Examensarbetet är utfört i samarbete med ett företag. Målen är att ta fram en användarvänlig digital modell av verkstaden, arbeta fram tre förbättringsförslag på layouter med omplaceringar av utrustning och maskiner. Förbättringar skall föreslås inom hållbarhetsaspektern aekonomi, social och miljö. För att nå målet att skapa en digital verkstadslayout har projektgruppen mätt upp hela fabriken med hjälp av laseravståndsmätare, då exakta ritningar saknades. Vid besök i fabriken kunde all nödvändig information mätas upp för skapandet av den digitala fabriksmodellen. Besöken vid fabriken har gett inspiration till nya layoutförslag och förbättringar. Observationer och intervjuer med personal har gjorts. Produktionsflöden och processer för de största produktgrupperna har kartlagts. Litteratur som berör produktionsteknik, arbetsmiljö och andra relevanta områden har studerats. Projektgruppen har utfört ljusmätning i fabriken. Belysningen var tillfredställande. Förslag på bullerdämpande åtgärder har framarbetats. Den digitala fabriksmodellen har skapats i programmet Microsoft Visio efter urval mot kravspecifikation från företaget samt KTHs programvaruutbud. De tre layoutförslag som tagits fram har värderats och ställts mot varandra i ett värderingsschema för att kunna bestämma ett slutgiltigt förslag till ny verkstadslayout. Layoutförslag 2 fick högst poäng i utvärderingen där lägre kostnader, förbättrat flöde samt förbättrad tillgång för truck var de bidragande faktorerna. Förslaget innebär kort att centerlesslipmaskinerna flyttas till den yta som renoverats, en svarv flyttas för att ge plats åt truckar, stationen för kvalitetskontroll flyttas och mer plats frigörs för lastpallar. / This thesis is done in collaboration with a company. The goals are to develop a userfriendly digital model of the workshop, to suggest three improved layout proposals with repositioning of equipment and machines. Improvements should also be proposed in the sustainability aspects of economy, social and environmental. To achieve the goal of creating a digital workshop layout, the project team measured the entire factory with the aid of laser rangefinders, because exact drawings were missing. When visiting the factory, all the necessary information could be measured for the creation of the digital factory model. The visits to the factory have provided inspiration for new layout suggestions and improvements. Observations and interviews with staff have been made. Production flows and processes for the largest product groups have been mapped. Literature relating to production technology, work environment and other relevant areas has been studied. The project group has carried out light measurement in the factory. The lighting was satisfactory. Noise reduction measures have been proposed. The digital factory model has been created in the Microsoft Visio software after evaluation based on company specification and KTH's software. The three layout proposals that have been developed have been evaluated and compared to each other in an evaluationscheme to determine a final proposal for a new workshop layout. Layout proposal 2 received the highest score in the evaluation, where lower costs, improved flow and improved access for forklifts were the contributing factors. In short the proposal suggest that the centerless grinders are moved to the area that has been renovated, a lathe is moved to accommodate forklifts, the quality control station is movedand more space is freed up for pallets.

