Engineering â€ș Industrial and Manufacturing Engineering

Flexible and Reconfigurable Manufacturing Systems

Description

This cluster of papers focuses on the design, operation, and optimization of reconfigurable manufacturing systems, emphasizing flexibility, scalability, and adaptability in industrial automation. It covers topics such as agent-based control systems, virtual commissioning, modular production, and the use of OPC UA in cyber-physical production systems.

Keywords

Reconfigurable Manufacturing Systems; Flexible Automation; Industrial Automation; Production Ramp-Up; Software Engineering; Agent-Based Control Systems; Modular Production; Virtual Commissioning; Model-Integrated Mechatronics; OPC UA

The Lean Production paradigm has become the major approach to create highly efficient processes in industry since the early 1990s. After the sudden end of the Computer Integrated Manufacturing (CIM) 
 The Lean Production paradigm has become the major approach to create highly efficient processes in industry since the early 1990s. After the sudden end of the Computer Integrated Manufacturing (CIM) era, which finally was doomed to fail due to its unrulable complexity of the required automation technology, the Lean approach was successful because of its high effectiveness by reducing complexity and avoiding non-value-creating process steps. Today, the term Industry 4.0 describes a vision of future production. Many people are at least skeptical or even hostile towards this new approach. This position paper gives an overview over existing combinations of Lean Production and automation technology, also called Lean Automation. Furthermore, it discusses major Industry 4.0 corner stones and links them to the well-proven Lean approach. Examples of combining both are smart watches for supporting the Andon principle or Cyber Physical Systems (CPS) for a flexible Kanban production scheduling.
In this paper, general requirements of next generation manufacturing systems are discussed, and the strategies to meet these requirements are considered. The production paradigms which apply these strategies are also 
 In this paper, general requirements of next generation manufacturing systems are discussed, and the strategies to meet these requirements are considered. The production paradigms which apply these strategies are also classified. Particular emphasis is put on the paradigm of Reconfigurable Manufacturing System (RMS). Some key issues of the RMS design are discussed, and a critical review is presented concerning the developments of RMSs. Finally, suggestions of the RMS research are made and future research directions are identified.
Abstract Automated Identification (Auto ID) applications can provide corporate information systems with the identity of each physical item in the supply chain in an automated and timely manner. The real 
 Abstract Automated Identification (Auto ID) applications can provide corporate information systems with the identity of each physical item in the supply chain in an automated and timely manner. The real time availability of item identity allows other information, related to the item, to be drawn on in order to assess both the current state of the product and future actions required. In the context of supply chain operations, widespread introduction of such systems represents a major opportunity to overhaul and improve tracking and tracing systems, process control and inventory management. In the longer term, it is possible that Auto ID systems may enable a complete re‐engineering of the supply chain, by removing a number of the constraints that limit today's supply chain structures. In this paper, we review some key challenges in supply chain operations and introduce the main elements of an Auto ID system. Using a simple categorization of supply chain operations, areas for short term deployment of Auto ID are identified and opportunities for longer term re‐engineering of different sections of the supply chain are highlighted.
There has been some uncertainty concerning the conditions under which a manufacturing system may be termed 'flexible'. To clarify this confusion eight types of flexibilities are defined and described. There has been some uncertainty concerning the conditions under which a manufacturing system may be termed 'flexible'. To clarify this confusion eight types of flexibilities are defined and described.
One of the most significant directions in the development of computer science and information and communication technologies is represented by Cyber-Physical Systems (CPSs) which are systems of collaborating computational entities 
 One of the most significant directions in the development of computer science and information and communication technologies is represented by Cyber-Physical Systems (CPSs) which are systems of collaborating computational entities which are in intensive connection with the surrounding physical world and its on-going processes, providing and using, at the same time, data-accessing and data-processing services available on the internet. Cyber-Physical Production Systems (CPPSs), relying on the newest and foreseeable further developments of computer science, information and communication technologies on the one hand, and of manufacturing science and technology, on the other, may lead to the 4th Industrial Revolution, frequently noted as Industry 4.0. The key-note will underline that there are significant roots generally – and particularly in the CIRP community – which point towards CPPSs. Expectations and the related new R&D challenges will be outlined.
