Virutual production
What are the different production trends?
- Digitalisation
- Sustainability
- Automation
- People
What are the diffrent parts of digitalisation (production trends)
Det handlar om användningen av teknik för att förbättra och effektivisera produktionsprocesser:
- Industrial Internet of Things (IIoT): Uppkoppling av maskiner och utrustning för att samla in data och möjliggöra smarta beslut i realtid.
- Additive manufacturing: Tekniker som 3D-printing, som gör det möjligt att skapa produkter mer flexibelt och med mindre resurser.
- Clouds & Big Data: Användning av molntjänster och stora datamängder för att analysera, optimera och automatisera processer.
What are the diffrent parts of sustainability (production trend)
Fokuserar på att göra produktion mer hållbar inom tre områden:
- Environmental (Miljö): Minskning av avfall, energieffektivisering och användning av förnybara resurser.
- Social (Attrahera och behålla personal): Skapa en god arbetsmiljö för att locka och behålla kompetenta medarbetare.
- Economic (Konkurrenskraft): Kostnadseffektivitet och innovation för att vara konkurrenskraftig på marknaden.
What are the diffrent parts of automation (production trend)
Automatisering handlar om att använda teknologi för att minska mänskligt arbete:
-AI & Machine Learning: Användning av artificiell intelligens för att förutsäga och optimera processer.
-Cyber-physical systems: Integration av digitala och fysiska system för att skapa smarta fabriker.
-Humans vs automation: Balans mellan mänskligt arbete och automatiserade lösningar.
What are the diffrent parts of People (production trends)
Handlar om arbetskraftens roll i framtidens produktion:
-Demographics (Aging): Hantering av en åldrande arbetskraft.
-Polarisation (of jobs): Ökad skillnad mellan jobb som kräver hög kompetens och de som automatiseras.
-Competence (gaps): Behovet av att fylla kunskapsluckor och vidareutbilda arbetskraften.
Draw a model of a general production system viewed from a perspective of sustainable developments where:
Input --> Energy, material, work, Capital
Relations ---> Product, machine equipments, emplyees, facilities
Output --> Energy losses, Products and services, Profit
Explain phsyical and cognitive automation
Physical automation
-Mechanical automation
-more control
-Tools, robots, etc
Cognitive automation
-Information and control
-Less control
-instruction, pick-by-light
What are the 5s
-Sort
-Structure
-Sanitize
-Standardize
-See to that
What is Just in time
It is about getting:
- The right material
- In the right quantity
- With the right quality
- At the right time
Takt time should decide the pace of production to avoid over/under production
Takttime = production time/customer demand
What is Jidoka
Automation with a human touch
-A defective product should be discovered as close to the error source as possible
-To prevent more errors, the productions i stopped until countermeasures have been made
What are the 7+1 types of waste (muda)
Overproduction
Warehouse
Re-work
Transportation
Un-utilized creativity
Over working
Movement
Wait
What is Productivity
It is a measurement of how effective resources are used in a production or process. It is about getting out as much as possible but with as little work as possible.
Output / input
What creates bottleneck
Bottlenecks occur when we have differences in process times through the process. To solve this you need to work with balancing.
Blocked or idle
Down time
set up time
What is the three step process in balancing
1. Calculate how much time we have to procuce one prodcuct (cycle time)
2. Illustate the order in a precedence garph
- list all suboperations
3. calculate how many stations is neaded based on cycletime and precedence graph.
How do you calculate Balancing loss
Loss / total through-put time
What are the diffrent types of losses
Cycle time variation
set up time
Small stoppages (operator can restore)
Breakdown (operator can not restore)
What is the theory of constraints?
A stratergy to find and eliminate the limiting factor.