Planning of the optimised production system is an intricate task. The reason behind this is changing demand, variations, and other disturbances. The main purpose of this study the current performance in the existing production system and provide recommendations for optimising the production in order to accommodate a new product. Since, the addition of new products may lead to bottlenecks in the flow which affects the output performance. The bottlenecks would lead to ineffective results, while tying up the capital in the production downstream as inventory gets stagnated in the assembly lines. The performance evaluation is a tedious process however, the study probes into the use of flow simulation tool to analyse the production performance. In this thesis work, Discrete Event Simulation (DES) is utilised as a tool to examine the performance of the production systems and to determine the cost consuming areas. To achieve that, the production system is replicated as a functional model into the DES system with the appropriate logics and parameters, with the thorough understanding of the existing workflows. To supplement it, the data from the orders, resources, and parts are charted.In the later part, production flow is analysed with the additions of determined improvisations to understand the impact on the output. Later, investigations are performed to identify the challenges and applicable changes required to meet future output. As an outcome, the production system is restructured and optimised, thus getting an overview of the future production set up as a digital factory layout. / Planering av det optimerade produktionssystemet är en invecklad uppgift. Orsaken bakom detta är förändrad efterfrågan, variationer och andra störningar. Huvudsyftet med denna studie är den nuvarande prestandan i det befintliga produktionssystemet och ger rekommendationer för att optimera produktionen för att rymma en ny produkt. Eftersom tillägg av nya produkter kan leda till flaskhalsar i flödet som påverkar uteffekten. Flaskhalsarna skulle leda till ineffektiva resultat, samtidigt som kapitalet i produktionen binds nedströms när lagret stagnerar i löpande band. Prestationsutvärderingen är en tråkig process, men studien undersöker användningen av flödessimuleringsverktyg för att analysera produktionsprestanda. I detta avhandlingsarbete används Discrete Event Simulation (DES) som ett verktyg för att undersöka produktionssystemens prestanda och bestämma de kostnadskrävande områdena. För att uppnå det replikeras produktionssystemet som en funktionell modell i DES -systemet med lämpliga logiker och parametrar, med en grundlig förståelse av de befintliga arbetsflödena. För att komplettera det kartläggs data från order, resurser och delar. I den senare delen analyseras produktionsflödet med tillägg av bestämda improvisationer för att förstå effekten på produktionen. Senare utförs undersökningar för att identifiera de utmaningar och tillämpliga förändringar som krävs för att möta framtida produktion. Som ett resultat omstruktureras och optimeras produktionssystemet och får därmed en överblick över den framtida produktionsuppsättningen som en digital fabrikslayout.

Die Werkzeuge und Methoden der Digitalen Fabrik sind bereits seit vielen Jahren in den einzelnen Phasen des Produktentstehungsprozess im Einsatz. Sie werden dabei u.a. auch zur Planung und Gestaltung menschlicher Arbeit eingesetzt. Mit Hilfe digitaler Menschmodelle können Aspekte des Arbeitsablaufs, der Zeitwirtschaft und der Arbeitsplatzgestaltung bereits frühzeitig untersucht und verbessert werden. Die Entwicklung effizienter Simulationssysteme steht auf diesem Gebiet jedoch insbesondere im Vergleich mit anderen Bereichen, wie beispielsweise der Robotersimulation, noch am Anfang. Die vorliegende Arbeit beschäftigt sich zunächst mit der Analyse bereits existierender Menschmodell-Simulationssysteme. Aus den identifizierten Schwachstellen dieser Systeme und weiteren durch Experteninterviews sowie Literaturrecherche gewonnenen Erkenntnissen wird eine Anforderungsliste erstellt, die als Grundlage für die Konzeption und Umsetzung eines innovativen Ansatzes zur Ansteuerung und Bewegungsgenerierung für digitale Menschmodelle dient. Diese neuartige Methodik wird schließlich in ein Simulations-Softwaresystem implementiert und anschließend im Praxis-Einsatz evaluiert. Es konnte gezeigt werden, dass das neue System die Mängel der vorhandenen Systeme behebt und somit als Werkzeug zur effizienten Planung, Gestaltung und Bewertung menschlicher Arbeit geeignet ist. / For many years the tools and methods of the Digital Factory are used in various stages of the product development process. They are also used for the planning and design of human work, which is typically done using a digital human model. Aspects of the workflow, time management and workplace design can be investigated and improved upon in the early stages of the product development process using digital human models. But in this field the development of efficient simulation systems is not matured enough compared to other fields for e.g. robot simulation. This paper starts with an analysis of existing simulation systems for digital human models. Afterwards a requirements list is created from the identified weaknesses of these systems, knowledge gained through expert interviews and literature reviews. These requirements serve as the base for the design and implementation of an innovative approach for motion generation and control of digital human models. This new methodology is then implemented as a simulation software system and evaluated in practical applications. The developed system fixed the shortcomings of existing systems and thus it is a suitable tool for efficient planning, design and evaluation of human labor.

