A proactive material handling method for CPS enabled shop-floor |
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| Affiliation: | 1. Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University, 127 West Youyi Road, Beilin District, Xi''an, Shaanxi, 710072, P.R. China;2. Department of Mechanical and Energy Engineering, Southern University of Science and Technology, 1088 Xueyuan Blvd., Nanshan District, Shenzhen, Guangdong, 518055, P.R. China;3. Department of Industrial and Manufacturing Systems Engineering, The University of Hong Kong, Pokfulam Road, Hong Kong, China;1. School of Automation Science and Electrical Engineering, and Beijing Advanced Innovation Center for Big Data-based Precision Medicine, Beihang University, Beijing 100191, China.;2. School of Automation Science and Electrical Engineering, Beihang University, Beijing 100191, China.;1. Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University, Xi''an 710072, China;2. College of Mechanical Engineering, Xi''an University of Science and Technology, Xi''an 710054, China;3. Department of Industrial and Manufacturing Systems Engineering, The University of Hong Kong, Hong Kong;1. Faculty of Mechanical Engineering, Institute of Technological Systems of Information, Lublin University of Technology, ul. Nadbystrzycka 36, Poland;2. Faculty of Management, Department of Enterprise Organization, Lublin University of Technology, ul. Nadbystrzycka 38, Poland;1. Department of Industrial Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xi''an, Shaanxi 710072, P.R. China;2. Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen, Guangdong 518055, P.R. China |
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| Abstract: | Cyber physical system (CPS) enables companies to keep high traceability and controllability in manufacturing for better quality and improved productivity. However, several challenges including excessively long waiting time and a serious waste of energy still exist on the shop-floor where limited buffer exists for each machine (e.g., shop-floor that manufactures large-size products). The production logistics tasks are released after work-in-processes (WIPs) are processed, and the machines will be occupied before trolleys arrival when using passive material handling strategy. To address this issue, a proactive material handling method for CPS enabled shop-floor (CPS-PMH) is proposed. Firstly, the manufacturing resources (machines and trolleys) are made smart by applying CPS technologies so that they are able to sense, act, interact and behave within a smart environment. Secondly, a shop-floor digital twin model is created, aiming to reflect their status just like real-life objects, and key production performance indicators can be analysed timely. Then, a time-weighted multiple linear regression method (TWMLR) is proposed to forecast the remaining processing time of WIPs. A proactive material handling model is designed to allocate smart trolleys optimally. Finally, a case study from Southern China is used to validate the proposed method and results show that the proposed CPS-PMH can largely reduce the total non-value-added energy consumption of manufacturing resources and optimize the routes of smart trolleys. |
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