1. Identify bottlenech that limits the system
-Buffer levels, que sizes, statistics, utalization levels
2. Exploit the systems constraints
-Find free time and use it
-prioritize emergency maintenance
-quality control vefore station
3. Sub ordinate the systems constraints
-Other machines must adapt to the constraints making sure it always runs
-no over production in other machines
4. elevate the system constarints
5. step one again
What is the aim of balancing
To distribute even work per station
To balance the flow to the TAKT time
What definies a balanced system
Even workload
A predefined order of tasks
What is the result of a good balance in the economy
High production capacity
High utilization of investment
Short lead time
Potentially fewer products in work and less stock
Potentially higher quality
Why viritual production?
Testing prior to installation
Lower cost pf changes
Change in design earlier stage
Right people involved earlier
The need for physical prototypes is reduced
The integration between product design and pricution can be verified
Lead times are reduced
What is the focus of the digital twin?
Before putting work into virtual production you must have one of these questions:
What to produce and it defines manufacturing assemblies
How to produce, defines operations and sequence
Where defines the factory and the assembly lines
Who defines for examples robots machines and workers
With defines the tolls to produce with (hammer, wrench)
By simulating these activities it is possible to accelerate the ramp up of initial production for new introduction, increase efficiency, as well as be a source for future process development and improvement
What is MBOM
A fabrication of assembly. A MBOM is a list of all the parts and compositions that is needed to build and deliver a finished product. It also shows how the products will be assembled and how the parts relate to each other. MBOM describes how something looks, det är en monterings sammansättning.
-The parts of assemblies required to build a complete and shippable product
-Is organized with regard to how the product is designed
-Is focused on the parts that are needed to manufacture a product ( also raw material)
-In addition to EBOM the MBOM also includes information about how the parts relate to each other.
-Shows how the product will be assembled (assembly structure)
What is BOP (bill of processes)
How you put together manufacturing of assembly in different processes and stations. You plan the processes and how they look. This is also where you start to look at the time it takes. Bop is “how do we produce”
-Comprise of detailed plans explaining the manufacturing process for a particular product
-Include in-depth information on machinery, plant resources, equipment layout, configuration tools, and instructions
-Include the routing (sequence) between operations (process structure)
-This is the time domain (station balancing)
What is BOR/BOF (bill of resources / Bill of factory)
A list of what resources are needed to be able to make the finished product. Everything from robots to workers are included.
-The list of resources, such as labour and equipment, needed to complete the saleable product
-Is the design view of the digital twin. It shows the 3D of the factory/lines/stations in the factory layout
What is thediffrance between deteministic and stocastic simulation?
The differance is in how the handle uncertainty
Deterministic simulation uses fixed predefined values and rules without randomness. The same input will always produce the same result. This is suitable for systems that are predictable with little uncertainty
Stochstic simulations inckludes random variations and probability distrubutions to accont for uncertainty. The same input can produce diffrent outputs. This is used for uncerainties where values are not precisly predicted.
What is the purpose of CAD (computer aided design)
It supplies digital models of production of produts and equipment components.
What is data management (PDM)
Database to manage product data
Enables configuration management (different product variants)
Version management (as product is evolved through new version)
Enables advanced search techniques for data (like google search)
What is PLM
Product life cycle mangement
The prodcess of managing the entirety of a product from inception through engineering design and manufactureto serve and disposal of maufatored products
What is ERP
Entreprise resoucre planing system
The integrated mangement of core bussiness processes, often in real-time and meditated by software technology like:
-Product planning, purchase
-Production planning
-Manufactoring or service delivery
-marketing and sales
-Material management
-Inventory management
-Shipping and payment
-Finance
Here you can find salaries, orders etc. BASICALLY EVERYTHING
What is MES
Manufactoring execution system
Computerized systems used in manufactoring to track and document the transformation of raw material to finsihed goods
Provides information that helps manufactoring decitionsmakers understand how current conditions of the plants´s floor can be optimized to improve product output.