拜科技進步之賜，虛擬模擬技術對於未來事件的預測準確度越來越高，而近年來發展出來「數位工廠」即是其中一個典型的工廠應用，因為「數位工廠」可利用三維立體模擬技術來進行工廠製程之設計與開發，可於投資決策前事先瞭解製程與成本之關係，藉此降低企業經營風險。 決策品質對於企業非常重要，關鍵的因素在於正確資訊及經理人的經驗，而經驗判斷也必須基於資訊情報之前提上，也就是說正確及高品質的資訊情報可提升決策之品質，而「數位工廠」則可事先模擬工廠之佈局及流程，提前獲得未來製造的情報，故決策之品質也將因此而提升。 近來許多國內外知名汽車企業紛紛導入「數位工廠」來提升製造之效率，例如日本豐田、德國賓士集團、中華汽車等領先之企業，但導入「數位工廠」絕不只是購買虛擬模擬軟體或是技術即可達成，其中必定包含許多的流程整合及應用過程，這樣才能使預測技術與決策品質一致化。 本研究以個案研究方法，透過觀察分析與訪談的方式，針對目前台灣有導入「數位工廠」的公司進行實證研究，但因台灣導入此類系統之研究樣本較少，故本研究將參考國外之期刊及技術文件，並實地訪問中華汽車，藉此討論汽車產業導入「數位工廠」成功關鍵因素與效益。 【關鍵詞彙】 數位工廠。 / A Study of the Critical Success Factors and Benefits of Implementing the Digital Factory System in Automotive industry － Example of China Motor Company. Thanks to the advance of technology. Virtual simulation technology is getting more accurate prediction of future events. In the recent years, the digital factory is one of the typical plant applications, because the digital factory can use the three-dimensional simulation for plant design, layout, and build up. Manager can check the factory process and cost in virtual simulation environment before company make investment decisions. And they also can reduce the risk by use virtual prediction result. It’s very important for businesses decision making. The key factors for making the right decision are the correct information and the manager's experience. All judgments must be based on the premise of right information, because the right information will improve the quality of decision-making. Recently, many well-known automobile companies develop the digital factory system to improve their manufacturing efficiency, such as Toyota, Mercedes group in Germany, the China motor in Taiwan. But building the digital factory is not just to purchase the virtual simulation software. It will contain the process integration and application process in order to make the good prediction for high quality of decision-making In this study, I use the case study for analysis, interview and observing of China Motor Company. Because the study sample is too small in Taiwan, this study will refer to foreign of journals and technical documents. And I also use field study of China Motor Company for discuss the critical success factors and benefits of digital factory. Key words: digital factory.

This master´s thesis describes the design and realization of the simulation in program Tecnomatix Process Simulate. The thesis deals with the creation of a simulated assembly line of gluing a protective glass to the headlight. For this operation is using four stationary robotic arms. Created simulation behaves like a real robotic assembly line. In simulation is implemented several input sensors, robotic operations and conveyer structure. The control is done with PLC programmed, designed in TIA portal 14. Thesis includes a detailed description of the design whole simulation, together with the Tecnomatix Process Simulate environment. This software offer a many external commissioning and three bigger were tested, two kinds of OPC servers and PLCSIM Advanced. The conclusion of the diploma thesis describes the way of simulation control with visualization of whole process cell.

This master‘s thesis is about how to create a virtual model of a sorting line by using Tecnomatix Process Simulate program. In this master‘s thesis is describe non-robotics operation as a controlling conveyor, material flow, working with sensors and simulaton of manufactory process. In the second part of my master’s thesis I realise virtual commissioning for this model of sorting line. I made program for real PLC and conected with model of sorting line via OPC server. I made SCADA aplication for users too. This model will be used in lessons and students will program PLC for controlling. In master’s thesis I explain, how to work in simulation environment Tecnomatix Process Simulate too.