The supply‐chain operations reference model (SCOR) is the first cross‐industry framework for evaluating and improving enterprise‐wide supply‐chain performance and management. The culmination of intensive work by 70 world‐class manufacturers, SCOR 
 The supply‐chain operations reference model (SCOR) is the first cross‐industry framework for evaluating and improving enterprise‐wide supply‐chain performance and management. The culmination of intensive work by 70 world‐class manufacturers, SCOR provides standard process definitions, terminology and metrics. It will enable companies to benchmark themselves against others, and influence future applications development efforts to ensure fit with manufacturers’ needs. The emerging process reference model concept is the logical extension of business process re‐engineering and other process improvement efforts. SCOR, which is structured in four levels, is based on a plan, source, make, deliver framework.
This paper presents one perspective on recent developments related to software engineering in the industrial automation sector that spans from manufacturing factory automation to process control systems and energy automation 
 This paper presents one perspective on recent developments related to software engineering in the industrial automation sector that spans from manufacturing factory automation to process control systems and energy automation systems. The survey's methodology is based on the classic SWEBOK reference document that comprehensively defines the taxonomy of software engineering domain. This is mixed with classic automation artefacts, such as the set of the most influential international standards and dominating industrial practices. The survey focuses mainly on research publications which are believed to be representative of advanced industrial practices as well.
ADVERTISEMENT RETURN TO ISSUEPREVArticleNEXTPerformance of Agitated Gas-Liquid ContactorsC. M. Cooper, G. A. Fernstrom, and S. A. MillerCite this: Ind. Eng. Chem. 1944, 36, 6, 504–509Publication Date (Print):June 1, 1944Publication History 
 ADVERTISEMENT RETURN TO ISSUEPREVArticleNEXTPerformance of Agitated Gas-Liquid ContactorsC. M. Cooper, G. A. Fernstrom, and S. A. MillerCite this: Ind. Eng. Chem. 1944, 36, 6, 504–509Publication Date (Print):June 1, 1944Publication History Published online1 May 2002Published inissue 1 June 1944https://pubs.acs.org/doi/10.1021/ie50414a005https://doi.org/10.1021/ie50414a005research-articleACS PublicationsRequest reuse permissionsArticle Views1406Altmetric-Citations527LEARN ABOUT THESE METRICSArticle Views are the COUNTER-compliant sum of full text article downloads since November 2008 (both PDF and HTML) across all institutions and individuals. These metrics are regularly updated to reflect usage leading up to the last few days.Citations are the number of other articles citing this article, calculated by Crossref and updated daily. Find more information about Crossref citation counts.The Altmetric Attention Score is a quantitative measure of the attention that a research article has received online. Clicking on the donut icon will load a page at altmetric.com with additional details about the score and the social media presence for the given article. Find more information on the Altmetric Attention Score and how the score is calculated. Share Add toView InAdd Full Text with ReferenceAdd Description ExportRISCitationCitation and abstractCitation and referencesMore Options Share onFacebookTwitterWechatLinked InRedditEmail Other access options Get e-Alerts
Competitive pressures will force major changes in inventory management in the next few years. Changes will result from businesses identifying and capitalising on the opportunities to manage their entire supply 
 Competitive pressures will force major changes in inventory management in the next few years. Changes will result from businesses identifying and capitalising on the opportunities to manage their entire supply chains as single entities. Supply chain management techniques deal with the planning and control of total materials flow from suppliers through end‐users (see Figure 1).
This review paper discusses the industrial and research activities around the IEC 61499 architecture for distributed automation systems. IEC 61499 has been developed to enable intelligent automation where the intelligence 
 This review paper discusses the industrial and research activities around the IEC 61499 architecture for distributed automation systems. IEC 61499 has been developed to enable intelligent automation where the intelligence is genuinely decentralized and embedded into software components, which can be freely distributed across networked devices. With the recent emergence of professionally made software tools and dozens of hardware platforms, IEC 61499 is getting recognition in industry. This paper reviews research results related to the design of distributed automation systems with IEC 61499, the supporting tools and the aspects related to the execution of IEC 61499 on embedded devices. The promising application areas of IEC 61499 include flexible material handling systems, in particular airport baggage handling, flexible reconfigurable manufacturing automation, intelligent power distribution networks and SmartGrid, as well as the wide range of embedded networked systems.