What is APS
Advanced planning system
A production managemnet process by witch raw material and production capacity are optimally alloctaed to meet demand. Applicable when simple planning methods cannot do the work. Makes it possible to test scenarios like sickness
What is PLC
Programmable logic computer
is an industrial computer that is used to control machines and processes.It receives signals from sensors, processes them according to a programmed logic scheme, and sends control signals to various components, such as motors and valves, to automate and monitor industrial systems.
What is the potential benefits of viritual commissioning
Reduced on-site testing
Reduced project lead time
Reduced project costs
Improved software quality
Increase productivity
Enable virtual training
Reduce Time-to-market
what is meant by frontloading the development circle?
Adressing key tasks and potentia issues early in the project. By validating designs, tetsing and optimizing processes upfront compoanies reduce cost, and speed up the timeline.
Benefits of virtual development
Testing prior to installation
Lower cost pf changs
Change in design earlier stage
Right people involved earlier
The need for physical prototypes is reduced
The integration between product design and production can be verified
Lead times are reduced
What are the diffrent levels of viritual development
Physical Process: Simulate product behavior and optimize designs virtually.
Machines and Tools: Design, test, and program CNC machines and robots offline.
Production Cell: Plan, sequence, and program workflows within production units.
Factory and Workshop: Optimize layouts, logistics, and analyze disturbances for efficiency.
What is DES
Discreate event simulation
Discrete Event Simulation (DES) is a modeling technique used to represent and analyze systems where events occur at specific points in time. It focuses on discrete changes, such as the arrival of customers, machine breakdowns, or process completions. Each event updates the system's state and triggers subsequent actions. DES is commonly used in industries like manufacturing, logistics, and healthcare to optimize processes, identify bottlenecks, and improve efficiency. By simulating real-world scenarios, it provides insights without disrupting actual operations, enabling informed decision-making. DES models are especially valuable for systems with variable or complex workflows, where continuous simulation would be less effective.
What are the objectives of DES
Shorten time from order to delivery
Evaluate product mix
Optimize amount of buffers, conveyor speed, forklifts, and other resources
Identify the bottlenecks
Layout design
Production planning
What are the four steps of a simulation projet and what do they include?
1. Preparation
- Formulation the problem
-Getting input data
- Involving all the irght people from the start is important
-Clerly define scope and models and goal and level of detail
-Create a conceptual model
2. Model
-coding
-verification
-Validation
3. Analysis
-Consider changes
-Where are bottlenecks
-what is resonable to test
-Consider sustanable effects
4. Documentation
What is included in Verification nad validation
Verification
See that the model mathes conceptual model
-Let others see the model and code
-Model test run
-Use debugging
-Viewing the animation
Validation
Making sure simulation macthes the reral system
-Show to customer
-Sensitivity analyses
-compare to historic data
Why is warmup important in simulation
at the beggining of a simulation the factory is empty, that is not always the case in the real world. Therefor you should let the simulation go up to normal mode before logging.
Common pitfalss in simulation
- Simulation takes time, evaluate cost and value
- Requires a lot of resources
- Bad input gives impresson of good output
- Challanging to gain acceptance of organization
- Simulation i not a define solution
- human choises are hard to model
If propper systems ar not in place what is a lot of time spent on
-Working on already one work
-Information searchiing
- meetings to share information
Exmaples of data
-Cycle times
-MTBF
-MTTR
-set up time
- Speed of conveyor
-Shift times
-Enviromental effect
Sources of input data
-Production technicans documents
-automated loggings systems
-bussiness systems (ERP.MES,MRP etc)
-Documents from the construction of the system
-Personal time-tudies
-video anallysis
New equipment
- Interviews
- historic data from similar machines
- Expert groups
- Data from supplier of machine
What is PDM
Product data management system
Organizes, store and manage product related information through its life cycle. Esures easy acces
What is meant by a configuration
A configuration is defined as a version of a complex product including versions of each if its components
IT systems that support the selections of components and parameter values are called Configurators.
