Showing posts with label Digital Transformation. Show all posts
Showing posts with label Digital Transformation. Show all posts

Thursday, May 7, 2026

Digital Twin - Bibliography

 Digital Twin Patent - GE - 2016

https://patents.google.com/patent/US20170286572A1/en



Novel Digital Twin Development Methodology for the Robot Cell Connectivity in a Smart Industry Environment

Thesis

Kuts, Vladimir

https://digikogu.taltech.ee/et/item/ca43f48b-c852-41b2-87cc-62e423e9c0c4


DEVELOPMENT OF A DIGITAL TWIN OF A FLEXIBLE MANUFACTURING SYSTEM FOR ASSISTED LEARNING

December 2018

DOI: 10.13140/RG.2.2.26398.08000

Thesis for: Master of Science

Advisor: Assoc .Prof. Andrei Lobov, Prof. Jose. Luis Martinez Lastra

Authors:Joe David

https://www.researchgate.net/publication/335234337_DEVELOPMENT_OF_A_DIGITAL_TWIN_OF_A_FLEXIBLE_MANUFACTURING_SYSTEM_FOR_ASSISTED_LEARNING


Towards a Digital Twin for the Smart Factory: An evaluation of the concept and technology of a digital twin

Authors: Ek, Jimmy, Norman Hult, Tobias

https://odr.chalmers.se/handle/20.500.12380/301027



Digital Twins - Avis Car Rental


https://www.iotworldtoday.com/2019/05/16/iot-world-awards-winners-announced/

https://www.scaleoutsoftware.com/products/digital-twin-builder/

https://www.iotworldtoday.com/2019/04/18/avis-budget-group-ceo-aims-to-reinvent-car-rental-industry/


Azure Digital Twins now generally available: Create IoT solutions that model the real world

December 16 & 8, 2020

Sam George Corporate Vice President, Azure IoT


To really understand these intricate environments, companies are creating digital replicas of their physical world also known as digital twins. With Microsoft Azure Digital Twins now generally available, this Internet of Things (IoT) platform provides the capabilities to fuse together both physical and digital worlds, allowing you to transform your business and create breakthrough customer experiences.


One company pushing the boundaries of renewable energy production and efficiency is Korea-based Doosan Heavy Industries and Construction. Doosan worked with Microsoft and Bentley Systems to develop a digital twin of its wind farms, which allows operators to remotely monitor equipment performance and predict energy generation based on weather conditions.

Additional resources

•    Learn more about Azure Digital Twins.

•    Get started with Azure Digital Twins technical resources.

•    Watch Azure Digital Twins demo video.

•    Read Azure Digital Twins customer stories.

•    Watch the Azure Digital Twins technical deep dive video featuring the WillowTwin solution.

•    Learn how IoT and Azure Digital Twins can help connect urban environments.

•    Learn more about Microsoft and Johnson Controls digital twin collaboration.

https://www.microsoft.com/azure/partners/news/article/azure-digital-twins-now-generally-available-create-iot-solutions-that-model

https://azure.microsoft.com/en-us/blog/azure-digital-twins-now-generally-available-create-iot-solutions-that-model-the-real-world/



https://praiseerianamie.medium.com/introduction-to-digital-twins-optimizing-the-real-world-through-the-virtual-world-e72e4785fe6c



Are You Using Digital Twins?

As computing power intensifies, the business imperative for digital twins is becoming crystal clear.

Peter Fretty

FEB 07, 2020

https://www.industryweek.com/technology-and-iiot/article/21121741/are-you-using-digital-twins


How to harness the transformative power of plant digital twins

What are the 8 key benefits of plant digital twin?

What are the challenges associated with plant digital twin?

11 Dec 2020

https://www.ey.com/en_gl/advanced-manufacturing/how-to-harness-the-transformative-power-of-plant-digital-twins


2022



Twinzo Digital Twins


What is twinzo?

Enjoy the perfect overview. An exact 3D Live Digital Twin of your facility. Whether your house, office, factory or even a whole city (perhaps a space station?). It enables you to have your 3D model on your smartphone, tablet, PC or Mac and gives you access to all your data you desired to see and monitor in real-time.

Scalable and Modular

You can monitor any type of IoT Sensor, database and data stream, process, or workflow, up to real-time visualization of any kind of tracking and monitoring technology. You are always only one click away from the perfect overview you always desired.



Digital twins: The art of the possible in product development and beyond

April 28, 2022 | Article

https://www.mckinsey.com/business-functions/operations/our-insights/digital-twins-the-art-of-the-possible-in-product-development-and-beyond?cid=other-pso-lkn-mop-mck-oth-2205


2026
Vivek Saxena


I help factories harness the superpower of their data.

Hopkins, Minnesota, United States

https://www.factory-twin.com/
https://www.linkedin.com/in/vivsaxena/

Ud.  7.6.2026,  26.5.2022,  25.2.2022

Pub 2.7.2021







Monday, November 10, 2025

Manufacturing Execution System - Evolution

 

1994

MES and CIM (Computer-Integrated Manufacturing)

CIM and its Relationship to Manufacturing Execution Systems (MES)

https://gregstanleyandassociates.com/whitepapers/CIM/cim.htm

1999

Part 1


Manufacturing Execution Systems:

Leveraging Data for Competitive Advantage


Six Sigma demands can strain any supply chain management system--don't let information technology be your program's weak link.

by Jonathan Kall

https://www.qualitydigest.com/static/magazine/aug99/html/body_mes.html



2021

Top 10 - MES

YouTube Video.

Eric Kimberling



1. Plex

2. IQMS

3. Epicor Advanced MES

4, Infor

5. Aptean

6. Oracle Netsuite

7. Microsoft Dynamics 365

8/ Fishbowl

9. SAP ME

10. E2 Shop System












Saturday, November 1, 2025

Digital Twins - Bibliography - DTs for Machine Tools and Machine Tool Components and Accessories

2025

Digital twin applications in Emerson

Zachary Sample, an enterprise consultant at Emerson.

Initially, the most common use of digital twins in biopharma was for process development. Engineers would use a combination of historical and experimental data as well as sound scientific principles to model, test, and then fine-tune unit operations. In recent years digital twins have started to be employed more widely. “Digital twin technologies can bring value across the entire biopharmaceutical development chain, leading to faster time to market. As a result, we are seeing digital twins implemented at every stage of the pipeline.



Industrial Digital Twins - NVidia
Build intelligent factories, warehouses, and industrial facilities for the era of physical AI.
Use Cases

 The Journal of Supercomputing  Article
Leveraging real-time digital twins for smart livestreaming platforms to enhance consumers’ experience
Open access
Published: 25 May 2025
Volume 81, article number 887, (2025)
You have full access to this
open access
article


Digital twin technology and artificial intelligence in energy transition: A comprehensive systematic review of applications
Author links open overlay panel
Abdelali Abdessadak a b c
, Hicham Ghennioui a
, Nadège Thirion-Moreau b
, 
Brahim Elbhiri d
, 
Mounir Abraim e
, 
Safae Merzouk c

Energy Reports
Volume 13, June 2025, Pages 5196-5218

Open access


Article
Open access
Published: 14 April 2025
Digital twin system for manufacturing processes based on a multi-layer knowledge graph model
Chang Su, Xin Tang, Qi Jiang, Yong Han, Tao Wang & Dongsheng Jiang 
Scientific Reports volume 15, Article number: 12835 (2025)



https://vasscompany.com/us-can/en/insights/blogs-articles/digital-twin/

https://www.researchgate.net/publication/367314465_Digital_Twin_Benefits_use_cases_challenges_and_opportunities

https://www.frontiersin.org/journals/sustainable-food-systems/articles/10.3389/fsufs.2025.1538375/pdf

https://www.hslu.ch/-/media/campus/common/files/dokumente/ta/ta-forschung/fmhm/digital-twins-recent-advances-and-future-direc-2025-intelligent-systems-wit.pdf?sc_lang=en

https://dspace.lib.cranfield.ac.uk/bitstreams/dcefbd88-5a74-42ea-af19-913adb6178cb/download

https://www.growingscience.com/uscm/Vol14/uscm_2025_6.pdf  - Digital twin applications in supply management

https://www.signavio.com/downloads/analyst-reports/spark-dto-2025/

--------------------------

3.5.2022
A Survey on AI-Driven Digital Twins in Industry 4.0: Smart Manufacturing and Advanced Robotics
Ziqi Huang, Yang Shen, Jiayi Li, Marcel Fey, and Christian Brecher
Sensors (Basel). 2021 Oct; 21(19): 6340. Published online 2021 Sep 23. doi: 10.3390/s21196340
PMCID: PMC8512418PMID: 34640660
https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8512418/