It has become obvious that Process organisation which is the traditional approach in production industries, provides an insuperable barrier to any significant improvement in production efficiency. It produces very complex 
 It has become obvious that Process organisation which is the traditional approach in production industries, provides an insuperable barrier to any significant improvement in production efficiency. It produces very complex material flow systems, leading to long throughput times and a high investment in stocks and work in progress. It makes it impossible to delegate efficiently and it hinders the development of automation. All these deficiencies can be eliminated by changing to “Product Organisation”, of which “Group Technology” (GT) is the final solution. Production Flow Analysis is a simple technique for planning this change.
This paper reviews recent work on the development of analytical models of Flexible Manufacturing Systems (FMSs). The contributions of each of the groups concerned with model development are summarized and 
 This paper reviews recent work on the development of analytical models of Flexible Manufacturing Systems (FMSs). The contributions of each of the groups concerned with model development are summarized and an assessment is made of the strengths and weaknesses of its modelling approach. A number of directions in which models require extension are outlined, in particular the representation of such aspects of FMS operation as the tool delivery systems, the blocking phenomenon, the transient behavior and the differences between flexible machining systems and flexible assembly systems. Further work is also required on the structure of FMS control and the integration with plant production planning and control.
The method of function point analysis was developed by A. J. Albrecht (1979) to help measure the size of a computerized business information system. Such sizes are needed as a 
 The method of function point analysis was developed by A. J. Albrecht (1979) to help measure the size of a computerized business information system. Such sizes are needed as a component of the measurement of productivity in system development and maintenance activities, and as a component of estimating the effort needed for such activities. Close examination of the method shows certain weaknesses, and the author proposes a partial alternative. A description is given of the principles of this Mark II approach. The results are presented of some measurements of actual systems to calibrate the Mark II approach, and conclusions are drawn on the validity and applicability of function point analysis generally.< <ETX xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">&gt;</ETX>
The vision of the 4th industrial revolution describes the realization of the Internet of Things within the context of the factory to realize a significantly higher flexibility and adaptability of 
 The vision of the 4th industrial revolution describes the realization of the Internet of Things within the context of the factory to realize a significantly higher flexibility and adaptability of production systems. Driven by politics and research meanwhile most of the automation technology providers in Germany have recognized the potentials of Industry 4.0 and provide first solutions. However, presented solutions so far represent vendor-specific or isolated production system. In order to make Industry 4.0 a success, these proprietary approaches must be replaced by open and standardized solutions. For this reason, the SmartFactoryKL has realized a very first multi-vendor and highly modular production system as a sample reference for Industry 4.0. This contribution gives an overview of the current status of the SmartFactoryKL initiative to build a highly modular, multi-vendor production line based on common concepts and standardization activities. The findings and experiences of this multi-vendor project are documented as an outline for further research on highly modular production lines.
Future industrial systems can be realized using the cyber-physical systems (CPSs) that advocate the coexistence of cyber and physical counterparts in a network structure to perform the system's functions in 
 Future industrial systems can be realized using the cyber-physical systems (CPSs) that advocate the coexistence of cyber and physical counterparts in a network structure to perform the system's functions in a collaborative manner. Multiagent systems share common ground with CPSs and can empower them with a multitude of capabilities in their efforts to achieve complexity management, decentralization, intelligence, modularity, flexibility, robustness, adaptation, and responsiveness. This work surveys and analyzes the current state of the industrial application of agent technology in CPSs, and provides a vision on the way agents can effectively enable emerging CPS challenges.