Configurators contain a set of rules that
Define which components that can be included in an instantiated product variant
Select components so that customer needs and manufacturing requirements are fulfilled
This is called a products configuration model.
What are the three phases of learning
The cognitive phase
The assiciative stage
The autonomous stage
What is the cognitive phase
the initial learning of a new skill. You are dependent on extral feedback and make a lot of mistakes and try to make a mental picture.
Focuses on:
Intellectual treatment of information connected to a new task
What to do and how the movement should be performed
Looking for the most appropriate movement strategy
Practical demonstration and trials is the fastest way forward
What is the assosiative stage
Imporving techniques and skill execution. Practise by repetition and starts to rely on interal feedback to improve the movement and do less errors
focuses on.
-Turning the muscle work , which becomes more efficient when the movement pattern is learning
-The attentions not need to focus on every detail that is connected to the assignment
-Attention still focused on the very execution of the movement
-The consciousness of the trainee is still on evaluating the result of the own work
What is the autonomous stage
The movement is fortified and you no longer focus on the movement, it comes natural. Able to focus on something else.
Advantages of viritual training?
-Reduced ramp up,
-reduced lead time
-cost efficient
-increased flexibility
-imroved learning
-increased quality
-Reduced rework
-reduce non value adding work in production
-Safer
What are the three parts of XR
Augmented reality (AR)
mixed reality (MR)
Virtual reality (VR)
What is VR
Virtual reality
Fully immersive 3D virtual environment that is rendered in real time and controlled by the user In production this can be used to walk around in a factory before you start building it.
What is Mixed reality
Mixed reality
Mixed reality (MR) blends the physical and digital worlds, allowing virtual and real objects to interact in real-time. It combines elements of augmented reality (AR) and virtual reality (VR), enabling immersive experiences where users can engage with both physical and virtual environments seamlessly.
What is AR
Augmented reality
AR uses experience in a real world environment with a generated perceptual information overlaid on top of it. Pokemon go uses this.
What are the diffrent areas for us of XR
Viritual prototyping
Production / layout planning
Ergonomics assessment
Training
Cognitive support/instruction
Machine / robot interaction
Data monotoring
What are the limits of viritual training?
- The physical connection is missing
- Infrastructure for hardware and training material
- Cyber security
- Big investments
- Resistansce from organisation (enjoy people training them)
what is a pointcloud
A point cloud is a collection of data points in 3D space, representing the external surface of an object, environment, or scene. Each point has coordinates (x, y, z) and may include additional attributes like color or intensity.
When do you use viritual reality?
Factory planning
Product visualisation
Virtual training for operators
Augmented reality areas of use
Training with existing equipments for operators
Instructions for operators, maintenance staff etc
Visualize machine models in real production facility
What is FMS
FMS (flexible manufacturing system)
Definition: FMS (flexible manufacturing system) consists of a group of processing work stations interconnected by means of an automated material handling and storage system and controlled by an integrated computer control system. (PLC = Programmable logic controller)
FMS (Flexibelt Tillverkningssystem) är som en smart fabrik som kan anpassa sig snabbt. Tänk dig att maskiner och robotar i fabriken kan göra olika saker utan att behöva byggas om varje gång. Om en kund vill ha en ny typ av produkt, kan systemet ändra sig och börja tillverka den snabbt. Det gör fabriken både snabb och flexibel!
WHen is FMS with high automation better even if not economic smart
-hazardous enviroment
-Heavy lifting
-Required skills
Application for industrial robots
Material handling
Spot welding
ARC welding
Laser welding
Painting
Explain the controller (robotics)
This is the "brain" of the system, responsible for processing instructions and controlling the robot's movements. The controller sends theoretical values for position, speed, etc., to the axis computer, which compares them with actual values (from resolvers and tachometers) and adjusts motor commands accordingly. This process happens with a sampling frequency of about 100 Hz.
Explain the manipulator (robotics)
This is the mechanical part of the robot that performs tasks. In summary, the controller plans and monitors the robot’s movements, while the manipulator physically executes the tasks based on these instructions.
