Process automation for discrete manufacturing excellence (PADME)

Com as evoluções tecnológicas nas áreas de hardware, microeletrônica, sistemas de informação e computação, o conceito de sistemas ciberfísicos (do inglês Cyber-Physical Systems) vem ganhando importância. Este sistemas se referem à junção entre sistemas computacionais distribuídos e processos físicos da natureza e, são base fundamental para a nova revolução industrial que esta sendo introduzida. Esta revolução industrial é marcada pela completa descentralização do controle dos processos produtivos e uma proliferação de dispositivos inteligentes interconectados, ao longo de toda a cadeia de produção e logística. Sistemas de automação, e particularmente os sistemas de automação industrial, nos quais elementos computacionais controlam e automatizam a execução de processos físicos em plantas industriais, são um exemplo de sistemas ciber-físicos. Com isso, percebe-se que é necessário relacionar objetos físicos a informações associadas a este objeto no mundo cibernético. Para isso, destaca-se o conceito e o uso do Digital Twin, que é uma representação virtual de objetos físicos. O Digital Twin possibilita a virtualização e centralização do controle no produto. Este estudo irá explorar uma metodologia de modelagem genérica e flexível para o Digital Twin usando a ferramenta AutomationML e propor uma arquitetura de comunicação para a troca de dados sob a ótica de Cyber Physical Systems. Com a implementação dessa metodologia, pretende-se validar o conceito proposto e oferecer um método de modelagem e configuração para obter dados, extrair conhecimento e proporcionar sistemas de visualização para os usuários. / With technological advances in the fields of hardware, microelectronics and computer systems, Cyber Physical Systems is a new concept that is gaining importance. This systems are integrations of computation, networking, and physical processes. Cyber Physical Systems are one of the pillars for the new industrial revolution, and it is marked by the complete decentralization of the control of production processes and, marked by a proliferation of interconnected intelligent devices throughout the production and logistics chain. Embedded computers and networks monitor and control the physical processes, with feedback loops where physical processes affect computations and vice versa. A industrial automation system, is an example of cyber physical systems where computational elements control and automate the execution of physical processes in industrial plants. Thus, it is clear the need to relate physical objects to information associated with this object in the cyber world. For this, this work pretends to use the concept of Digital Twin, that is a virtual representation of physical objects. Digital Twin enables the virtualization of physical components and descentralization of control. This study will explore a generic and flexible modeling methodology for Digital Twin using the AutomationML tool. Also this work proposes a communication architecture for the exchange of data from the perspective of Cyber Physical Systems. With the implementation of this methodology, we intend to validate the proposed concept and offer a modeling and configuration method to obtain data, extract knowledge and provide visualization systems for users.

