A cyber-physical system for production monitoring of manual manufacturing processes

The computerization of manufacturing is one of the major challenges of the so-called fourth industrial revolution or Industry 4.0. Virtualization of the smart factory should provide real-time vision, control and monitoring of production through interactive dashboards and synchronization of data coming from different factory functions. The latter characteristics are particularly difficult to implement when the manufacturing core relies on traditional manual labour rather than on automation, as in the case of manual assembly. Monitoring or even controlling the manual work in real-time is extremely difficult to put into practice. Therefore, realizing the principles of Industry 4.0 in manual or semi-automatic labour contexts means developing new production control systems that involve the worker in the monitoring process without negatively affecting the production times or the psychological status of the workers. In particular, the authors propose a computer-aided production control framework based upon multimedia manuals and smart completeness control systems that can be used to implement the principles of Industry 4.0 in manual or semi-automatic work environments. This technology has been successfully tested in laboratory on the basis of a real industrial case study. The response of the testers has been positive and the outcomes in terms of increased product quality are promising.

[1]  I. Ricapito,et al.  Preliminary piping layout and integration of European test blanket modules subsystems in ITER CVCS area , 2015 .

[2]  Manuel F. Suárez-Barraza,et al.  Thoughts on kaizen and its evolution: Three different perspectives and guiding principles , 2011 .

[3]  Salvatore Gerbino,et al.  On the influence of scanning factors on the laser scanner-based 3D inspection process , 2016 .

[4]  Michael Fisher,et al.  Process improvement by poka‐yoke , 1999 .

[5]  G. Di Gironimo,et al.  Plasma facing components: a conceptual design strategy for the first wall in FAST tokamak , 2015 .

[6]  Colette Rolland,et al.  An Assembly Process Model for Method Engineering , 2001, CAiSE.

[7]  Olivia Penas,et al.  Multi-scale approach from mechatronic to Cyber-Physical Systems for the design of manufacturing systems , 2017, Comput. Ind..

[8]  F. Crisanti,et al.  Preliminary electromagnetic, thermal and mechanical design for first wall and vacuum vessel of FAST , 2015 .

[9]  Giuseppe Di Gironimo,et al.  From virtual reality to web-based multimedia maintenance manuals , 2013 .

[10]  Algirdas Bargelis,et al.  Impact of human factors and errors for product quality and reliability in the integrated approach of product and process design, maintenance and production , 2014 .

[11]  Wayne H. Wolf,et al.  Smart Cameras as Embedded Systems , 2002, Computer.

[12]  Andrea Tarallo,et al.  The DTT device: First wall, vessel and cryostat structures , 2017 .

[13]  Emanuele Menegatti,et al.  Calibration of a dual-laser triangulation system for assembly line completeness inspection , 2012, 2012 IEEE International Symposium on Robotic and Sensors Environments Proceedings.

[14]  J Bowe,et al.  Total quality management. , 1992, Contemporary longterm care.

[15]  Johnathan Yerby,et al.  Legal and ethical issues of employee monitoring , 2013 .

[16]  Ivan Stojmenovic,et al.  Machine-to-Machine Communications With In-Network Data Aggregation, Processing, and Actuation for Large-Scale Cyber-Physical Systems , 2014, IEEE Internet of Things Journal.