. The original Follow-up Sequencing Algorithm is presented, which is still developed by the authors. The main goal of the research is to find the most effective algorithm in terms of minimization of painting gun changeovers and synchronization necessary color changes with periodic gun cleanings. Carried out research shows that the most advanced algorithm proposed by the authors outperforms other tested methods, so it is promising to be used in the automotive industry.

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Section: Background Of New Problemmentioning

confidence: 99%

Archives of Control Sciences

Bysko¹,

Krystek²,

Bysko³

et al. 2019

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“…This starts with the creation of products and system components in a virtual engineering (VE) environment, then using virtual commissioning (VC) in the following stages. From this perspective, VC is regarded as one of the core elements of Industry 4.0 [4] that offers the following benefits [5]:…”

Section: Introductionmentioning

confidence: 99%

Virtual Engineering and Commissioning to Support the Lifecycle of a Manufacturing Assembly System

et al. 2022

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Prior to the physical build of the industrial automation system, some challenges arise, such as processes’ cycle times calculations, ergonomics and safety evaluation, and the integration of separate machines to the complete production shops. This, in turn, requires reconfiguring the processes and component parameters. As a result, the lifecycle of the system development is prolonged, and the potential for erroneous performance increases. In modern digital manufacturing environments, virtual engineering (VE) and virtual commissioning (VC) serve as effective tools to tackle the aforementioned problems and their consequences. The virtual models developed for VE and VC not only assist system developers in the physical build stage but also in the following stages of the system lifecycle by providing a common virtual model, a digital twin (DT), of the manufacturing processes and the product. This developed model should possess the ability to simulate the system behaviour, e.g., the mechanics, kinematics, speed and acceleration profiles. Three stakeholders are involved in the development process: the machine builder, system integrator and end user. The current work focuses on the virtual engineering approach to support the entire lifecycle of a manufacturing system from the machine builder, system integrator and end user perspectives. For this purpose, it puts forward a systematic methodology of implementing VC and VE using a toolset developed by the Automation Systems Group at the University of Warwick within an industrial project. The suggested methodology is illustrated in a case study where a digital twin of a physical station was modelled, developed and tested in parallel with the physical machine development and build. Finally, the benefits and limitations are highlighted based on the gained outcomes and the implemented activities.

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“…The new problem is real-time CS using a buffer to take into account dynamic changes. Analyses are made by comparing the simulation results of the proposed approach (Krystek et al , 2019). This study also demonstrates that the degradation of vehicle lines in the automobile assembly line in the paint shop still offers an application area that is still being studied and is open to development.…”

Section: Introductionmentioning

confidence: 99%

Minimizing deviations of car sequencing in a JIT production painting line

Denizhan

Özçelik

Havuç

2021

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Purpose The first in first out (FIFO) rule is an indispensable rule in the automotive industry. However, during production, the order of coming to welding operation and exiting through the painting operation is broken. Consequently, the rule of FIFO also gets broken. The purpose of this paper is to eliminate the deviations of the automotive painting process in a just in time (JIT) environment. Design/methodology/approach The paper has been solved using observations and expert’s opinions and recorded data in the real problem area. Bypass technique and express line have been used as a real problem for the minimization of these deviations. The current process and the bypass process have been compared with simulation optimization. Findings This paper provides analytical insights about how to prevent delays during the JIT production painting process. Delays have been prevented by using the bypass technique and express line together. The number of delays reduced with an improvement of 129. The ratio of effect (for four months) has been founded to be 0.12. The output rate has been increased from 80% to 89%. Research limitations/implications This paper focused on the number of vehicles in the cooling area of the painting process in the study; there may occur bottleneck processes or products. It does not contain station-based bottleneck processes. Practical implications From the real-case problem, one will see that the bypass technique and the express line can be applied and generalized to many similar problems and help companies conduct their assembly lines more efficiently. Originality/value This paper is the only example that has been used to bypass technique and express line together on the paint/cooling process in a JIT production system.

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Virtual Commissioning as the Main Core of Industry 4.0 – Case Study in the Automotive Paint Shop

Cited by 11 publications

References 11 publications

Archives of Control Sciences

Archives of Control Sciences

Virtual Engineering and Commissioning to Support the Lifecycle of a Manufacturing Assembly System

Minimizing deviations of car sequencing in a JIT production painting line

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