Review of Digital Twin-based Interaction in Smart Manufacturing: Enabling Cyber-Physical Systems for Human-Machine Interaction
Jasper WilhelmORCID Icon,Christoph Petzoldt,Thies Beinke &Michael FreitagORCID Icon
Pages 1031-1048 | Received 21 Aug 2020, Accepted 25 Jul 2021, Published online: 13 Sep 2021
International Journal of Computer Integrated Manufacturing 
Volume 34, 2021 - Issue 10
https://www.tandfonline.com/doi/full/10.1080/0951192X.2021.1963482

Digital Twins and Virtual Commissioning in Industry 4.0
POSTED 07/09/2019
https://www.automate.org/tech-papers/digital-twins-and-virtual-commissioning-in-industry-4-0

Digital Twins - Bibliography


CII Students Report
https://ciiscmconnect.com/wp-content/uploads/2020/06/Digital-Twin-Team-Intensity.pdf

Digital Twins in Defence
https://www.qinetiq.com/-/media/fe512bcae17044cc997d779e57c8a158.ashx


7 Digital Twin Applications for Manufacturing
Mar 17, 2021
by Mark Crawford


Digital Twins for Machine Tools and Machine Tool Components and Accessories



Digital Twins in Remote Labs
https://books.google.co.in/books?id=HtShDwAAQBAJ&pg=PA289#v=onepage&q&f=false


Optimized Additive Manufacturing Using Digital Twins and Cyber Physical Systems
https://books.google.co.in/books?id=HtShDwAAQBAJ&pg=PA65#v=onepage&q&f=false

Process Parameter Monitoring Using Digital Twin
https://books.google.co.in/books?id=HtShDwAAQBAJ&pg=PA74#v=onepage&q&f=false



Machine Tool: From the Digital Twin to the Cyber-Physical Systems
Mikel Armendia Aitor Alzaga Flavien Peysson Tobias Fuertjes Frédéric Cugnon Erdem Ozturk Dominik Flu
First Online: 05 January 2019

https://link.springer.com/chapter/10.1007/978-3-030-02203-7_1

Liu and Xu proposed a new generation of machine tools, machine-tool 4.0, cyber-physical machine tools that, apart from the CNC machine tool, include  data acquisition devices, smart human–machine interfaces and a cyber twin of the machine tool.

A new application of the digital twin is “virtual commissioning” . In this case, a virtual representation of the machine is used to design, program and validate the controller. Simulation models can be used for the  virtual commissioning  which consists in the usage of the digital twin of a physical system to set-up the controller even before the physical system is ready for that.

The state of the art in virtual machining is presented in a recent keynote paper by Altintas.

There are two types of tool path simulation software available in the market for machining. The first type, Geometry-based simulation tools (Volumill  and Vericut Optipath) can  calculate material removal rate and uncut chip thickness variation along a given tool path. They cannot simulate process mechanics and dynamics, and hence, they cannot predict cutting forces, tool breakages due to high cutting forces, form errors and vibrations. The second type can simulate cutting forces.  Vericut provides a force module that includes cutting force for the tool path optimization procedure. Machpro [22] can let the user learn about stability issues in addition to simulation of cutting forces.

For simulation of effect of certain process parameters, there are analytical and FEA analysis-based simulation software available on the market. Cutpro  software runs analytical model for calculation of cutting forces and stability for a given set of parameters. Deform  and Advantedge  are FEA packages for simulation of cutting forces and temperatures in machining. These software packages cannot be used in simulation of the complete tool path for a given part.


Virtual Machine Tool
In 2005, Altintas summarized the research performed on virtual machine tool technology. Main developments in the field consist of machine tool structure kinematic (rigid body)  and dynamic (FEM) analysis.

Commercial simulation packages used for machine tool structural analysis -  two categories. Rigid-body simulation software (MSC ADAMS, LMS Virtual.Lab )  does not consider all the deformation and vibrational characteristics of the structural parts of complex machines.  The finite element method packages (MSC Nastran, ABAQUS, SAMCEF ) are more appropriate to analyse complex compliant systems. But the simulations are time prohibitive.

Hoffmann, P., Maksoud, T. M. A.: Virtual commissioning of manufacturing systems: a review and new approaches for simplification. In: Proceedings 24th European Conference on Modelling and Simulation; Kuala Lumpur, Malaysia (2010)

Lee, C.G., Park, S.C.: Survey on the virtual commissioning of manufacturing systems. J. Comput. Des. Eng. 1(3), 213–222 (2014)

Hoffmann, P., Schumann, R., Maksoud, T.M.A., Premier, G.C.: Virtual commissioning of manufacturing systems—a review and new approaches for simplification. In: Proceedings of the 24th European Conference on Modelling and Simulation (ECMS 2010), pp. 175–181. Kuala Lumpur, Malaysia

Altintas, Y., Kersting, P., Biermann, D., Budak, E., Denkana, B., Lazoglu, I.: Virtual process systems for part machining operations. CIRP Ann. 63(2), 585–605 (2014)

Altintas, Y., Brecher, C., Weck, M., Witt, S.: Virtual machine tool. CIRP Ann. Manuf. Technol. 54(2), 115–138 (2005)

Fesperman, R.R., Moylanb, S.S., Vogl, G.W., Alkan Donmez, M.: Reconfigurable data driven virtual machine tool: geometric error modeling and evaluation. CIRP J. Manufact. Sci. Technol. 10, 120–130 (2015)

Reyes-Uquillas, D.A, Yeh, S.S.: Tool holder sensor design for measuring the cutting force in CNC turning machines. In: 2015 IEEE International Conference on Advanced Intelligent Mechatronics (AIM), , pp. 1218–1223, Busan (2015)

Möhring, H.-C., Wiederkehr, P., Gonzalo, O., Kolar, P.: Intelligent Fixtures for the Manufacturing of Low Rigidity Components. Lecture Notes in Production Engineering. Springer, Berlin (2018).

GEORG to unveils digital twin for its machine tools in 2019.

a specialist in machine tools and a pilot customer of Siemens, Heinrich GEORG GmbH has already implemented the digital twin in the form of Sinumerik ONE for two of its machines – the GEORG ultragrind SG2 grinding machine and the GEORG ultramill H moving column milling machine.

 “The GEORG digital twin is key to the digital transformation of our machines. It allows us to simulate and test our customers’ operations in a completely virtual environment. Thanks to the interplay between the virtual and the physical machine combined with GEORG’s engineering know-how, our high-capacity machines and the new high-performance Sinumerik ONE software, our customers are sure to benefit from significant productivity gains in manufacturing."
https://mfgtechupdate.com/2019/09/georg-unveil-digital-twin-machine-tools-emo-2019/


From now on, SCHUNK is providing digital twins for tool holders
23 July, 2019

DIN 4000 is already established in the tools sector. Now comes the next step in the digitization of tool management: SCHUNK now provides the data of its standardized precision toolholders of the TENDO hydraulic expansion toolholder, TRIBOS polygonal clamping technology and SINO expansion toolholder free of charge as digital twins in a standardized format based on DIN 4000.
https://www.cnctimes.com/editorial/from-now-on-schunk-is-providing-digital-twins-for-tool-holders


VERICUT Digital Twin -  CGTech Support
https://www.cgtech.co.in/digital-twin/

VERICUT User Stories
https://www.cgtech.co.in/solutions/user-stories/




Virtual machine tools and virtual machining—A technological review
Aini Abdul Kadirab Xun Xua Enrico Hämmerlea
Robotics and Computer-Integrated Manufacturing
Volume 27, Issue 3, June 2011, Pages 494-508
https://www.sciencedirect.com/science/article/abs/pii/S0736584510001481




Ud 1.11.2025,  3.5.2022, 26 May 2021
Pub 29 Feb 2020

Monday, July 21, 2025

Digital Transformation at Daimler Benz - Now Daimler is Digital Champion of PWC Survey


11 July 2018

PWC 2018 survey of Industry 4.0 implementation classified Mercedes Benz as Digital Champion.