Concerning current approaches to planning of manufacturing processes, the acquisition of a sufficient data basis of the relevant process information and subsequent development of feasible layout options requires 74% of 
 Concerning current approaches to planning of manufacturing processes, the acquisition of a sufficient data basis of the relevant process information and subsequent development of feasible layout options requires 74% of the overall time-consumption. However, the application of fully automated techniques within planning processes is not yet common practice. Deficits are to be observed in the course of the use of a fully automated data acquisition of the underlying process data, a key element of Industry 4.0, as well as the evaluation and quantification and analysis of the gathered data. As the majority of the planning operations are conducted manually, the lack of any theoretical evaluation renders a benchmarking of the results difficult. Current planning processes analyze the manually achieved results with the aid of simulation. Evaluation and quantification of the planning procedure are limited by complexity that defies manual controllability. Research is therefore required with regard to automated data acquisition and selection, as the near real-time evaluation and analysis of a highly complex production systems relies on a real-time generated database. The paper presents practically feasible approaches to a multi-modal data acquisition approach, its requirements and limitations. The further concept of the Digital Twin for a production process enables a coupling of the production system with its digital equivalent as a base for an optimization with a minimized delay between the time of data acquisition and the creation of the Digital Twin. Therefore a digital data acquisition approach is necessary. As a consequence a cyber-physical production system can be generated, that opens up powerful applications. To ensure a maximum concordance of the cyber-physical process with its real-life model a multimodal data acquisition and evaluation has to be conducted. The paper therefore presents a concept for the composition of a database and proposes guidelines for the implementation of the Digital Twin in production systems in small and medium-sized enterprises.
Reconfigurable manufacturing systems (RMSs), which possess the advantages of both dedicated serial lines and flexible manufacturing systems, were introduced in the mid-1990s to address the challenges initiated by globalization. The 
 Reconfigurable manufacturing systems (RMSs), which possess the advantages of both dedicated serial lines and flexible manufacturing systems, were introduced in the mid-1990s to address the challenges initiated by globalization. The principal goal of an RMS is to enhance the responsiveness of manufacturing systems to unforeseen changes in product demand. RMSs are costeffective because they boost productivity, and increase the lifetime of the manufacturing system. Because of the many streams in which a product may be produced on an RMS, maintaining product precision in an RMS is a challenge. But the experience with RMS in the last 20 years indicates that product quality can be definitely maintained by inserting in-line inspection stations. In this paper, we formulate the design and operational principles for RMSs, and provide a state-of-the-art review of the design and operations methodologies of RMSs according to these principles. Finally, we propose future research directions, and deliberate on how recent intelligent manufacturing technologies may advance the design and operations of RMSs.
This paper discusses production systems with a focus on the relationships between product supply and customer demand in the context of Industry 2.0–4.0. One driver of production evolution is changes 
 This paper discusses production systems with a focus on the relationships between product supply and customer demand in the context of Industry 2.0–4.0. One driver of production evolution is changes in customer demand over time, which is categorised into several dimensions. Major production systems – flow line, Toyota production system (TPS), job shop, cell, flexible manufacturing system and seru – have been developed and applied to supplies to match different demand dimensions over time. For each production system, two questions are addressed: what and how. Comparisons between seru with TPS and cell are given. The possibilities of a future smart factory equipped with internet of things are discussed. The demand dimensions of Industry 4.0, the product architecture change in the automobile industry and the impact of 3D printing are elaborated. Potential applications of lean and seru principles for Industry 4.0 are presented.
Abstract Manufacturing flexibility improves a firm’s ability to react in timely manner to customer demands and to increase production system productivity without incurring excessive costs and expending an excessive amount 
 Abstract Manufacturing flexibility improves a firm’s ability to react in timely manner to customer demands and to increase production system productivity without incurring excessive costs and expending an excessive amount of resources. The emerging technologies in the Industry 4.0 era, such as cloud operations or industrial Artificial Intelligence, allow for new flexible production systems. We develop and test an analytical model for a throughput analysis and use it to reveal the conditions under which the autonomous mobile robots (AMR)-based flexible production networks are more advantageous as compared to the traditional production lines. Using a circular loop among workstations and inter-operational buffers, our model allows congestion to be avoided by utilizing multiple crosses and analyzing both the flow and the load/unload phases. The sensitivity analysis shows that the cost of the AMRs and the number of shifts are the key factors in improving flexibility and productivity. The outcomes of this research promote a deeper understanding of the role of AMRs in Industry 4.0-based production networks and can be utilized by production planners to determine optimal configurations and the associated performance impact of the AMR-based production networks in as compared to the traditionally balanced lines. This study supports the decision-makers in how the AMR in production systems in process industry can improve manufacturing performance in terms of productivity, flexibility, and costs.