Die Werkzeuge und Methoden der Digitalen Fabrik sind bereits seit vielen Jahren in den einzelnen Phasen des Produktentstehungsprozess im Einsatz. Sie werden dabei u.a. auch zur Planung und Gestaltung menschlicher Arbeit eingesetzt. Mit Hilfe digitaler Menschmodelle können Aspekte des Arbeitsablaufs, der Zeitwirtschaft und der Arbeitsplatzgestaltung bereits frühzeitig untersucht und verbessert werden. Die Entwicklung effizienter Simulationssysteme steht auf diesem Gebiet jedoch insbesondere im Vergleich mit anderen Bereichen, wie beispielsweise der Robotersimulation, noch am Anfang. Die vorliegende Arbeit beschäftigt sich zunächst mit der Analyse bereits existierender Menschmodell-Simulationssysteme. Aus den identifizierten Schwachstellen dieser Systeme und weiteren durch Experteninterviews sowie Literaturrecherche gewonnenen Erkenntnissen wird eine Anforderungsliste erstellt, die als Grundlage für die Konzeption und Umsetzung eines innovativen Ansatzes zur Ansteuerung und Bewegungsgenerierung für digitale Menschmodelle dient. Diese neuartige Methodik wird schließlich in ein Simulations-Softwaresystem implementiert und anschließend im Praxis-Einsatz evaluiert. Es konnte gezeigt werden, dass das neue System die Mängel der vorhandenen Systeme behebt und somit als Werkzeug zur effizienten Planung, Gestaltung und Bewertung menschlicher Arbeit geeignet ist. / For many years the tools and methods of the Digital Factory are used in various stages of the product development process. They are also used for the planning and design of human work, which is typically done using a digital human model. Aspects of the workflow, time management and workplace design can be investigated and improved upon in the early stages of the product development process using digital human models. But in this field the development of efficient simulation systems is not matured enough compared to other fields for e.g. robot simulation. This paper starts with an analysis of existing simulation systems for digital human models. Afterwards a requirements list is created from the identified weaknesses of these systems, knowledge gained through expert interviews and literature reviews. These requirements serve as the base for the design and implementation of an innovative approach for motion generation and control of digital human models. This new methodology is then implemented as a simulation software system and evaluated in practical applications. The developed system fixed the shortcomings of existing systems and thus it is a suitable tool for efficient planning, design and evaluation of human labor.

Virtual Reality (VR) is a tool with great potential and is under constant development for use in new fields. The project Fabriksvisualisering (Factory Visualization), has within the digital factory field, developed a tool for companies to build their factories in Unreal Engine (UE) and VR. The tool gives companies the opportunity to test their factory layouts, before implementing in the real world, to avoid costly mistakes. The following report examines possibilities for users to simulate and visualize their factory workflows as a part of the project Fabriksvisualisering. To achieve this, different solutions for visualizing the flow of products, staff and vehicles have been explored. User tests were carried out to test how an effect from UE can be used to visualize a flow of products in VR. The result gives users the opportunity to experience the interactions with factory workflows and visualize how they flow in VR.  The project resulted in two options that visualizes product flow and four options that visualizes workflow. Out of these six solutions, three were chosen and implemented to the project Fabriksvisualisering. These solutions are based on the construction of splines and include both alternatives for product flows and one alternative for workflows. The selection was based on functionality, user-friendliness and how realistic the outcome is. The result gives users the opportunity to experience the interactions with factory workflows and visualize how they flow in VR.  The conclusion is that there are several ways to visualize four out of seven factory workflows. The flows that are possible to visualize are material handling of raw materials, semi-finished and finished products, as well as the transportation and movements of workforce. This can be visualized with the help of AI, a robot system within UE, the construction of splines and Niagara systems connected to splines.

Industrial revolutions bring dynamic change to industry through major technological advances (Freeman & Louca, 2002). People and companies must take advantage of industrial revolutions in order to reap its benefits (Bruland & Smith, 2013). Currently, the 4th industrial revolution, industry is transforming advanced manufacturing and engineering capabilities through digital transformation. Company X’s production system was investigated in the research. Detailed evaluation the production process revealed bottlenecks and inefficiency (Melton, 2005). Using the Digital Twin and Discrete Event Factory Simulation, the researcher gathered factory and production input data to simulate the process and provide a system level, holistic view of Company X’s production system to show how factory simulation enables process improvement. The National Academy of Engineering supports Discrete Event Factory Simulation as advancing Personalized Learning through its ability to meet the unique problem solving needs of engineering and manufacturing process through advanced simulation technology (National Academy of Engineering, 2018). The directed project applied two process optimization experiments to the production system through the simulation tool, 3DExperience wiht the DELMIA application from Dassualt Systemes (Dassault, 2018). The experiment resulted in a 10% improvement in production time and a 10% reduction in labor costs due to the optimization