Mercedes-Benz as pioneer of the digital transformation: From Car Manufacturer to Networked Mobility Service Provider

Frankfurt, Sep 14, 2015


 The automotive industry is changing fundamentally, things are speeding up. A new  megatrend is “digitalisation” – also known in an economic context as “Industry 4.0”. Mercedes-Benz is a pioneer in this development. The inventor of the automobile is actively driving forward the transition from automotive manufacturer to networked mobile mobility service. Dr. Dieter Zetsche, Chairman of the Board of Management of Daimler AG and Head of Mercedes‑Benz Cars, explained the strategy and the current status of development on the eve of the 2015 Frankfurt International Motor Show (IAA). Presenting the “Concept Intelligent Aerodynamic Automobile”, known for short as “Concept IAA”, Zetsche showed a concrete example of the fascinating opportunities offered by digital product development.





Picture source:
http://media.daimler.com/dcmedia/0-921-1845911-1-1847484-1-0-1-0-0-1-12639-0-0-3842-0-0-0-0-0.html?TS=1460971376431


Digitalisation has been a central strategic issue in all areas of Mercedes-Benz for many years. Technical innovations like driveline electrification and autonomous driving, in particular, would be unthinkable without the digital transformation. The same applies to production, where the brand with the three-pointed star likewise plays a leading role. In parallel, the progress of digitalisation in the area of marketing & sales means Mercedes-Benz is taking into account altered customer expectations and the associated transformation in communication patterns and behaviour.

“It’s about nothing more and nothing less than the complete networking of the entire value chain – from research and development, through production to marketing and sales,” said Zetsche, speaking on the eve of the show. “This digital transformation is in full swing at Mercedes-Benz. We are transitioning from car manufacturer to networked mobility provider, whereby the focus is always on the individual – as customer and employee. This is how we will continue to develop the company and thereby ensure our future competitiveness.”


Digital prototype – more speed, more precision, more diversity


Digitalisation at Mercedes-Benz is particularly advanced in the area of research and development. By way of comparison, computer renderings with around one thousand elements were possible in the 1970s. One decade later, this had risen to 25 times as many. Today, the figure stands at up to 80 million elements and rising.

Digital prototyping accelerates the development of new generations of cars – but more than that, it also raises their quality and offers opportunities for increased diversity. The car of the future is being simulated and optimised as a digital prototype from the earliest stages of its development.

“With the aid of digital prototypes, we are also improving the passive safety of our vehicles – faster, more precisely and more efficiently than ever before,” said Prof. Dr. Thomas Weber, Member of the Board of Management of Daimler AG responsible for Group Research and Mercedes-Benz Cars Development. Another particularly impressive example is aerodynamics. “The key term here is Big Data, the evaluation of large quantities of data from a wide range of sources,” continued Weber. “Before we let a new car anywhere near our wind tunnel, it has already successfully passed a barrage of digital tests as a complete data model.”
The opportunities and potential this unlocks for production development are not difficult to imagine. One example is that current Mercedes-Benz production cars are already aerodynamic world champions in virtually all classes. The opportunities presented by digitalisation are already being used to the maximum by the Formula 1 team. From add-on parts such as aerodynamic features, through to new engine and drive components, the route from computer data model to race track is often impressively short and fast.

Production – shorter innovation cycles and better ergonomics


Production, too, is becoming more flexible and efficient thanks to digitalisation. The aim is intelligent production, notable for its transformability, resource efficiency and better ergonomics for workers. Dr. Zetsche: “The more diversity we have in the market, the more flexibility we need in production. The key here, too, is digitalisation. Plants will become smart factories, where equipment and components are seamlessly networked. And what’s even more important – people and robots will work harmoniously together in the smart factory of the future.”

Robots are already omnipresent in automotive production today – especially where the work would be particularly strenuous or even ergonomically harmful for people. Nowadays, an assembly step is generally completed either by workers or by robots, the latter still being enclosed in protective cages for safety reasons. This is set to change, with people and robots interacting directly with one another in future.

Man and machine work hand-in-hand.

Combining the cognitive superiority and flexibility of human beings with the power, stamina and reliability of robots not only increases quality, but also leads to significant improvements in productivity. And at the same time, it offers a whole array of new possibilities when it comes to ergonomic and age-appropriate work – also and particularly in respect of demographic changes in society.

Markus Schäfer, Board Member responsible for Mercedes-Benz Cars Production and Supply Chain Management: “The intelligent cooperation of people and robots plays a central role for us. To state it clearly, the use of new types of robots is not a matter of ‘man or machine?’ We are committed to an intelligent teamwork approach.”

Wilfried Porth, Member of the Board of Management of Daimler AG responsible for Human Resources: “The experience, creativity and flexibility of our colleagues cannot be replaced by robots – now or in future. There will, however, be less seriously strenuous, heavy work. This is what we see as the ideal division of labour between people and robots.”

Production planning – increasing flexibility and precision


Through digitalisation, production equipment and installations can be designed to be highly flexible in future, enabling construction, expansion and adaptation without major delays. This not only improves the prerequisites for long-term planning, but also enables faster response to short-term shifts in the market.

One example of this transformable production is the so-called object-coupled assembly system, whereby mobile robot systems can be used in production in a variety of different ways, without the need to technically modify or stop the production line. The robots can dock onto the respective bodyshell on the production line, carry out their work and switch to the next vehicle while the line keeps moving. Daimler is also using digitalisation in quality assurance, involving the cooperation of entire installations. Smart factories, holistic automation and control technology, company-wide standard modules and new, network-based working models will enable detailed dialogue between individual plants in future. This will see the global network of Daimler AG grow closer together and lead to greater efficiency in production and sales.

This efficiency will also carry through to suppliers – problems with a production system can be identified, analysed and resolved via remote diagnostics. Such networking with other companies also enables faster and more efficient processes within those companies and raises the quality of cooperation in general.

Marketing & sales – more individuality through digitalisation


However, the digital revolution does not end when a vehicle leaves the production line. Mercedes-Benz is also using the opportunities presented by digitalisation in marketing & sales. Within the scope of Best Customer Experience, Mercedes-Benz is working with the multi-channel approach that flexibly interlinks a large number of innovative marketing & sales formats and digital elements. Major emphasis is being placed on the digitalisation of all channels – in communication as well as sales and service. Online stores are enhancing existing sales outlets and making it possible to order or lease a vehicle at any time.

Greater focus is being placed on digital interaction in the real world, too. The Mercedes me stores are equipped with a wide array of digital design elements. Prospects can configure exactly the car they want easily and conveniently at multi-touch monitors and plasma screens. In addition, more than half a million people are interacting with Mercedes-Benz every day via the brand’s global social media platforms – more than with any other car maker.

The easiest access to the personalised brand world is offered by the Mercedes me online portal, where Mercedes-Benz is accessible at any time. The spectrum ranges from electronic appointment booking for classic customer service, through individual networking with a customer’s own vehicle to the offer of personally configured financial services. Customers can also find products that are not restricted to their own car. This includes mobility services like car2go and information on lifestyle activities and entertainment offerings.

Mercedes me was launched one year ago, enabling customers across Europe to connect with their vehicles anywhere, anytime. Customers of not-yet networked vehicles will also soon be able to enjoy the pleasures of conveniently networking their vehicles – with the Mercedes connect me adapter. A total of 24 car model lines dating back to 2002 can be retrofitted to enable secure access to vehicle information. Mercedes-Benz will begin this connect me offensive in early 2016, with successive implementation in European markets where connect me is also offered.