Com as evoluções tecnológicas nas áreas de hardware, microeletrônica, sistemas de informação e computação, o conceito de sistemas ciberfísicos (do inglês Cyber-Physical Systems) vem ganhando importância. Este sistemas se referem à junção entre sistemas computacionais distribuídos e processos físicos da natureza e, são base fundamental para a nova revolução industrial que esta sendo introduzida. Esta revolução industrial é marcada pela completa descentralização do controle dos processos produtivos e uma proliferação de dispositivos inteligentes interconectados, ao longo de toda a cadeia de produção e logística. Sistemas de automação, e particularmente os sistemas de automação industrial, nos quais elementos computacionais controlam e automatizam a execução de processos físicos em plantas industriais, são um exemplo de sistemas ciber-físicos. Com isso, percebe-se que é necessário relacionar objetos físicos a informações associadas a este objeto no mundo cibernético. Para isso, destaca-se o conceito e o uso do Digital Twin, que é uma representação virtual de objetos físicos. O Digital Twin possibilita a virtualização e centralização do controle no produto. Este estudo irá explorar uma metodologia de modelagem genérica e flexível para o Digital Twin usando a ferramenta AutomationML e propor uma arquitetura de comunicação para a troca de dados sob a ótica de Cyber Physical Systems. Com a implementação dessa metodologia, pretende-se validar o conceito proposto e oferecer um método de modelagem e configuração para obter dados, extrair conhecimento e proporcionar sistemas de visualização para os usuários. / With technological advances in the fields of hardware, microelectronics and computer systems, Cyber Physical Systems is a new concept that is gaining importance. This systems are integrations of computation, networking, and physical processes. Cyber Physical Systems are one of the pillars for the new industrial revolution, and it is marked by the complete decentralization of the control of production processes and, marked by a proliferation of interconnected intelligent devices throughout the production and logistics chain. Embedded computers and networks monitor and control the physical processes, with feedback loops where physical processes affect computations and vice versa. A industrial automation system, is an example of cyber physical systems where computational elements control and automate the execution of physical processes in industrial plants. Thus, it is clear the need to relate physical objects to information associated with this object in the cyber world. For this, this work pretends to use the concept of Digital Twin, that is a virtual representation of physical objects. Digital Twin enables the virtualization of physical components and descentralization of control. This study will explore a generic and flexible modeling methodology for Digital Twin using the AutomationML tool. Also this work proposes a communication architecture for the exchange of data from the perspective of Cyber Physical Systems. With the implementation of this methodology, we intend to validate the proposed concept and offer a modeling and configuration method to obtain data, extract knowledge and provide visualization systems for users.

Os avanços tecnológicos no setor de Tecnologia de Informações (TI) têm revolucionando a relação entre pessoas e o mundo dos negócios através da conectividade. Esta conectividade agora avança para comunicação entre coisas, dotadas de capacidade de processamento, através daquilo que é chamado de Internet das Coisas (IoT). A IoT avança também na área de manufatura, incluindo máquinas, dispositivos, sensores e o próprio produto em processamento, possibilitando uma comunicação autônoma entre máquinas (M2M), produtos e sistemas. Conectada através da internet, esta comunicação não se limita apenas à fábrica, mas integra toda a cadeia produtiva através de redes colaborativas. É neste contexto que se desenha a mudança radical de paradigma para o conceito de Indústria 4.0 (I4.0). Diante desta mudança, os atores que participam da Cadeia de Fornecimento de Sistemas para Automação da Manufatura (CFSAM) também precisam rever suas estratégias e estar atentos às novas oportunidades e ameaças que surgem neste novo cenário. O objetivo deste estudo é compreender, do ponto de vista de gestão, a reação das indústrias de manufatura no Brasil aos paradigmas da I4.0, e os potenciais impactos e oportunidades que a I4.0 traz para estes atores. Este trabalho mostra, através de Estudo de Múltiplos Casos em onze empresas brasileiras, a reação a esta mudança na automação da manufatura e analisa os potenciais impactos e oportunidades para estes atores. A escolha das unidades de estudo foi feita por conveniência e focada principalmente no grupo de provedores de tecnologia e infraestrutura para a implantação da plataforma I4.0. O resultado deste estudo revelou que há uma baixa compreensão do que realmente é a I4.0 entre as empresas de manufatura no Brasil e que ainda estão pouco engajadas na implantação prática dos conceitos da I4.0, adotando uma estratégia de seguidores de tecnologia. A contribuição deste trabalho inclui o esclarecimento do que realmente é a I4.0 fazendo distinção entre conceitos básicos da I4.0 e suas possibilidades tecnológicas. Inclui ainda a identificação das principais reações ao paradigma I4.0 e a análise de oportunidades para os atores da CFSAM com base nas mesmas. O estudo conclui que apesar da I4.0 não dispor comercialmente da padronização das duas tecnologias básicas (arquitetura orientada a serviços e semântica), que não permitem o aproveitamento pleno de suas potencialidades ao longo de todas as camadas da ISA-95, os conceitos já estão sendo praticados parcial e gradativamente e estão mais avançados nas atividades de negócios. / Advances in Information Technology (IT) have revolutionized the relationship between people and the business world through connectivity. This connectivity now advances to communication between things, endowed with processing capacity, through the Internet of Things (IoT). IoT also advances in the manufacturing industry, including machines, devices, sensors and the product in process, enabling autonomous communication between machines (M2M), products and systems. This communication of things through internet is not limited to the factory, but integrates the entire production chain through collaborative networks. It is in this context that the radical paradigm shift is devised for the concept of Industry 4.0 (I4.0). Facing this change, actors in the Manufacturing Automation Systems Supply Chain (CFSAM) also need to review their strategies and be aware of the new opportunities and threats that arise in this new scenario. The objective of this study is to understand, from the management point of view, the reaction of the manufacturing industries in Brazil to the paradigms of I4.0, and the potential impacts and opportunities that I4.0 brings to these actors. This work shows, through a Multiple Case Study, in eleven Brazilian companies, the reaction to this change in manufacturing automation and analyzes the potential impacts and opportunities for these actors. The study units were chosen purposefully and focused mainly on the group of technology and infrastructure providers for the implementation of the I4.0 platform. The result of this study revealed that there is a poor understanding of what is really the I4.0 among manufacturing companies in Brazil and that they are still little engaged in the practical implementation of the concepts of I4.0, adopting a strategy of technology followers. The contribution of this work includes the clarification of what really I4.0 is, distinguishing between basic concepts of I4.0 and its technological possibilities. It also includes the identification of the main reactions to the I4.0 paradigm and the analysis of opportunities for CFSAM actors based on them. The study concludes that although I4.0 does not commercially dispose of the standardization of the two basic technologies (service oriented architecture and semantics), which do not allow the full use of its potentialities across all ISA-95 layers, concepts already are being practiced partially and gradually, and are more advanced in the upper business layers.