How many DOF (degrees of freedom) do.a robot have?
6, X,Y,Z and the thre axes of orientation
How do we deal with wth translation and orientation (robotics)
Use a 4x4 homogeneous tranformation matrises. SInce it desribes all 6 DOF
What is forward kinematics
Describes TCS (Tool Coordinate System) in terms of the known joint variables.
What is Inverse kinematics
Calculate the jointsvariables given the TCS (tool cordinate system)
What is the diffrances and advantages with offline and online programming
Offline programming
Done on a computer or a seperate system away from the machine. Advantages are that amchiens remain operational, reducing downtime. Programs can be tested and it is safer.
Online prgramming
Done on the actual machine or robot. Advantages are imidiate feedback and simpler for quick fixes and minor changes
MoveL penna_gr, v200, z50, PENNTCP\WObj:=REFRAM_PAPPER;
From current position the robot will move the tool coordinate system “PENN TCP” linear against the goal position “penna_gr”
The speed will be 200mm/s
The goal position is defined relative “REFRAM_PAPER”
The zone size is “z50” ; it will have an accuracy of that specified between two positions. The change will take place 50 mm from “penna_gr” otherwise it will be a stopping point
Simulation of robots...
-Allows you to find. compare and optimice different solutions regarding the layouts, robots, external axes, tooling, fixturing etc
-Allows you to see if the robot is capable of reaching the target points
-Allows you to see if the robot (tool and/or workpiece) is colliding with any object
-High level of modeling is required. More or less everything in the real world has to be there - robots, tools, cables, fixtures, parts, turntables, toolstands, pillarns, cable channels, hoods etc.
-The kinematics is taken care of by the simulation software - targets can be generated graphically on the CAD models
-Calibration is required - using workobjects is important
-All kinds of processes and cycle time is verified
-Robot safety functions can be configured
-Sensors and signals can be dealt with as well as PLC control of related things like clamping zone allocation etc. It is even possible to connects a real PLC to the simulated
The four parts of an concept map and their sublevels
Ecological
-enviroment
-resources scarity
Social
-social impact
-values
-future (temporal)
-Unbalanced (spatical)
Economical
-Technology
-economy
Institutional
-education
actros and stakeholders
Hur räknar man ut complexity index
man delar röda linjer med antal cirklar Högt numer innebär complext system
What is intra generational distribution
How well-being is distributed among people on earth
What is intergenerational distribution
How well-being is distributed among different generations, including future ones
Explan the four diifrent layouts
Fixed position, functional layout, cell layout, line layout
Why will you be more efficient using virtual production planning compared to using non-3D planning systems (word excel powerpoint) (3p)
Possibility to test the planning in a digital twin
Enables you to test concept and new production scenarios without disrupting production
The ability to change is easy and cheap compared to changes in real life.
Describe in general terms what happens in the robot controller sample by sample when programmed motion instruction (e g Move L) is executed. (2p)
Motion planning:
The main computer (the "brain" of the robot) reads the motion instruction in the robot program, e.g., "Move the tool from point A to point B along a straight line."
It calculates an ideal trajectory, determining the theoretical values for position, speed, and acceleration over time to achieve the motion.
Reading actual values:
The robot's sensors, such as resolvers (rotational position sensors), measure the real-time position and speed of each motor and joint.
Comparison and compensation:
For each small time interval (sample), the controller compares the actual values from the sensors with the theoretical values from the planned trajectory.
If there’s a difference (which is common due to friction, load variations, or disturbances), the controller calculates how much adjustment each motor requires to stay on the desired path.
Controlling the motors:
These corrected signals are sent to the axis computer (a secondary controller that manages individual motors).
The axis computer controls the motor’s speed and torque (force) using PWM (Pulse Width Modulation), which precisely regulates the power supplied to the motors via components like rectifiers and drivers.