Mercedes me – digital access to the personalised world of Mercedes  


“Mercedes me always places the customer front and centre, enabling him or her to access the brand anywhere, anytime, regardless of whether they need a service, require entertainment or want remote control of vehicle functions,” said Ola Källenius, Member of the Board of Management of Daimler AG, responsible for Marketing & Sales Mercedes-Benz Cars.

Mercedes me innovations include the new Lifestyle Configurator, which enhances the classic vehicle configurator. The customer can use it to enter their individual preferences in furnishings, travel destinations or sporting disciplines and, on the basis of their selections, is suggested a vehicle that would be the best match for them.

Ola Källenius: “You can use the Lifestyle Configurator to search for a new Mercedes-Benz in exactly the same way you would search the internet today for, say, fashion – simply, interactively and without having to be a technology buff.”

Dieter Zetsche: “In Marketing & Sales, digitalisation brings us first and foremost the opportunity to address our customers’ desires even more individually. The new Lifestyle Configurator shows us that the digital and real customer worlds will continue to merge at Mercedes.”

Vehicle communication and data protection


The rapid development of communications technology is still opening up completely new perspectives. Experts assume, for instance, that a 5G mobile communications network will be up to 100 times faster than LTE. Comprehensive updates to the car’s software, for instance, can then also be handled online in just a matter of seconds.

Due to this in particular, data protection is especially important to the company. Dieter Zetsche: “The opportunities are enormous; as is our responsibility to protect our customers’ private lives and to ensure that personal information does not fall into the hands of third parties. This responsibility also means our vehicles must be secure against manipulation from outside. It is therefore our duty and our aim to make our cars as secure as possible. We are working incredibly hard on this.”

The digital transformer – “Concept IAA”


At the Frankfurt International Motor Show, Mercedes-Benz is showing what digitalisation can mean for the car as a product in real terms, with the “Concept IAA” (Concept Intelligent Aerodynamic Automobile). The increase in speed and efficiency through digitalisation is impressively demonstrated in figures. Design development, which alone would previously have taken up to two years, was achieved in less than eleven months.

The Mercedes-Benz Concept IAA is two cars in one – an aerodynamic world record holder with a cd figure of 0.19 and a four-door coupé with a fascinating design. The study, which will be premiered at the IAA in Frankfurt, automatically switches from Design mode into Aerodynamic mode upwards of 80 km/h, altering its form with a large number of active aerodynamic measures. Inside, the Concept IAA carries forward the design lines of the S-Class and S-Class Coupé, offering new, touch-based functionalities and a highly emotional, digital operating experience. At the same time, the interior provides a glimpse into the interior of a business sedan of the near future. Outside, the rear lights are a particular highlight evocative of the stardust or glow of a jet engine. These lights with their “stardust effect” will celebrate their premiere in a production model in early 2016.

The Concept IAA is also the perfect example of the technologically fundamental changes in the automotive sector driven by digitalisation. For Mercedes-Benz, a fully digital process chain from research and development, through production to sales, logistics and services is far more than science-fiction. Dieter Zetsche: “What’s definitely clear to me is that this car here and the outlook for Mercedes‑Benz have one thing in common – they both look damn good.”

Media release by Daimer - 14 September 2015
https://media.daimler.com/dcmedia/0-921-1845911-1-1847484-1-0-0-0-0-0-0-0-0-1-0-0-0-0-0.html

Updated     21.7.2025,  11 July 2018,
First posted 18 April 2016

Wednesday, July 16, 2025

Smart Factory and Smart Manufacturing - Productivity Improvement




Productivity Improvement Achieved by Best Practice Companies.

Read the information available on each plant to become aware of the effective use made by these companies of Industry 4.0 Technologies in various processes and systems.



Apple Inc. - Industrial Engineering Activities - Industrial Engineering 4.0


Bosch Automotive - Bursa - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


CEAT - Halol, India Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant.


4. Dr Reddy's - Hyderabad Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


5. .Ericsson - Lewisville Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

6. Foxconn - Shenzen Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


8. GlaxoSmithKline (GSK) Hertfordshire Plant - Industrial Engineering 4.0


9. Haier - Hefei Plant - Industrial Engineering 4.0 - Industry 4.0 WEF-McKinsey Lighthouse


10. Ingrasys - Taoyuan, Taiwan Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


11. Johnson & Johnson - Industrial Engineering - Productivity Improvement Activities - Industry 4.0 Lighthouse Plant


12. K-Water - Hwaseong - REPUBLIC OF KOREA - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


13. LONGi Solar - Jiaxing Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

15. Mondelēz - Beijing Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
Mondelez - Sricity

16. Novo Nordisk - Hillerød Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

17. Otis - Industry 4.0 - Industrial Engineering 4.0 - Productivity and Quality Engineering and Improvement.


18. Procter & Gamble - Takasaki Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

19. Quaker Houghton - Industrial Engineering 4.0 - Intelligent Die Casting

20. Renault - Industrial Engineering 4.0



22. S   Schneider Electric - Hyderabad

23. T  The Coca-Cola Company - Ballina

24. U  Unilever - Sonepat

25. V   Volkswagen - Industrial Engineering 

26. W   Western Digital - Bang Pa-In

27. X    Xiaomi Corporation - Industrial Engineering 4.0  - vacuum cleaner

29. Y   Yamaha - Industrial Engineering 4.0

30. Z   Zymergen - Emeryville




Monday, December 14, 2020
The Dimensions of the New MESA Smart Manufacturing Model

Technologies, capabilities and lifecycles. 

The New MESA Smart Manufacturing Model will  provide guidance to practitioners and provide a practical down-to-earth vision of what Smart Manufacturing can and should be.

http://blog.mesa.org/2020/11/the-value-of-new-mesa-smart.html

http://blog.mesa.org/2020/11/getting-new-mesa-smart-manufacturing.html

http://blog.mesa.org/2018/02/diiot-idiot.html

http://blog.mesa.org/2018/02/the-importance-of-standards-for-smart.html

http://blog.mesa.org/2017/12/is-industry-40-really-smart.html

http://blog.mesa.org/2017/11/the-smart-factory-shifts-from-reactive.html

http://blog.mesa.org/2017/08/virtual-smart-advisors-kickstart-smart.html

http://blog.mesa.org/2017/06/industry-40-and-smart-services-welt.html

http://blog.mesa.org/2017/05/notes-from-smart-manufacturing-and-iiot.html

http://blog.mesa.org/2017/04/top-3-drivers-for-mes-in-industry-40.html



http://blog.mesa.org/2016/07/how-smart-are-we-in-manufacturing-today.html

http://blog.mesa.org/2016/06/the-smart-manufacturing-landscape_30.html

http://blog.mesa.org/2016/03/smart-manufacturing-and-continuing-need.html

http://blog.mesa.org/2016/03/the-smart-manufacturing-elevator-pitch_25.html

http://blog.mesa.org/2016/03/the-smart-manufacturing-elevator-pitch.html

http://blog.mesa.org/2016/03/smart-manufacturing-isnt-so-smart.html

http://blog.mesa.org/2016/02/how-to-achieve-smart-manufacturing.html

http://blog.mesa.org/2016/01/smart-manufacturing-what-if-they-threw.html

http://blog.mesa.org/2015/04/join-development-of-smart-manufacturing.html  First post on smart manufacturing in MESA Blog



---------------
The Smart Factory - Deloitte Insights - 2019

Major features: connectivity, optimization, transparency, proactivity, and agility.

Each of these features can play a role in enabling more informed decisions and can help organizations improve the production process.