Using the mobile phone to play games is very common today. The development is going forward, which has increased the demands from the users. Demands such as; increased visual appearance, faster feedback and improved interactive possibilities. To meet with these requirements a more powerful computer can facilitate the work for the mobile phone, for example rendering a game and sending the image data to the phone using wireless communication. The phone can then decode and display the image on its screen. The main object for this thesis is to implement a JPEG based decoder on Windows-based phones using C# and XNA 4.0. The decoder is based on an existing C++ implementation, which follows the JPEG standards. The need of an 8x8 matrix made the existing XNA matrix inapplicable, which lead to the use of own defined matrices instead. Even though it seemed promising, the matrices that were own defined were too slow and created a bottleneck in the decoding process. C# is not efficient at iterating through arrays with lots of data. An XNA based stream to decode the compressed image data made it possible to decode the image without using the matrices, and resolve the bottlenecks. The FromStream method is in some cases almost nine times faster than the own implementation, the bottlenecks are for the mostly found in the matrix calculations. When possible, use C++ when creating applications, it handles large amounts of data much faster than equal C# applications, unfortunately C++ will not work on all devices, such as Windows based phones.

The thesis reviews the current situation related to the Industry 4.0 and puts it into context. In the first part of the thesis, there is an introduction to the current economic situation and the major challenges. The concept and vision of Industry 4.0 is introduced together with the world's leading initiatives and examples of Industry 4.0 technologies in manufacturing processes presented by tech leaders. The thesis also includes examples of readiness models and simulated calculation ROCE. The finding of the thesis is that, although the very concept of Industry 4.0 is not well known, digitization and automation of production continues and both are considered a necessity. Interviews with experts from the business practice in the Czech Republic introduces key opportunities and challenges arising from new technologies and when they might become the new standard.