Executing the motion:
The motors adjust based on the new signals, moving the robot closer to the planned trajectory.
This process repeats for every sample until the motion is fully executed.
How is balancing loss calculated
NC-T / NC
What is the quantitative value used in the SSLP method representing and why is it important to consider qualitative measures as well when selecting layout. (2p)
The quantitative is good since it provides an objective value for how well they fulfill the preset requirements for the layout. It removes bias. But qualitative methods are also important in the sense that they account for other aspects that also need to be considered.
Explain the trade-off between volume and variant when designing a layout of a production system (2p)
When a higher number of product variants is created there is a higher demand for flexibility. That could mean that a product layout or a functional layout is more suited. But if there is a higher volume of products created with less flexibility required it is more suited to have a line production. It is also important to take the size of the products into a count, if the product is hard to move product layout is required.
Describe systems and dataflows in a modern production system
CAD (Computer-Aided Design) används för att skapa 3D-modeller av produkter och utrustning. Dessa modeller skickas vidare till andra system.
PDM/PLM (Product Data Management/Product Lifecycle Management) lagrar all viktig information om produkten, som till exempel en EBOM (Engineering Bill of Materials) – en lista över alla delar som behövs för att tillverka produkten.
I Virtual Production kan man testa och simulera produktionen digitalt innan den påbörjas. Här skapas MBOM (Manufacturing Bill of Materials), arbetsinstruktioner och maskinprogram som används för själva produktionen.
ERP (Enterprise Resource Planning) tar hand om planering, resurser och order. Den skickar vidare information till MES (Manufacturing Execution System) och APS (Advanced Planning and Scheduling).
MES övervakar produktionen i realtid och ger feedback till andra system. APS ser till att produktionen sker så effektivt som möjligt genom smart planering.
Genom att alla dessa system samarbetar utbyts viktig data som gör produktionen snabbare, billigare och mer precis. Det är som ett lag där varje spelare har en viktig roll!
Two benefits of usisng collaborations plattforms such as 3Dexperiance for viritual planning
concurrent engineering
gives better understanding of future production
A robot is theoretically controlled by calculating the forward kinematic and inverse
kinematics.
Forward kinematics describes the tools position and orientation based on how much it has moved.
Inverse kinematics calculates how much each joint has to move to reach a certain goal value.
How can buffers be used to identify bottlenecks in production flows? exemplify how you used buffers in the DPS project, (3p)
By using buffers you can identify bottlenecks by the size of the buffer as well as the short ques after and long before a buffer. In the DPS project we also used the buffers to solve a station's down time making so it can gain time.
What does the expression “trash in—> trash out” mean in the simulation context?
It points to the fact that a simulation is only as good as the data put into it. If the input is bad the output won't be accurate to real life.
It is important with validation and verification to ensure that there is not trach in.
How can augmented reality (AR) be used to ease the work for maintenance personnel
and service technicians?
Reduced time for training
higher quality (standardized work process and increased product quality)
Safer and shorter ramp-up time
Reduced training on real objects
Explain the word sociotechnical, as it is used to describe systems. (2p)
Systems and processes that are socio-technical are a combination of human and machine and their operation depends on both.
What do you need in terms of data to describe Mean time to repair for a NC machine
NC is referring to numerical control machines that we usd in the simulation project. The data required is the mean time it takes to repair the machine. So the total amount of time the machine has been under repair divided by the amount of times.
Define efficiency and explain the difference versus effectiveness?
Efficiency is the internal view, are we doing this right? It looks at how we are using our resources. Effectiveness is the external view decided by the customer, are we doing the right things. It is about how well we deliver what they want.
Why is there a growing need among manufacturing companies to work with virtual technologies?
With a shorter product life cycle today than before and more new products being introduced to the market it becomes necessary to have the ability to quickly change the production from one product to the other. By working virtually the changes can be verified before installation therefore reducing changeover times and potential errors.