Benefits of the smart factory

Asset efficiency - productivity

Product Performance and Quality

Lower cost

Safety and sustainability


https://www2.deloitte.com/us/en/insights/focus/industry-4-0/smart-factory-connected-manufacturing.html


ud. 16.7.2025, 1.1.2021, 2 Jan 2020
posted 23.10.2019

Thursday, January 9, 2025

Industrial Engineering in MES - Vaeso

 


https://vaeso.com/mes-solution/industrial-engineering


https://vaeso.com/blogs



Waste Measurement and Reporting Using MES - Manufacturing Execution Sytem

 

Lean Manufacturing and MES — Minimize Waste and Improve Productivity

Warren Andrade

January 13, 2021

https://www.pinpointinfo.com/blog/lean-and-mes-minimize-waste-improve-productivity


Defining the Right Manufacturing Metrics is the First Step to Proving the Benefits of MES

FEBRUARY 09, 2021

https://www.ibaset.com/defining-the-right-mes-metric-is-the-first-step-to-proving-the-benefits/

Expand Lean Manufacturing with MES

White Paper

https://discover.3ds.com/expand-lean-manufacturing-with-mes


A Novel Methodology to Integrate Manufacturing Execution Systems with the Lean Manufacturing Approach

Gianluca D’Antonio, Joel Sauza Bedolla, Paolo Chiabert

Procedia Manufacturing

Volume 11, 2017, Pages 2243-2251

https://doi.org/10.1016/j.promfg.2017.07.372

https://www.sciencedirect.com/science/article/pii/S2351978917305802


A recent research  showed that companies need to increase the degree of use of IT tools in order to implement lean practices. The importance of MES in this field has also been shown. Cottyn [10] developed a first framework for the alignment of MES to lean objectives. He defined an automatic Value Stream Mapping (aVSM) methodology: the aVSM benefits from the information provided by the MES, since it is a rich source of information and historical data useful to define continuous improvement actions. The methodology is validated through the case studies of a furniture firm and a food and beverage company. In, the support of MES to lean manufacturing has been discussed through the case study of a supplier of components for buses and coaches. Nevertheless, a methodology for fully integrating the MES capability in data analysis and dispatching with lean practices is still lacking.


The methodology for data analysis 

Data source. First, the data necessary to perform the analysis and their sources must be defined. On the shopfloor several kinds of devices can be deployed to collect data. First, the PLC of the machine involved in the process can provide helpful data concerning, for example, axes position and errors, axes and spindle movement, the deployed tool and the content of the stock, the applied power and torque, and some key performance indicator (e.g. cycle times, throughput, the incidence of failures). Furthermore, different kind of sensors can be integrated into the machine to collect data related to the quality process and the state of the tool. In machining processes, the most deployed sensors are dynamometers, accelerometers, thermometers, acoustic emission and current sensors. 

Sensors can be used both online - while the process is occurring - or offline, for example to evaluate the quality of a finished part (e.g. geometrical dimensions, mechanical strength, electrical properties); of course, sensors collecting different kind of data can be used and their information can be integrated to have a more exhaustive picture. 

Data processing and Feature generation. The second step consists in choosing the mathematical technique to analyze the collected data. The aim of data processing is to transform data, regardless of the source, into information through the generation of a finite set of features. 

Mainly, two classes of data processing techniques can be used. The first one consists in mathematical models, based on deterministic or statistic approaches. This technique is convenient when the analyzed system is not too complex and its behavior is fully known. In particular, the statistical approach is effective in dealing with a huge amount of data and is widely used, for example, with data acquired by a sensor set. 

The second class of data processing techniques consists of simulation tools: they are preferable when the analytical description of the system is too complex. Data provided in input to the simulation can provide from several sources: theoretical (or expected) data can be used to evaluate the behavior of the system in standard situations; real data, collected at the shop-floor are helpful to be aware of the reaction of the system in the current situation. 

Feature extraction and Decision making. The role of the data processing technique is to synthesize the collected data into a smaller set of information features; nevertheless, some of them may be not significant or reliable to take decisions and, thus, should be discarded. Furthermore, new significant features can be extracted by combining some parameters: overall indices can be obtained by averaging features, by generating response surfaces or by comparing the expected state with the real condition of a process or a product. 

Finally, a strategy for decision making must be defined, based on the results of the feature extraction. The decision can be automatically taken by an algorithm able to choose the values of a set of parameters in order to optimize a given metric. Alternatively, the algorithm may provide hints to an operator and leave him free to act on the process. Furthermore, the decision making algorithm should also provide an estimation of the state of the process after such intervention, to evaluate the impact on the performance of the process.

Case study 

Step 1. Process and wastes. A manufacturing process in the field of aeronautics is presented.

The process of gear grinding is considered. This is a critical process, because these workpieces must be manufactured with great accuracy.  Since grinding is a costly operation , it should be utilized under optimal conditions. The established manual operation consists of two steps. First, a pre-processing task is made to identify the workpiece axis that minimizes the geometrical distortions. This action is performed by finishing the two countersinks of the gear, which are used to place the part into the grinding machine. Then, gear grinding is performed. The operators highlighted an excessive rate of defective parts; this led to expensive reworking operations and to process variability resulting, in turn, in excessive waiting times and inventory parts accumulating through the process. The latter two waste sources were confirmed by the Value Stream Mapping analysis. Therefore, a novel system to perform gear centering prior to the grinding operation has been studied. 

Step 2. Process description. After having identified the wastes affecting the process, a thorough description of the grinding process has been made. The input components are the gears leaving the upstream heat treatment process; gears belong to a finite set of well-known part families, and are grinded one-by-one. The quality of the output parts is measured through functional tolerances: residual concentricity for the bearing seats and the gear, and total axial runout of the side surface; the range of such tolerances – defined in the ISO 1101 standard  – is in the rder of 0.05-0.1 mm. The performance of he process is measured through well-established indicators: cycle-time, work in process, throughput and rate of failures. In order to perform the process, a skilled operator is necessary to perform the correct positioning of the workpiece in the machine. 

In order to improve the performance of the grinding process and the quality of the machined gears, a novel system to support piece positioning has been developed, supported by a proper mathematical technique. Mainly, the gear is placed into a manufacturing machine to finish two surfaces – at the top and bottom extremities of the piece – with the aim of defining a new reference system for the part that minimizes the residual geometrical error. Such surfaces are used in the subsequent grinding operation to easily place the gear into the machine. 

Step 3. Data-analysis. First, the sources for data acquisition have been selected. Given the strict quality needs, displacement transducers are used to measure the profile of the gear where the tolerances are set, 

2c. To perform the measurement, a rotation of the gear about the axis of the machine is made. Since the tolerances are tight, sensors with high reproducibility (30 μm) have been used and a high acquisition rate is set (3600 points/revolution). After the acquisition, data are processed: to minimize the impact of measurement noise and errors, a least-squares interpolation is made for each of the gathered profiles. In particular, the three radial sections (i.e. the gear and the bearing seats) are interpolated through least-squares ellipses, and the coordinates of their centers are extracted. 

Given the cost of the manufactured parts, the manufacturer is interested in exploiting as much as possible the functional tolerances, in order to minimize the quantity of rejected parts. Hence, an objective function has been defined: it collects the current positioning errors, eventually weighted according to the tolerances values. This function is based on two independent variables, corresponding to the two part rotations that can be made to correct the position of the gear into the machine. Finally, the objective function is minimized to reduce as much as possible the residual positioning error; the calculated values for the two feasible rotations are provided to the machine to correct the position of the gear within the machining area. Then, the two reference surfaces are finished. 

The role of MES. The integration of this monitoring and control system with a MES enables to analyze and use the collected data at different time-scales with different purposes. On the short-medium term, MES allows to check whether the process is stable or not. Further, when instability symptoms appear, MES can predict when the process is going to be out of control and produce parts not matching the expected quality. Thus, setup or maintenance interventions can be planned in a preventive approach, also taking into account further constraints, such as the availability of operators or already planned downtime. This kind of prediction is helpful to avoid producing parts that will be rejected, thus reducing waste. On the long term, MES information can be further analyzed to extract historical trends, to synthesize criticalities and identify the sources of issues and wastes. The integration of a traceability system strongly supports this functionality: in this case study, each workpiece is identified by a unique ID. Information concerning each gear, such as the time at which the centering operation occurs and the expected results of the alignment, can be collected and stored into a database. This information can be useful to monitor the results of the centering process over time, and identify the reasons for possible decays or drifts; however, a careful analysis of these data is necessary, since issues identified on the centering machine can be due to inefficiencies in the upstream workstations. The results of this analysis can be shared with different departments of the company. For example, the business unit can benefit from this information to define new strategies, or to correct the previously defined ones; the design department can use this experience-driven knowledge to improve the design of a product or process. The feedback information provided by the MES supports the test and validation of new process or product releases. This, in turn, enables the implementation of kaizen practices for continuous improvement, such as the PDCA cycle.





