Knowledge-Based Virtual Modeling and Simulation of Manufacturing Processes for Industry 4.0

Abstract

Industry 4.0 aims at providing a digital representation of a production landscape, but the challenges in building, maintaining, optimizing, and evolving digital models in inter-organizational production chains have not been identified yet in a systematic manner. In this paper, various Industry 4.0 research and technical challenges are addressed, and their present scenario is discussed. Moreover, in this article, the novel concept of developing experience-based virtual models of engineering entities, process, and the factory is presented. These models of production units, processes, and procedures are accomplished by virtual engineering object (VEO), virtual engineering process (VEP), and virtual engineering factory (VEF), using the knowledge representation technique of Decisional DNA. This blend of the virtual and physical domains permits monitoring of systems and analysis of data to foresee problems before they occur, develop new opportunities, prevent downtime, and even plan for the future by using simulations. Furthermore, the proposed virtual model concept not only has the capability of Query Processing and Data Integration for Industrial Data but also real-time visualization of data stream processing.     

Ageing workforce management in manufacturing systems: state of the art and future research agenda

The workforce ageing phenomenon is recently affecting most of the Organisation for Economic Co-operation and Development (OECD) member countries, due to a general ageing of their populations and a higher average retirement age of the workforce. In this paper, the topic of ageing workforce management is addressed from a production research standpoint, with the aim of understanding how older workers can be supported and involved in a manufacturing system. First, the current state of the art related to the ageing workforce in production systems is presented. This is structured according to four main topics: (1) analysis and evaluation of ageing workers’ functional capacities, (2) consideration of ageing workers’ capacities in industrial system modelling and management, (3) analysis and exploitation of ageing workers’ expertise, (4) acknowledgement, analysis, design and integration of supporting technologies. Next, the discussion on the impact of the ageing workforce on manufacturing systems’ performances leads to the comparison of some technological advances that are related to the Industry 4.0 paradigms. Finally, a future research agenda on this topic is proposed, based on the same topics classification proposed for the literature analysis. Five different research areas are derived, suggesting future directions for appropriate research concerning the employ of older workers in production environments.     

Symptoms and risks for musculoskeletal disorders among male and female footwear industry workers

BackgroundConsidering the growing participation of woman in the labor market and the high prevalence of the musculoskeletal disorders (MSD) in the footwear industry workers, the aim of this study was to evaluate and compare female and male footwear industry workers in relation to their demographics, occupational characteristics, stress levels, MSD symptoms prevalence, physical activity levels, alcohol and tobacco use.MethodsThe study included 175 female and 182 male footwear industry workers. Data was collected using the Perceived Stress Scale – 10, the Standardized Nordic Questionnaire, the International Physical Activity Questionnaire, the Alcohol Use Disorders Identification Test, and the Fagerstrom test for Nicotine Dependence.ResultsThe female workers were younger, had less time in the company and in the current job. They reported more stress (p = 0.001), had less time for physical activity (p = 0.004), higher prevalence of MSD symptoms in the last 12 months (p = 0.003), and consumed less alcohol (p = 0.006) than the male workers.ConclusionsFemale and male footwear industry workers presented significant differences in their demographics, occupational characteristics, stress levels, MSD prevalence, physical activity levels, alcohol and tobacco use. These differences should be taken into consideration in the implementation of intervention programs for optimum outcomes.Relevance to industryFemale footwear industry workers were more stressed, presented higher prevalence of MSD symptoms, and reported less time for physical activity than male footwear industry workers. The differences between male and female workers should be taken into consideration in the implementation of MSD prevention programs.     

Smart control of the assembly process with a fuzzy control system in the context of Industry 4.0

Assembly line balancing is important for the efficiency of the assembly process, however, a wide range of disruptions can break the current workload balance. Some researchers explored the task assignment plan for the assembly line balancing problem with the assumption that the assembly process is smooth with no disruption. Other researchers considered the impacts of disruptions, but they only explored the task re-assignment solutions for the assembly line re-balancing problem with the assumption that the re-balancing decision has been made already. There is limited literature exploring on-line adjustment solutions (layout adjustment and production rate adjustment) for an assembly line in a dynamic environment. This is because real-time monitoring of an assembly process was impossible in the past, and it is difficult to incorporate uncertainty factors into the balancing process because of the randomness and non-linearity of these factors. However, Industry 4.0 breaks the information barriers between different parts of an assembly line, since smart, connected products, which are enabled by advanced information and communication technology, can intelligently interact and communicate with each other and collect, process and produce information. Smart control of an assembly line becomes possible with the large amounts of real-time production data in the era of Industry 4.0, but there is little literature considering this new context. In this study, a fuzzy control system is developed to analyze the real-time information of an assembly line, with two types of fuzzy controllers in the fuzzy system. Type 1 fuzzy controller is used to determine whether the assembly line should be re-balanced to satisfy the demand, and type 2 fuzzy controller is used to adjust the production rate of each workstation in time to eliminate blockage and starvation, and increase the utilization of machines. Compared with three assembly lines without the proposed fuzzy control system, the assembly line with the fuzzy control system performs better, in terms of blockage ratio, starvation ratio and buffer level. Additionally, with the improvement of information transparency, the performance of an assembly line will be better. The research findings shed light on the smart control of the assembly process, and provide insights into the impacts of Industry 4.0 on assembly line balancing.     