In the last decade, numerous learning factories for education, training, and research have been built up in industry and academia. In recent years learning factory initiatives were elevated from a 
 In the last decade, numerous learning factories for education, training, and research have been built up in industry and academia. In recent years learning factory initiatives were elevated from a local to a European and then to a worldwide level. In 2014 the CIRP Collaborative Working Group (CWG) on Learning Factories enables a lively exchange on the topic "Learning Factories for future oriented research and education in manufacturing". In this paper results of discussions inside the CWG are presented. First, what is meant by the term Learning Factory is outlined. Second, based on the definition a description model (morphology) for learning factories is presented. The morphology covers the most relevant characteristics and features of learning factories in seven dimensions. Third, following the morphology the actual variance of learning factory manifestations is shown in six learning factory application scenarios from industrial training over education to research. Finally, future prospects of the learning factory concept are presented.
Zusammenfassung Die Digitalisierung in der industriellen Fertigung bietet erhebliche Potenziale zur Prozessoptimierung und Effizienzsteigerung. Ein zentraler Standard zur UnterstĂŒtzung dieser Entwicklung ist die Asset Administration Shell (AAS), die einen interoperablen 
 Zusammenfassung Die Digitalisierung in der industriellen Fertigung bietet erhebliche Potenziale zur Prozessoptimierung und Effizienzsteigerung. Ein zentraler Standard zur UnterstĂŒtzung dieser Entwicklung ist die Asset Administration Shell (AAS), die einen interoperablen Informationsaustausch ermöglicht. Dieser Beitrag untersucht die Integration von Zeitreihendaten und automatisierten Serviceanfragen der dafĂŒr relevanten AAS-Teilmodelle, mit dem Ziel, die Effizienz und ZuverlĂ€ssigkeit industrieller Prozesse zu verbessern. Die fĂŒr die Asset-Integration, sowie Integration von Zeitreihen erforderliche Architektur wird mit ihren Bestandteilen erlĂ€utert. Eine Fallstudie demonstriert deren Anwendung unter Einsatz von Softwarekomponenten wie Eclipse BaSyx, InfluxDB und externen Tools zur Anomaliedetektion. Dies erfolgt unter Nutzung etablierter Schnittstellen aktueller Steuerungssysteme.
In the context of Industry 4.0 (I4.0), the Asset Administration Shell (AAS) has been gaining significant attention in recent years. The AAS serves as a standardized digital representation of an 
 In the context of Industry 4.0 (I4.0), the Asset Administration Shell (AAS) has been gaining significant attention in recent years. The AAS serves as a standardized digital representation of an asset, encapsulating all relevant information about the asset throughout its lifecycle. Since its introduction in 2015, the past decade has seen considerable progress in developing traditional AAS solutions, namely AAS Type 1 and Type 2. As this initial phase reaches maturity, it becomes essential to shift focus toward AAS Type 3 (proactive), a specific category that extends traditional AAS functionalities by incorporating higher levels of autonomy, intelligence, and collaborative capabilities. However, AAS Type 3 is still in its early stages, lacking formal specifications and comprehensive implementation guidelines. In this context, Multi-Agent Systems (MAS) have been investigated as a means to enhance traditional AAS solutions toward the realization of AAS Type 3, particularly by embedding autonomous, intelligent, and collaborative behaviors. Building on this perspective, this paper explores the role of MAS in realizing AAS Type 3 through a comprehensive analysis of existing agent-based AAS approaches in the literature. Furthermore, this paper proposes a reference model based on common patterns found in the literature to support the development of AAS Type 3 solutions, contributing to the discussion on the formalization of specifications and providing greater clarity on this emerging topic. Finally, to better demonstrate key aspects of the model, some illustrative examples are presented to guide its application and facilitate understanding.
Abstract OPC Unified Architecture (OPC UA) is widely considered a key enabler of “Industry 4.0” and one of the most promising standardized platforms for industrial communications from sensor to cloud. 
