SIMTER - A Joint Simulation Tool for Production Development

2008

Production development can conflict with production ergonomics and management of environmental impacts. In this paper, we describe how ergonomics can be assessed in production system design by means of a joint simulation tool. The tool enables ergonomics and environmental impacts assessment in conjunction with production process development. The ergonomics sub-tool is based on a digital human model, which has been improved by introducing an updated data measurement system and neural network processing and inference functionality. The results will extend the new simulation modelling capabilities of the existing digital human model by increasing the motion prediction accuracy and providing freedom to model a multitude of task-related motions in a realistic way.

2004

Computer based discrete event simulation (DES) is one of the most commonly used aids for the design of automotive manufacturing systems. However, DES tools represent machines in extensive detail, while only representing workers as simple resources. This presents a problem when modelling systems with a highly manual work content, such as an assembly line. This paper describes research at Cranfield University, in collaboration with the Ford Motor Company, founded on the assumption that human variation is the cause of a large percentage of the disparity between simulation predictions and real world performance. The research aims to improve the accuracy and reliability of simulation prediction by including models of human factors.

2021

This paper describes two approaches for integrating human factors into discrete event simulations of production systems. In the first, biomechanical loading information was integrated with a simulation model in a car dismantling operation. In the second study, the productivity sensitivity of three systems with varying parallelisation was tested with respect to a) allowing operators to take breaks ‘as desired’, and b) having ‘reduced capacity’ operators at work. Both methods provided insight into design options that gave superior performance with improved ergonomics. Such ‘virtual ergonomics’ approaches can help establish boundary crossing discussions to support ergonomics application in early design stages.

InImpact: The Journal of Innovation Impact, 2016

Recently, a paradigm called Industry 4.0 has brought important concepts that can contribute to environmental, economic and societal sustainability. Technologies like cyber-physical systems, cloud computing or visual analytics may be linked to bring transparency to industry increasing sustainability. However, to implement those technologies in machines and factories shop floors, some important subjects like sensor technologies, data gathering systems, virtual simulation or human factor have to be outlined. As a result of an initiative towards Industry 4.0, use examples of the abovementioned subjects, based on analysis over relevant industrial companies, have brought up difficulties related with the possibilities to implement the appropriate infrastructure to push in the so-called industry paradigm shift. As preliminary result of this initiatives, recommendations based on Etxe-Tar own experience, are given in order to get a clear view of the opportunities to achieve an optimum impleme...

2009

Handling flexibility in an ever changing manufacturing environment is one of the key challenges for a successful industry. By using tools for virtual manufacturing, industries can analyze and predict outcomes of changes before taking action to change the real manufacturing systems. This paper describes a simulation tool that can be used to study the effect of level of automation issues on the design of manufacturing systems, including their effect on the overall system performance, ergonomics, environment, and economic measures. Determining a suitable level of automation can provide a manufacturing system with the flexibility needed to respond to the unpredictable events that occur in factory systems such as machine failures, lack of quality, lack of materials, lack of resources, etc. In addition, this tool is designed to use emerging simulation standards, allowing it to provide a neutral interface for both upstream and downstream data sources.

Robotics and Computer-Integrated Manufacturing, 2019

Manufacturing ergonomics refers to the application of ergonomic principles and human factors analysis to the design of manufacturing tasks with the final aim to optimize the workers' wellbeing and guarantee the expected process performance. Traditional design approaches are based on the observation of individual workers performing their jobs, the detection of unnatural postures (e.g., bending, twisting, overextending, rotating), and the definition of late corrective actions according to ergonomic guidelines. Recently, computerintegrated simulations based on virtual prototypes and digital human models (DHMs) can be used to assess manufacturing ergonomics on virtual manikins operating in digital workplaces. Such simulations allow validating different design alternatives and optimizing the workstation design before the creation, and pave the way to a new approach to manufacturing system design. The present paper aims at comparing different computer-integrated setups to support the design of human-centred manufacturing workstations. It defines a protocol analysis to support workstation design by analysing both physical and cognitive aspects, and applies the protocol within different digital setups. In particular, the study investigates a 2D desktop setup using standardized DHMs and a 3D immersive mixed reality setup based on motion capture of real workers' acting into a mixed environment, comparing them with the traditional approach. An industrial case study focusing on design optimization of a manufacturing workstation in the energy industry is used to test the effectiveness of the two digital setups for the definition of redesign actions.

Applied Computer Science

Sustainable development is an very important idea nowadays and it influences on many factors. It is very important to focus on the goals of sustainable development and implement them both in industry and in everyday life. The aim of the article is to analyse the impact of implementing an automatic conveyor belt transport system between the stands of an exemplary assembly line on sustainable development in economic and environmental terms. The analyzed production process consists of one production line with six assembly stations. The efficiency of individual design solutions and electricity consumption were adopted as the evaluation criteria. To compare the two processes, a simulation analysis was performed in the Plant Simulation program. First chapter is the introduction to the article. The second chapter describes the current applications of simulation tests. The third chapter describes the production system that is improved by adding conveyors. The next chapter compares the proce...

2012

This article deals with the propositon of a new generation of our industrial factories. The integration of the most resulting advanced techniques will lead to a change of paradigm in the definition of new efficient production systems. In this article, we develop the main ideas of the project ARTUR. The core is to build new and executable strategies for embedding both current and new simulation capabilities into factory material processing and product evaluation; thereby creating a human friendly "robotic" factory environment where online simulation can control both process and product performance in real-time.