Animations showing Lego manipulative tasks: Three potential moderators of effectiveness

Evidence suggests that transient visual information, such as animations, may be more challenging to learn than static visualizations. However, when a procedural-manipulative task is involved, our evolved embodied cognition seems to reverse this transitory challenge. Hence, for object manipulative tasks, instructional animations may be more suitable than statics. We investigated this argument further by comparing animations with statics using a Lego task shown to university students, by examining three potential moderators of effectiveness: (a) the environment of manipulation (virtual or physical), (b) the quality of visual information (focused or unfocused), and (c) the presence of hands (no hands or with hands). In Experiment 1 we found an advantage of animation over statics, and no differences among the environments. In Experiment 2, we again observed an animation advantage, a small advantage of focused static information compared to unfocused static information, and a positive effect of not showing the hands.     

Cloud based cyber-physical systems: Network evaluation study

In recent years, the Industry 4.0 concept brings new demands and trends in different areas; one of them is distributing computational power to the cloud. This concept also introduced the Reference Architectural Model for Industry 4.0 (RAMI 4.0). The efficiency of data communications within the RAMI 4.0 model is a critical issue. Aiming to evaluate the efficiency of data communication in the Cloud Based Cyber-Physical Systems (CB-CPS), this study analyzes the periods and data amount required to communicate with individual hierarchy levels of the RAMI 4.0 model. The evaluation of the network properties of the communication protocols eligible for CB-CPS is presented. The network properties to different cloud providers and data centers’ locations have been measured and interpreted. To test the findings, an architecture for cloud control of laboratory model was proposed. It was found that the time of the day; the day of the week; and data center utilization have a negligible impact on latency. The most significant impact lies in the data center distance and the speed of the communication channel. Moreover, the communication protocol also has impact on the latency. The feasibility of controlling each level of RAMI 4.0 through cloud services was investigated. Experimental results showed that control is possible in many solutions, but these solutions mostly cannot depend just on cloud services. The intelligence on the edge of the network will play a significant role. The main contribution is a thorough evaluation of different cloud providers, locations, and communication protocols to provide recommendations sufficient for different levels of the RAMI 4.0 architecture.     

Investigation into polishing process of CVD diamond films

A new technique used for polishing chemical vapor deposition (CVD) diamond films has been investigated, by which rough polishing of the CVD diamond films can be achieved efficiently. A CVD diamond film is coated with a thin layer of electrically conductive material in advance, and then electro-discharge machining (EDM) is used to machine the coated surface. As a result, peaks on the surface of the diamond film are removed rapidly. During machining, graphitization of diamond enables the EDM process to continue. The single pulse discharge shows that the material of the coated layer evidently affects removal behavior of the CVD diamond films. Compared with the machining of ordinary metal materials, the process of EDM CVD diamond films possesses a quite different characteristic. The removal mechanism of the CVD diamond films is discussed.     

中国与世界IC产业发展态势

该文对中国与世界IC产业的发展进行了历史回顾，重点阐述了产业现状与发展方向，并对新世纪的前景进行了科学预测。     

Expressive Facial Gestures From Motion Capture Data

Human facial gestures often exhibit such natural stochastic variations as how often the eyes blink, how often the eyebrows and the nose twitch, and how the head moves while speaking. The stochastic movements of facial features are key ingredients for generating convincing facial expressions. Although such small variations have been simulated using noise functions in many graphics applications, modulating noise functions to match natural variations induced from the affective states and the personality of characters is difficult and not intuitive. We present a technique for generating subtle expressive facial gestures (facial expressions and head motion) semi‐automatically from motion capture data. Our approach is based on Markov random fields that are simulated in two levels. In the lower level, the coordinated movements of facial features are captured, parameterized, and transferred to synthetic faces using basis shapes. The upper level represents independent stochastic behavior of facial features. The experimental results show that our system generates expressive facial gestures synchronized with input speech.     

B737机务CBT系统建设方案的探讨

通过对AICC制订的CBT课件开发规范的探讨，阐述了CBT的基本概念和波音737飞机机务CBT的开发制作过程，以及利用Authorware开发软件制作多媒体课件的技术难点。