This thesis describes the implementation of a Digital Twin tied to Virtual Reality environment thatcould, by easy means be expanded to Augmented Reality-solution. The field is of interest due to thefact that movement into Industry 4.0 puts the traditional operator in a new seat of work. Previoushands-on tasks are replaced with system monitoring and supervision roles. New interconnectedindustrial hardware allows for extensive data collection, while interactive technology like VR/ARhelps monitoring live systems in completely new manners. An operator can overview and debugindustrial systems while not even being in close proximity of the physical system. This provides theopportunity to increase the level of system information presented to the operator. The Cyber PhysicalFactory created by Festo was targeted to be represented as a digital twin. The question asked: What arethe advantages and/or disadvantages of monitoring and troubleshooting a Festo CP-Factory by meansof a digital twin-driven visualization? proved to be extensive and the work included mapping ofimportant factory data and DRM-research to find visual improvements between the provided solutionsby Festo, and an implemented digital twin. The solution we produced focuses on overview anddebugging and it connects to OPC-servers on each mapped module of the Cyber Physical Factory andacquires the data. This data can then be used to expand, test and debug previous sessions. Each realimplementation of a factory has some type of logging of data, our solution allows visualization of thoselog entries as close to reality as possible, reducing the need to search databases for indications ofproblems. The Unity 3D created software also handles dynamic connections where the operator canmodify which nodes to connect to in an intuitive way, this enables our software to abstract and modifyinformation outside of the source code.

The new Health 4.0 concept brings the idea of combining modern technologies from field of science and technology with research in healthcare and medicine. This work realizes a system of secured actigraph data transfer and preprocessing based on the concept of Health 4.0. The system is successfully designed, implemented, tested and secured. With the help of a non-invasive method of monitoring the movement and temperature of the subject using the GENEActiv actigraph allows the system to securely transfer, process and evaluate the subject's sleep data using the machine learning algorithm XGBoost. The proposed system is in accordance with the valid law of the Czech Republic and meets legal requirements.

The diploma thesis deals with the production of gearbox shaft components using a CNC machine tool, shaft programming in Tebis 4.0 R8 software, Sinumerik SinuTrain 7.5, and manufacturing accuracy checking using 3D scanning technology, which allows you to compare the CAD model and the scan of the manufactured part.

Traditional value stream mapping (VSM) is used to identify non-value-added (NVA) activities in lean production systems. However, VSM lacks flexibility and responsiveness due to its static nature, which limits its usage in complex and flexible production environments. Furthermore, in a production system, the internal logistics and production value streams are interconnected to each other. Therefore, they face the challenges of same nature such as poor material handling, lack of flexibility and lack of responsiveness. These challenges are disseminated from poor integration of internal logistics and production value streams. The lack of flexibility in VSM is discussed in previous research works to some extent but its lack of responsiveness has not received much attention. Similarly, poor material handling and lack of flexibility of internal logistics system are discussed extensively in previous research works; however, the lack of responsiveness of internal logistics has received very little attention. Furthermore, poor integration of internal logistics and production value streams has not received any attention in the previous research works. To overcome aforementioned challenges, this thesis emphasizes on combining digital technologies (e.g., RFIDs, sensors, barcodes, simulation and intelligent interfaces) with VSM and internal logistics system. However, there is very limited research that addresses improvement potentials in VSM and internal logistics system through digitalization. Therefore, this thesis aims to fill this gap by investigating the improvement potentials of digitalization for both value stream mapping and the internal logistics. In this regard, firstly the core challenges in value stream mapping and internal logistics system are identified. As a second step, possible improvement opportunities are identified in these two areas to increase the productivity of the production system through the adoption of digitalization. A qualitative research approach is performed in data collection methods such as observations and interviews. Furthermore, an empirical study is performed to provide an overview of the current production value streams and internal logistics system at a case company. The study concludes that the combination of VSM with simulation and real time data collection is vital to increase the flexibility and responsiveness of VSM. The improved flexibility and responsiveness of VSM will make it efficient to identify non-value-added activities. It is also discussed and demonstrated that the integration of internal logistics and production value streams can be improved through implementation of digital technologies such as AGVs, RFIDs/barcodes, IoT, data analytics and intelligent algorithms in the context of Industry 4.0. The improved integration of internal logistics and production value streams can improve the productivity of the production system to a large extent.