Manufacturing execution systems driven process analytics: A case study from individual manufacturing

Lea Mayer, Nijat Mehdiyev, Peter Fettke

Procedia CIRP

Volume 97, 2021, Pages 284-289

https://doi.org/10.1016/j.procir.2020.05.239

https://www.sciencedirect.com/science/article/pii/S2212827120314608



Online Loss Capturing Using  MES


Various losses occurring in a manufacturing plant have direct bearing on reduced productivity and increased costs. Though some losses like asset failure can be measured using traditional methods, advance systems are required for root cause analysis. Then there are many miniscule losses which are very difficult to measure. Their frequency of occurrence can be high and hence their cumulative effect significant. These are referred to as ‘minor stoppages’. Yet other types of losses occur due to lack of coordination between various departments. This case study demonstrates how PlantConnect SFactory, a Smart Factory solution from Ascent Intellimation tracks and analyzes all types of losses and helps in eliminating some losses and reducing others. The installation is done in. Overall business requirements of customer are:


• Loss analysis

• OEE improvement

• Just-In-Time Maintenance


THE SOLUTION PlantConnect SFactory with integrated Loss Analysis Module was deployed. Losses are categorized as:


• availability losses

• performance losses

• quality losses





Ud. 9.1.2025, 31.1.2022

  Pub 29.12.2021





Saturday, December 21, 2024

Cost Measurement in Manufacturing Execution System (MES)

 

A production process can be very expensive, that is why managing industrial costs is a key activity for every manufacturing company. The sum of direct costs of materials, employees and production costs is the industrial cost of manufacturing. Sistrade® offers a solution to record all the material costs, including indirect costs to calculate cost estimation closest to real.

Real job order cost

Work in process cost

Estimated/real cost comparison

Order profitability

Automatic update of standard costs

Distribution of indirect costs by manufacturing stage

Distribution of indirect costs by cost centres





Dynamic Costing

Many organizations face challenges in obtaining clear and accurate cost data. Our Dynamic Costing solution encompasses the key guiding principles associated with traditional activity-based costing and other operational costing approaches to more accurately zero in on the true costs of a particular product.  Leveraging advanced analytics and industry specialization, our team of professionals is able to create visibility to your costing data and more importantly map how that costing data flows onto the company’s financial statements.  

Our analytic approach is fully integrated with some of the leading MES and ERP systems, enabling visibility from the shop floor to the c-level suite.




IFAC Proceedings Volumes
Volume 35, Issue 1, 2002, Pages 175-180
IFAC Proceedings Volumes
DYNAMIC COST CONTROL METHOD IN PRODUCTION PROCESS AND ITS APPLICATION
Full article available


Design and application of dynamic cost control system based on MES
August 2003, Dongbei Daxue Xuebao/Journal of Northeastern University 24(8):719-722
Authors: W. Liu, Y.-G. Chu, T.-Y. Chai
https://www.researchgate.net/publication/289479763_Design_and_application_of_dynamic_cost_control_system_based_on_MES

December 2020
Justifying Investment in Manufacturing Execution Systems
Dirk Sweigart, BSME, BSCS, MBA

https://imfactory.com.pl/en/knowledge/total-manufacturing-cost-and-cost-allocation-in-a-company-part-3-the-role-of-mes-and-erp-in-cost-management/


https://www.criticalmanufacturing.com/mes-for-industry-4-0/mes-investment-and-roi/


Ud. 21.12.2024
Pub. 29.12.2021













Thursday, December 19, 2024

CNC Machine Tools - Evolution - Industry 4.0

https://engtechgroup.com/cnc-machines-evolution/

https://www.marposs.com/eng/application/machine-tool-retrofit


2024

Case Study

Client Challenge 

The need to adapt to Industry 4.0 standards with Adequate RoI.

Client Background: 
A leading manufacturing plant specializing in precision engineering with Computer Numerical Control (CNC) technology faced challenges in optimizing production processes and ensuring the seamless integration of advanced technologies. The client, operating in a highly competitive industry, sought to enhance efficiency, reduce downtime, and elevate the overall productivity of their manufacturing operations. 

2023

August 13, 2023
The role of 5-Axis CNC Machining in Industry 4.0
Reshaping Manufacturing through Technological Advancements



2021

Clea is SECO’s suite solution for the remote management of  devices and machines


Clea is SECO’s suite solution for the remote management of  devices, of data generated in the field, and its aggregation in the cloud to support business analytics. With Clea, you will have everything you need to enable your custom IoT solution: dedicated hardware, connectivity, a platform, telemetry, data management, analytics, and consulting.

A Case - Challenge

A manufacturer of industrial machinery for woodworking and the processing of other materials had the initial requirement to reduce warranty costs  for CNC machines, computer controlled machining tools which are able to process materials without a manual operator.

What SECO did
SECO enabled the equipment of CNC machines with ad-hoc smart sensors and gateways, connecting them to EDGEHOG Device Manager to allow production cycle data analysis, remote control and update – with OTA updates – and predictive maintenance through dedicated algorithm. Connectivity was enhanced by equipping the machines with a global SIM card, Wi-Fi and Bluetooth connection and geo-localization microservice.

Results achieved

Making the customers’ machinery smart and connected allowed for offering a better user experience with  the possibility of remote assistance with annual subscription. From a production standpoint, there was an increase in the quality of the pieces produced, while reducing production waste of 30%. The supply chain was provided with a better support, allowing cost (10%) and lead time (40%) reduction of the spare parts.

https://www.seco.com/en/case-studies/industrial-automation/smart-connected-cnc-machine

Mazak - Smart Machine Tool Developments

Mazak

The Global Leader in Machine Tools - Turning centers, Machining centers, Multi-tasking, Hybrid multi-tasking, Laser processing,
CNC technology, Automation and IoT solutions.

SMART Manufacturing Thanks to Smooth Technology
Today manufacturers everywhere face many challenges - constantly striving to reduce production costs, increasing the use of automation, a growing shortage of skilled employees among many others. "The Mazak iSMART FactoryTM" technology can be used to meet manufacturers' demands to establish production plants using the IoT. By utilizing advanced Mazak machine tools together with software, we can effectively support your goal of realizing data-driven manufacturing for higher productivity.
https://english.mazak.jp/machines/technology/factory-network/ismart-factory/

Mazak SmartBox?

Mazak SmartBox is a revolutionary launch platform for easy and highly secure entrance into the Industrial Internet of Things (IIoT). It is a scalable solution that connects your manufacturing equipment to your factory network and allows the free flow of information to your management systems via MTConnect® for Overall Equipment Efficiency (O.E.E.).

Mazak offers the smartbox in various configurations/kits based on the scenarios and challenges in which the units will be used. The device physically mounts to the side of machines without having to integrate into a machine’s electrical cabinet.  One Mazak SmartBox may connect several machine tools along with other associated manufacturing equipment, depending on the application.

THE BENEFITS OF USING Mazak SmartBox?
Mazak SmartBox  is designed to be a launch platform for anything IIoT. It:

Secures the machine from the network
Secures the network from the machine
Enables Edge/Fog computing and analytics
Uses MTConnect as standard supported protocol
Enables easy monitoring of equipment status and utilization
https://www.mazakusa.com/machines/technology/digital-solutions/mazak-smartbox/

Mazak Smartbox Implementation Case Study


The SmartBox is one of many innovative components in Mazak’s dynamic iSMART Factory concept, which enables complete digital integration of advanced manufacturing cells and systems to achieve free-flow data sharing in terms of process control and analytics.

The iSMART Factory concept also incorporates Mazak SMOOTH TECHNOLOGY, a complete process-performance technology platform that includes the various levels of the new Mazak MAZATROL Smooth CNC as well as advanced machine hardware and servo systems. SMOOTH TECHNOLOGY represents a key first step towards digital factory integration.

