flexible automation is tuning your production
TRANSCRIPT
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
ISyE - INDUSTRIAL SYSTEMS ENGINEERING
CENTER OF EXCELLENCE IN INDUSTRIAL AUTOMATION
Graaf Karel de Goedelaan 5, 8500 Kortrijkwww.XiaK.be
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ISyE - INDUSTRIAL SYSTEMS ENGINEERING
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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UNDERSTANDING FLEXIBILITY
Source: Upton (1994)
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UNDERSTANDING FLEXIBILITY
Source: Upton (1994)
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UNDERSTANDING FLEXIBILITY
Source: Upton (1994)
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UNDERSTANDING FLEXIBILITY
Source: Upton (1994)
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UNDERSTANDING FLEXIBILITY
Source: Upton (1994)
FLEXIBILITY
PR
OD
UC
TIO
N C
OS
T
Fully automated assembly
Craftsmanship
Flexible assembly cell
Mass customization at cost of mass production
UNDERSTANDING FLEXIBILITY
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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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UNDERSTANDING FLEXIBILITY
UNDERSTANDING FLEXIBILITY
“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
UNDERSTANDING FLEXIBILITY
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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
FLEXIBLE AUTOMATION CONCEPT
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De Milwaukee-Matic-II (1959)
One of the first “flexible”machines: CNC withautomatic tool change
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FLEXIBLE AUTOMATION CONCEPT
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FLEXIBLE AUTOMATION CONCEPT
Flexible manufacturing systems
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FLEXIBLE AUTOMATION CONCEPT
Automatic loading &unloading by mobile
units
The operator as a knowledge worker
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FLEXIBLE AUTOMATION CONCEPT
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FLEXIBLE AUTOMATION CONCEPT
Matrix production
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FLEXIBLE AUTOMATION CONCEPT
Strong technology evolution
The robot as a flexible tool
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FLEXIBLE AUTOMATION CONCEPT
Strong technology evolution
2D/3D Vision
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FLEXIBLE AUTOMATION CONCEPT
Strong technology evolution
Wireless identification and localisation
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FLEXIBLE AUTOMATION CONCEPT
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FLEXIBLE AUTOMATION CONCEPT
INFORMATION INTEGRATION
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FLEXIBLE AUTOMATION CONCEPT
INDUSTRY 4.0
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FLEXIBLE AUTOMATION CONCEPT
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
VISiv – FLEXIBELE AUTOMATISERING
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
+32 476 51 90 70
Jan KempeneersSirris
+32 498 91 94 85
Alain Wayenberg.AGORIA
+32 475 80 88 99
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RELATED PROJECTS
VISiv – FLEXIBELE AUTOMATISERING
QUESTIONS?
Thank you for your attention!
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