FLEXIBLE AUTOMATION IS TUNING YOUR PRODUCTION

FLEXIBLE AUTOMATION IS TUNING

YOUR PRODUCTION

Prof. Johannes Cottyn, Coordinator Industrial Autom ation, XiaK-UGent

Donderdag 16 november 2017

ISyE - INDUSTRIAL SYSTEMS ENGINEERING

XiaK - CENTER OF EXCELLENCE IN INDUSTRIAL AUTOMATION


CENTER OF EXCELLENCE IN INDUSTRIAL AUTOMATION

Graaf Karel de Goedelaan 5, 8500 Kortrijkwww.XiaK.be

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CORE RESEARCH LAB - CLUSTER FLEXIBLE ASSEMBLY

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Smart & Agile Assembly lab

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- Market evolution towards mass customization- Understanding flexibility- Flexible automation concept- Enabling technologies- How do you best approach the flexibility challenge?- Related projects

PRESENTATION OUTLINE

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Trend towards a high level of product variety introduces manufacturingchallenges (switch between products, new and more variants, …) whichdirectly impact the manufacturing systems design and operation to cope withproduct changes efficiently and cost effectively.

A high level of flexibility and reconfigurability of the wor kplace isneeded.

MARKET EVOLUTION

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Trend towards a high level of product variety introduces manufacturingchallenges (switch between products, new and more variants, …) whichdirectly impact the manufacturing systems design and operation to cope withproduct changes efficiently and cost effectively.

A high level of flexibility and reconfigurability of the wor kplace isneeded.

MARKET EVOLUTION

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MARKET EVOLUTION

Source: Jack Meredith

New vs. traditional approach towards cost-effective production

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MARKET EVOLUTIONShift towards mass customization

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Alternation - Can I replace a given component with

another component that has a different structure?

Orientation - Can I reposition a module in 3D space,

while maintaining the interface with another

module?

Placement - Which physical locations can I move a

given module to?

Connectivity - For a given module, which other

modules can I interface with?

Dependency - For a given module, which modules

are necessary to precede or follow?

Adaptability - To what degree should we allow re-

configuration after the initial configuration?

Uniformity - Which pieces should be pre-built and

standardized with limitations on modularity so that

the end product can retain a predictable form?

Modularize your People, Processes and Products

Source: Jordan Reynolds @viewpoints.io

MARKET EVOLUTION

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UNDERSTANDING FLEXIBILITY

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Source: Upton (1994)

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FLEXIBILITY

PR

OD

UC

TIO

N C

OS

T

Fully automated assembly

Craftsmanship

Flexible assembly cell

Mass customization at cost of mass production


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What-if scenarios related to change management

- Product family extension- Multiple product families- New products- Production volume increase- New operator- New manufacturing method- New materials- Rush order initiation- Order changes- …

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“Flexibility is the ability to change or react with little penalty in time, effort, cost or performance.” (Upton, 1994)

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Flexibility dimensions

�Volume Flexibility�Machine Flexibility�Product Flexibility�Program Flexibility� Labour Flexibility�Mix Flexibility�Routing Flexibility�Design-change Flexibility�Material-handling Flexibility�Operation Flexibility�Process Flexibility

Potential versus demonstrated flexibility

MOBILITY

UNIFORMITY

RANGE

MOBILITY

UNIFORMITY

RANGE


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But flexibility is a subjectiveand company-specificrequirement or measure …

… and totalflexibility is most probablyoverkill.

Manual labour

Programmableautomation

Fixed automation

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FLEXIBLE AUTOMATION CONCEPT

Flexibleautomation


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De Milwaukee-Matic-II (1959)

One of the first “flexible”machines: CNC withautomatic tool change

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Flexible manufacturing systems

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Automatic loading &unloading by mobile

units

The operator as a knowledge worker

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Matrix production

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Strong technology evolution

The robot as a flexible tool

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2D/3D Vision

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Wireless identification and localisation

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INFORMATION INTEGRATION

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INDUSTRY 4.0

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INDUSTRY 4.0

Interconnected resources -> Distributed intelligence -> Local autonomy

Basic automation Principle (USA)1. Understand/rethink your processes

� Input/output analysis� Value chain analysis� Charting techniques and mathematical modelling

2. Simplify your processes� Reduce unnecessary steps and moves

3. (Re)Automate your processes with flexibility in mind

IGNORE THE TECHNOLOGY PUSH AT FIRST

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HOW DO YOU BEST APPROACH THEFLEXIBILITY CHALLENGE ?

THEN SELECT APPROPRIATE TECHNOLOGY

10 strategies for Automation and Production Systems

1. Specialization of operations2. Combined operations3. Simultaneous operations4. Integration of operations5. Increased flexibility6. Improved material handling and storage7. On-line inspection8. Process control and optimization9. Plant operations control10. Computer-integrated manufacturing (CIM)

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HOW DO YOU BEST APPROACH THEFLEXIBILITY CHALLENGE ?

VISiv – FLEXIBELE AUTOMATISERING

Doel

Beschikbare en voor een KMO inzetbare tools en innov aties mbt flexibele automatisering laten doorstromen naar de innovatiev olgers

Aanpak

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RELATED PROJECTS

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RELATED PROJECTS


RELATED PROJECTS

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Create and filter assembly information based on relevance by using a context-aware system

Experimental validation of flexible assembly architectures

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RELATED PROJECTS

Capability-based task allocation in human-robot collaboration

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RELATED PROJECTS

More information

Prof. Johannes CottynXiaK-UGent

[email protected]

+32 476 51 90 70

Jan KempeneersSirris

[email protected]

+32 498 91 94 85

Alain Wayenberg.AGORIA

[email protected]

+32 475 80 88 99

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RELATED PROJECTS


QUESTIONS?

Thank you for your attention!

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Documents

FLEXIBLE AUTOMATION IS TUNING YOUR PRODUCTION