MACHINES AND OTHER EQUIPMENT

65 machines, paint test stands, and other devices are connected through MTConnect at the Kentucky Mazak factory. In the initial complete installation of a machine-monitoring system encompasses SmartBoxes, six horizontal machining centers (HMCs) in an automated flexible manufacturing system, three other HMCs in a similar automated system, and six large bridge-type milling machines.

A series of 60-inch display monitors presents real-time utilization data in the test section of the plant and cycles through a series of KPI reports that are viewable for short periods of time using MERLIN. The Cisco switch enables network isolation, which creates a higher level of cybersecurity for enhanced 
machine monitoring and analytics. The majority of reports focus on a specific machine, and display performance-based gauges and readouts. Other reports compare all connected machines according to a variety of critical metrics, such as uptime and stoppages by category.

For the first time, for Mazak, top management, as well as everyone across the company’s shop floor, has access to the same actionable reports and/or monitored data through mobile devices. Shop floor employees now have easy-to-interpret, visual report formats that give them at-a-glance information 
about how machine tool conditions are influencing efficiency. Bar graphs that summarize activity across several machines simultaneously inform supervisors and managers of trends useful for decision making and long-term planning, such as when additional operator training may be needed.

The company is now fully aware of program stops, feed holds, spindle overrides, tool changes, and other reasons why a machine is idle. By analyzing collected data, Mazak personnel are able to identify and easily fix such downtime-related inefficiencies to improve overall utilization. Another new advantage is that individuals, such as equipment suppliers, can log on to Mazak’s network and have access to only those machines Mazak permits through SmartBox technology

PROJECT RESULTS
Almost as soon as   reports  were produced on its plant floor, the company experienced a six-percent increase in utilization. Without any other actions taken, these immediate gains resulted from operators simply being aware of how their time management affected machine utilization. To date, efforts to 
reduce downtime — as based on factory-floor report data — have yielded a more than double-digit percentage improvement in machine utilization for the monitored machines. As a result of this windfall machine capacity, Mazak reduced operator overtime by 100 hours per month and brought 400 hours 
per month of previously outsourced work back in house.

Source: Complete Digital Factory Integration and the IIoT by Mazak- A Cisco Report
https://www.cisco.com/c/dam/en_us/solutions/industries/docs/manufacturing/smart-box.pdf

THE NUTS & BOLTS OF INDUSTRY 4.0 - MAZAK
Published: 06/07/2018

The reality of Industry 4.0 data analytics for a Mazak customer, detailing the needs and some of the benefits of easily applied system components suitable for SMEs
https://www.machinery.co.uk/machinery-features/the-nuts-bolts-of-industry-4-0-mazak

https://www.mazakusa.com/news-events/blog/artificial-intelligence-makes-spindle-health-monitoring-a-reality/



Implementation of a machine tool retrofit system

https://www.tib-op.org/ojs/index.php/th-wildau-ensp/article/view/19/10

https://www.bosch.com/stories/industry-4-0-retrofit-project/


2020

Strategic Retrofitting: Older Machines Get an IIoT Update
Affordable alternatives can help upgrade legacy equipment.

W. David Stephenson
MAR 10, 2020


Low-Cost Automation: Retrofitting Old Machines
https://www.industrialautomationindia.in/articleitm/358/Low-Cost-Automation:-Retrofitting-Old-Machines-/articles

3/23/2020 
The Anatomy of a CNC Machine IoT Solution
https://www.productionmachining.com/blog/post/the-anatomy-of-a-cnc-machine-iot-solution

https://smartech.gatech.edu/bitstream/handle/1853/62850/NGUYEN-THESIS-2020.pdf

http://www.rae.ca/wp-content/uploads/industry_guide_sensor_technology_solutions_for_the_machine_tool_industry_en_im0018543.pdf



CASE STUDY
Retrofit Enables Threefold Increase in Capacity
Henshaw replaces legacy CNC system with programmable numeric control (PNC) to improve machining cell performance and flexibility

2018

https://www.sme.org/technologies/articles/2018/october/industry-4.0-and-cadcam-software-five-questions/

Machine tool retrofit to increase productivity, user convenience and safety
"PCU Retrofit for Sinumerik 840D" service offered for machine tools with a Sinumerik 840D pl controller
PCU-based (Panel Control Unit) controller updated
After a short retrofitting time, equipment is ready again for immediate use
https://press.siemens.com/global/en/pressrelease/machine-tool-retrofit-increase-productivity-user-convenience-and-safety


2017

https://www.americanmachinist.com/enterprise-data/5-ways-machine-tools-are-impacted-industry-40

IoT enabled CNC Milling Machine
IIT Madras B.Tech project 2017
https://www.tkbala.com/iotcnc

6/14/2017

Data-Driven Manufacturing: Retrofit Your Machines
The Fraunhofer Institute has developed a retrofit solution to upgrade production systems with network capability, enabling users of older machines to reap the benefits of data-driven manufacturing.
https://www.mmsonline.com/articles/data-driven-manufacturing-retrofit-your-machines



CNC Machine Sensors

2014
https://www.techna-tool.com/blog/importance-of-cnc-tool-sensors-in-modern-day-cnc-machines/



About CNC Machines



http://home.iitk.ac.in/~nsinha/CNC.pdf


Ud 19.12.2024, 8.10.2021
Pub 11.8.2021

Saturday, September 28, 2024

Accenture - IoT - Digital Transformation - Operations Twin - Digital Twin Practice

 


Haier Europe makes its products smart and connected with Internet of Things.

https://www.accenture.com/us-en/case-studies/industrial/haier-smart-connect-services



Visual Design in Accenture Operations Twin


Timeframe


March-October 2021


Introduction

A digital twin is an accurate representation of something from the “real world.” As part of their Industry X initiative, Accenture wanted to develop a digital twin program that integrated artificial intelligence and machine learning in order to empower users to optimize and prioritize their work based on real data and predictions.


Over the course of several months, I worked in the design team of three visual designers, and two experience designers. We worked closely with the business analysts and used user research, tests, and check-ins with subject matter experts to guide the designs.



 Industry X Plant Control Tower - an Accenture Operations Twin Application

With the Industry X Plant Control Tower, an Accenture Operations Twin Application you are unlocking many Possibilities for your Industry – here are just 5:

 
1️⃣ Predictive Maintenance: With real-time data from sensors and IoT devices, Digital Twins can forecast equipment failures before they happen, minimizing downtime and saving costs.
 
2️⃣ Efficient Operations: By creating a virtual representation of an industrial process, operators can simulate different scenarios, optimize processes, and improve overall efficiency.
 
3️⃣ Remote Monitoring and Control: Imagine having the ability to remotely control and monitor complex machinery or critical infrastructure from anywhere in the world.
 
4️⃣  Energy Efficiency: Industries can reduce energy consumption by modeling and simulating energy usage patterns.
 
5️⃣  Data-Driven Decision Making: Digital Twins provide a wealth of data that can drive informed decision-making and strategic planning.
























Saturday, September 21, 2024

Modern Industrial Engineering - Industrial Engineering through Process Mining

New.

Popular E-Book on IE,

Introduction to Modern Industrial Engineering. 

In 0.1% on Academia.edu. 10,600+ Downloads so far.

FREE Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0


Process Mining


Process and task mining helps organizations discover and visualize all business processes across the enterprise, and analyze the traces of process related data recorded by IT systems, providing greater business process transparency and optimization.

The analytics tools of process mining helps users to analyze vast amounts of data in real-time, providing  end-to-end operational intelligence in real time. 

Process experts often design processes expecting that their execution will be faithful to the design. However, designs tend to be incomplete and not executable in practice, and people tend to develop workaround to bypass designed processes or to compensate for the inconveniences. Process mining highlights the deviations and helps designers and managers to modify the designed processes in light of actual working of processes or to train the operating staff in designed processes.

These challenges are more prevalent than ever as rapid changes are occurring and getting introduced in the processes due to digital transformation programs, adoption of global business services, and the introduction of bots and other AI into the business processes.