Sustainability, 2022

At the current worrisome rate of global consumption, the linear economy model of producing goods, using them, and then disposing of them with no thought of the environmental, social, or economic consequences, is unsustainable and points to a deeply flawed manufacturing framework. Circular economy (CE) is presented as an alternative framework to address the management of emissions, scarcity of resources, and economic sustainability such that the resources are kept ‘in the loop’. In the context of manufacturing supply chains (SCs), the 6R’s of rethink, refuse, reduce, reuse, repair, and recycle have been proposed in line with the achievement of targeted net-zero emissions. In order to bring that about, the required changes in the framework for assessing the state of manufacturing SCs with regard to sustainability are indispensable. Verifiable and empirical model-based approaches such as modeling and simulation (M&S) techniques find pronounced use in realizing the ideal of CE. The simulation models find extensive use across various aspects of SCs, including analysis of the impacts, and support for optimal re-design and operation. Using the PRISMA framework to sift through published research, as gathered from SCOPUS, this review is based on 202 research papers spanning from 2015 to the present. This review provides an overview of the simulation tools being put to use in the context of sustainability in the manufacturing SCs, such that various aspects and contours of the collected research articles spanning from 2015 to the present, are highlighted. This article focuses on the three major simulation techniques in the literature, namely, Discrete Event Simulation (DES), Agent-Based Simulation (ABS), and System Dynamics (SD). With regards to their application in manufacturing SCs, each modeling technique has its pros and its cons which are evinced in case of data requirement, model magnification, model resolution, and environment interaction, among others. These limitations are remedied through use of hybrids wherein two or more than two modeling techniques are applied for the desired results. The article also indicates various open-source software solutions that are being employed in research and the industry. This article, in essence, has three objectives. First to present to the prospective researchers, the current state of research, the concerns that have been presented in the field of sustainability modeling, and how they have been resolved. Secondly, it serves as a comprehensive bibliography of peer-reviewed research published from 2015–2022 and, finally, indicating the limitations of the techniques with regards to sustainability assessment. The article also indicates the necessity of a new M&S framework and its prerequisites.

2010

Sustainability has become a very significant research topic, it impacts many different manufacturing industries. To achieve sustainable manufacturing, designing manufacturing systems that have less negative impact on the environment is critical. Modeling and Simulation (M&S) is an essential ingredient for success of sustainable manufacturing through its ability to predict the effect of implementing certain facility, process, and product actions. M&S for sustainable manufacturing requires the exchange of information with a variety of manufacturing systems, applications, and databases. M&S also provides appropriate models and methods to tailor algorithms for performing accurate transformations of the data. This paper introduces a methodology to support interoperability among simulation tools and other manufacturing systems that support sustainability. The methodology describes how to collect and process the identified data in order to make it reusable for M&S studies to achieve sustainable manufacturing. Three potential case studies are identified and discussed as a scope for future work.

Strojniški vestnik – Journal of Mechanical Engineering, 2012

Production systems that are by their structure designed according to principles of group technology must, despite their perfection, rapidly adapt to changes in surroundings and engage in a battle with their market rivals. First of all, they must get closer to customers and suppliers, representing one of first principles of lean philosophy. It is one of the ways to successfully valorise comparative values with competition, despite its internal restructuring. This paper presents the influence of certain lean tools as well as application of statistical analyses, simulation and graphics tools for achieving greater effectiveness and efficiency of production systems. Application or integration of these tools enables shortening of the production cycle, reduces the degree of complexity of material flows, reduces the supplies and expenditure of energy resources while it creates an increased degree of functionality of the organisation, utilization of workspace etc. Combination of different tools presented in this paper can valorise new technological, organisational and informational achievements in production that will secure an even better position on the market for industrial systems.

American Journal of Industrial Medicine, 1999

2013

New standards on work organization in the automotive industry, require a new concept of design methods: the human centred process. In Fiat Group Automobiles (FGA) the “Digital Manufacturing” (DM) project has started with the goal to create simulation tools and methods to improve the design of new cars’manufacturing processes giving a special attention to manual operations. The DM approach is based on a detailed “virtual plant” where virtual mannequins interact with digital models of car’s components, equipment, containers, etc. in order to simulate and improve working conditions with many benefits on ergonomics, safety, final product quality, work organization and general production costs. The key factor for this approach is that with DM methodologies, designers and engineers have, already in the design phase of a new car’s manufacturing process, a preliminary estimation of the numerical indices used in the plants to check if workcells are compliant to international standards and re...

2004

The research described in this thesis is concerned with human performance modelling as an aid in the process of manufacturing systems design and re-design. Most manufacturing systems are highly complex constructs and their behaviour is of a dynamic and stochastic nature. They have to be constantly designed and re-designed as organisations are continually being pressured to change their manufacturing facilities, technologies, methods, people and products. All design methods have some form of evaluation where discrete event simulation models are usually used to undertake a comparative analysis of different system designs. Within these discrete event simulation models it is common practice to represent workers as simple resources, often using deterministic performance values. Conversely, the work measurement literature indicates that worker task performance varies between different workers carrying out the same task and moreover for the same worker when repeating a task. The current ap...

Sustainable Development, 2006

This paper seeks to establish a practical definition of the term sustainable development, and relate it to a company's performance. Simulation and modelling tools are applied to gain a holistic view of the activities associated with a metal casting company, which includes production, transportation and recycling. In the simulation model, four case scenarios are investigated, including the comparison of original and re-designed cast products of 20% runner weight reduction, and the recycling of scrap metal at two different remelters. The focus of the case study is to monitor the amount of scrap, dross, carbon dioxide emissions from both energy consumption and transportation, productivity and costs during the metal material cycle. From the case study, various 'sustainability indicators' are highlighted.