 Abstract OPC Unified Architecture (OPC UA) is widely considered a key enabler of “Industry 4.0” and one of the most promising standardized platforms for industrial communications from sensor to cloud. One of its key features is a powerful framework for information modeling that allows to compose semantic models and enables self-describing information provisioning. As the way semantic information is represented in OPC UA is akin to Semantic Web technologies and knowledge graphs, a relatively new field of research deals with exploiting synergies between the two technology domains and with combining OPC UA with different artificial intelligence (AI) paradigms. This paper provides a literature review of this area, structures the existing contributions, and provides an outlook on future research directions. We argue that large untapped potential lies in applying AI techniques, in particular machine reasoning, to OPC UA data to orchestrate dynamic, self-organizing, and flexible production processes in a highly automated fashion.
| Religionswissenschaft
Abstract This paper presents the BMW body shop construction project in Munich as a case study for the effective application of digital planning, industrialized construction, and precast building methods in 
 Abstract This paper presents the BMW body shop construction project in Munich as a case study for the effective application of digital planning, industrialized construction, and precast building methods in large‐scale industrial developments. The article outlines key project details and highlights specific innovations in planning and execution, including the use of advanced 4D Building Information Modeling (BIM), pre‐stressed precast concrete columns, and the transformation of traditionally in‐situ concrete cores into fully prefabricated units. These solutions were tailored to meet complex structural requirements and were supported by integrated digital modeling and precise on‐site coordination. Digital planning and industrialized construction using precast elements contribute significantly to keeping large projects on budget and on schedule, while also increasing overall construction productivity. Accelerated construction timelines and reduced on‐site labor help address growing labor shortages in the industry. Furthermore, component optimization—such as minimizing wall thickness and reinforcement through prefabrication—can support sustainability goals. To fully leverage these benefits, the use of precast systems should be considered from the earliest design phases. However, many structural engineers still rely on conventional in‐situ methods, limiting the adoption of more efficient alternatives. This case underscores the advantages of industrialized construction and demonstrates its practical potential. The findings contribute to both academic discourse and practical implementation, emphasizing the need for broader education, understanding, and innovation in prefabricated building systems.
| Maschinenbau Schweizer Industriemagazin
| Maschinenbau Schweizer Industriemagazin
The increasing importance of mobility, along with the growing complexity of the operational environment, has necessitated the design of appropriate and flexible responses. These responses are based not only on 
 The increasing importance of mobility, along with the growing complexity of the operational environment, has necessitated the design of appropriate and flexible responses. These responses are based not only on the acquisition of high-performance technical equipment but also on ensuring efficient lifecycle management planning to maintain continuous operational readiness. This study proposes an efficient monitoring method for a medium- sized fleet of special-purpose vehicles. As a result of implementing this method, the time required to restore the operational readiness coefficient to 100% is reduced by 40%.
Die staatliche Anerkennung der OTA-Ausbildung war ein Meilenstein fĂŒr die Professionalisierung dieses anspruchsvollen TĂ€tigkeitsfelds. Um die zahlreichen neuen Bestimmungen zu erfĂŒllen und gleichzeitig den Herausforderungen des Berufsalltags gerecht zu werden, 
 Die staatliche Anerkennung der OTA-Ausbildung war ein Meilenstein fĂŒr die Professionalisierung dieses anspruchsvollen TĂ€tigkeitsfelds. Um die zahlreichen neuen Bestimmungen zu erfĂŒllen und gleichzeitig den Herausforderungen des Berufsalltags gerecht zu werden, mĂŒssen AusbildungsstĂ€tten ihre Konzepte grundlegend ĂŒberarbeiten. Das im Folgenden vorgestellte modulare Ausbildungskonzept des UniversitĂ€tsklinikums Hamburg-Eppendorf zeigt beispielhaft, wie die Herausforderungen der neuen gesetzlichen Rahmenbedingungen zu einer Chance fĂŒr Innovation und Weiterentwicklung werden können. Zwar variieren die gesetzlichen Vorgaben je nach Bundesland, dennoch kann es als Fallbeispiel dienen und nĂŒtzliche Anregungen liefern.
| WASSERWIRTSCHAFT
Jasmin Pölking , Collin Jacobs | Informationen aus Orthodontie & KieferorthopÀdie