Process and task mining offer a set of novel tools and techniques for the factual analysis of business processes. Based on system logs and/or screen recordings, they automatically map and visualize how processes have been executed in reality, and help companies to improve processes and standardize to much a greater extent.


Topic of Computer Aided Industrial Engineering (CAIE) - Proposal by Prof. Narayana Rao K.V.S.S.

IISE 2021 Annual Conference Paper.


Process Mining is a  new area of study grounded in a long tradition of businesses striving to optimize business outcomes by improving the efficiency, effectiveness and productivity of their critical workflows.

Frederick Taylor Winslow was  the first person to study and optimize workplace productivity. His publications, 1895 (Piece rate system), 1903 (shop management) 1911 (The Principles of Scientific Management) pioneered the idea that a business’s core operations should be analyzed, standardized and improved on.


Evolution of Process thinking: Taylor - Ford's Mass Production - Toyota Production System - Six Sigma

Process Mining happens in four distinct stages 

• Collection of time-stamped event log data from key transactional systems

• Discovery within that data of real processes taking place

• Enhancement of those processes to increase and optimize  efficiency, effectiveness and productivity

• Monitoring these changes for further adjustments required to make them standard operations. 


 “Process Mining is analyzing processes based on event data... i.e., based on what’s really happening." 

For based on the event logs,  process discovery and conformance checking is done. Process improvement engineers re-engineer processes. 

Process Mining software systems are  purpose-built to handle the inherent complexity and dynamism of the modern process environment. It delivers deep visibility and control into the minutiae of individual processes, the relationships between them, and the outcomes they deliver.


Reference

Celonis, The Ultimate Guide to Process Mining: A handbook for process excellence

What is Process Mining?

24 Feb 2022

IBM Technology

Process mining is technique that applies data science to discover, validate and improve workflows by extracting available knowledge from event log systems in an organization. 

In this lightboard video, Jamil Spain with IBM, explains how process mining can help a business better understand the performance of their processes, find bottlenecks and other areas the need improvement. 

https://www.youtube.com/watch?v=YNxpGimyCt0


Process Mining Manifesto


Process mining is sits between computational intelligence and data mining and process modeling and analysis on the other hand. 

The idea of process mining is to discover, monitor and improve real processes (i.e., not assumed processes) by extracting knowledge from event logs readily available in today’s (information) systems  

Process mining includes (automated) process discovery (i.e., extracting process models from an event log), conformance checking (i.e., monitoring deviations by comparing model and log), social network/organizational mining, automated construction of simulation models, model extension, model repair, case prediction, and history-based recommendations.

Process mining is an enabling technology for continuous process improvement (CPM), BPI, TQM, Six Sigma, and the like.

Starting point for process mining is an event log. It is possible to sequentially record events that happen in a process such that each event refers to an activity (i.e., a well-defined step in some process) and is related to a particular case (i.e., a process instance). Whenever possible, process mining techniques provide  extra information such as the resource (i.e., person or device) executing or initiating the activity, the timestamp of the event, or data elements recorded with the event (e.g., the size of an order).

Event logs of the processes (actual runs) can be used to conduct three types of process mining. The first type of process mining is discovery. A discovery technique takes an event log and produces a model or chart of the process utilized.  The second type of process mining is conformance. Here, an existing process model is compared with an event log of the same process. Conformance checking can be used to check if reality, as recorded in the log, conforms to the model.   The third type of process mining is enhancement. Here, the idea is to extend or improve an existing process model using information about the actual process recorded in some event log. To support enhancement, by using timestamps in the event log,  the process model can show  bottlenecks, service levels, throughput times, and frequencies.

Guiding Principles for Design of Process Mining System and Development of Process Maps


GP1: Event Data Should Be Treated as First-Class Citizens

GP2: Log Extraction Should Be Driven by Questions

GP3: Concurrency, Choice and Other Basic Control-Flow Constructs Should be Supported

GP4: Events Should Be Related to Model Elements

GP5: Models Should Be Treated as Purposeful Abstractions of Reality

GP6: Process Mining Should Be a Continuous Process

Challenges

C1: Finding, Merging, and Cleaning Event Data

C2: Dealing with Complex Event Logs Having Diverse Characteristics

C3: Creating Representative Benchmarks

C4: Dealing with Concept Drift

C5: Improving the Representational Bias Used for Process Discovery

C6: Balancing Between Quality Criteria such as Fitness, Simplicity, Precision, and Generalization

C7: Cross-Organizational Mining

C8: Providing Operational Support

C9: Combining Process Mining With Other Types of Analysis

C10: Improving Usability for Non-Experts

C11: Improving Understandability for Non-Experts


Process Mining

Manifesto  released by the IEEE Task Force on Process Mining.


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4 Ways Process Mining Uses Automated Root Cause Analysis

UPDATED ON AUGUST 8, 2022    |     PUBLISHED ON MARCH 3, 2022 

https://research.aimultiple.com/automated-root-cause-analysis/

Ph.D Student Senderovich Arik

Subject Queue Mining: Service Perspectives in Process Mining

Department Department of Industrial Engineering and Management

Supervisors Professor Avigdor Gal

Professor Emeritus Avishai Mandelbaum

Abstract

Business processes are supported by information systems that record process-related events in event logs. Process mining aims at discovering useful information about the business process from these event logs. Process mining can be viewed as the link that connects process analysis fields (e.g. business process management and operations research) to data analysis fields (e.g. machine learning and data mining).

Process mining techniques  aim at answering operational questions such as `does the executed process as observed in the event log correspond to what was planned?', `how long will it take for a running case to finish?' and `how should resource capacity or staffing levels change to improve the process with respect to some cost criteria?

Prior to this thesis, process mining techniques overlooked dependencies between cases when answering such operational questions. For example, state-of-the-art methods for predicting remaining times of running cases considered only historical data of the case itself, while the interactions among cases (e.g. through queueing for shared resources) were neglected. 

In service processes in healthcare, banking, transportation etc.,  multiple customer-resource interactions occur, and customers often compete over scarce resources. Consequently, the central argument of this thesis is that for service-oriented processes, process mining solutions must consider case interactions when answering operational questions.

The main contribution of this research thesis is the start of bridging a noticeable gap between process mining and queuing theory. To this end, we introduce queue mining (a term coined in this thesis), which is a set of data-driven methods (models and algorithms) for queueing analysis of business processes.

Our queue mining techniques address the problems of prediction (delays and total times in the process), conformance to schedule (planned vs. actual), and process improvement (via production policy optimization). We demonstrate the effectiveness of these techniques with experiments on real-world data that comes from three domains: banking (a bank's call center), transportation (city buses), and healthcare (an outpatient hospital).

http://www.graduate.technion.ac.il/theses/Abstracts.asp?Id=29534


Presentation on theme: "Service Perspectives in Process Mining"— Presentation transcript:

https://slideplayer.com/slide/14748344/


Process Mining Presentations

Prof. Vil wan der Aalst

https://www.slideshare.net/wvdaalst/process-mining-chapter03datamining

About Process Mining - 2018

https://medium.com/@pedrorobledobpm/process-mining-plays-an-essential-role-in-digital-transformation-384839236bbe


Process Mining for Six Sigma: Utilising Digital Traces

I.Kregel D.Stemann J.Kochc A.Coners

Computers & Industrial Engineering

Available online 24 December 2020, 107083

In Press, Journal Pre-proof

Computers & Industrial Engineering

https://www.sciencedirect.com/science/article/abs/pii/S0360835220307531


Machine Learning in Manufacturing and Industry 4.0 applications

Using process mining to improve productivity in make-to-stock manufacturing

Rafael Lorenz,Julian Senoner,Wilfried Sihn &Torbjørn Netland

International Journal of Production Research 

Volume 59, 2021 - Issue 16 

https://www.tandfonline.com/doi/full/10.1080/00207543.2021.1906460



Ud. 21.9.2024,  15.10.2022,  2.4.2022, 2.2.2022

pub: 31.12.2020





Process Mining
is purpose-built to handle the inherent
complexity and dynamism of the modern