Complex central production systems are usually not very flexible - especially when changes are made at short notice. Moreover, their susceptibility to failure increases with complexity. The basic idea of Industry 4.0 offers a way out: In self-organizing, intelligent production processes, products, machines, people, plants and logistics act autonomously. Modern information and communication technology enables them to exchange relevant data and information in real time.
The Ingolstadt-based management consultancy BLSG AG is currently addressing the question of how such a decentralized production system can be implemented in existing manufacturing structures. Networking and shifting decision-making power to decentralized elements should make the entire value chain more flexible and efficient. This can make a valuable contribution to ensuring the competitiveness of existing production sites.
Modifying slack time
The concept involves equipping all objects - including parts, products, conveyor technologies and industrial robots - in a production line with the necessary intelligence. Hardware and software components enable the objects to make independent decisions about how to interact intelligently with their environment. For example, the delivery date can be set as an important control or decision criterion.
To decide which production order gets priority in the system, each production order calculates a kind of slack time - that is, the remaining time of a production order until a delivery date minus the processing and minimum transition times. The order that has the smallest slack time compared to other decision-relevant production orders is assigned the highest priority.
In addition, the concept takes into account rework times and quotas that are held in the delivery date. They are permanently recorded by the affected plants and communicated to the relevant production orders in the event of changes, thus changing the slack time and, if necessary, the priority of these production orders. Since the system independently prioritizes delayed orders and selects the optimal production sequence, this control logic ensures optimal on-time delivery even in the event of unexpected disruptions or changes.
Model factory with intelligent production
BLSG AG was able to test the influences of the various control parameters in a model factory. In this model factory consisting of conveyor technology elements with a multi-strand buffer and fictitious machining and reworking stations, each production order acts autonomously and makes its decisions taking into account the other production orders in the system.
In addition, various scenarios such as machine malfunctions and order changes could be simulated in the model factory. In this laboratory situation, the concept demonstrated a promising approach to meeting the market's increased demands for flexibility and robustness in the face of disruptions.
Industry 4.0: Historical Development
A distinction can be made between four formative stages, which are often referred to as "revolutions" in the literature. In the 18th century, the industrial revolution began with the use of steam engines. The beginning of automation as well as the introduction of mass production based on the division of labor led to the second industrial development. The third stage of industrial development is characterized by the use of industrial robots and the increasing use of information and communication technology (KIT). At the same time, the third stage of industrial development is characterized by increasing individualization of mass production. Under the name Industry 4.0, the intelligent factory with its cyber-physical systems is considered the fourth industrial revolution.
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Intelligent Production in Industry 4.0. (Photo credit: Fotolia©MimiPotter_93312053)