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Smart Manufacturing and Metrology

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Smart Manufacturing and Metrology SMART MANUFACTURING AND METROLOGY How can metrology enable smart manufacturing? Authors: Supervisors: Eric Tell Andreas Archenti Alexander Ökvist Bo Karlsson Bachelor Thesis in Product Realization and Industrial Engineering Abstract To create the possibilities needed for more precise simulations and calculations regarding manufacturing changes in the equipment and new technology has to be implemented. This work investigates possible solutions for the gathering of information in manufacturing companies. To get a wider understanding of the current situation in manufacturing we have also researched some possible solutions and applications that can be applied in manufacturing. The work consists of a literature study regarding the possible solutions and technologies of smart manufacturing complemented by a survey and a follow-up interview with scientist and employees’ at large corporations to get their view of the business today and possibilities for the future. The benefits from a successful implementation of metrology can help companies toward success in the transformation toward smart manufacturing. This report also investigates what is needed for implementing smart manufacturing and the transformation in manufacturing companies to get economic advantages with a technological adaption. It also covers the possible difficulties and problems that may occur when this implementation is performed. Sammanfattning Vid skapandet av grunder för att möjliggöra beräkningar och simulering för produktion så finns det krav på att nya verktyg och ny teknik implementeras. Detta arbete undersöker möjliga lösningar för att samla in information i industriella företag samt hur dessa företag ska gå tillväga för att möjliggöra denna omställning. För att få en bättre förståelse för området har vi även undersökt några möjliga applikationer som kan implementeras inom industrin. Arbetet består av en litteraturstudie där vi undersökte området smart manufacturing samt möjliga lösningar och tekniker som krävs för att uppnå detta. Som komplement till detta skapades även en enkät som baserades på området, svaren från enkäten följdes upp av intervjuer med deltagarna. Deltagarna var särskilt utvalda personer på större industriföretag eller institutioner vilka hade erfarenheter inom området metrologi. Detta användes som utökad grund för att få både en uppfattning av dagsläget samt idéer inför framtiden. Fördelarna med en lyckad implementering av metrologi kan hjälpa företag att ta steget mot att applicera smart manufacturing i deras produktion. Detta kan möjliggöra enklare produktion för operatörer men även ekonomiska fördelar för företaget i helhet. Arbetet tar även upp möjliga problem eller svårigheter som kan ske under denna implementation. i Content 1 The development of the industry 1 1.1 Complexity in modern manufacturing 2 1.2 Smart manufacturing 3 1.2.1 Metrology and smart manufacturing 4 2 Purpose, research question and limitations 5 3 Method 6 3.1 Literature study 6 3.2 Survey 6 3.3 Interviews 7 4 Theory 8 4.1 Cyber-Physical Productions Systems and cloud-based manufacturing 8 4.2 Manufacturing prognosis 10 4.3 Smart sensors 11 5 Applications 14 6 Results 16 6.1 Survey 16 6.2 Interviews 21 6.2.1 Present situation 21 6.2.2 Metrology 21 6.2.3 Data collection and analysis 23 6.2.4 Implementation 24 6.2.5 Examples 26 6.2.6 Challenges and the future 26 6.2.7 Effects 27 7 Discussion 28 8 Conclusion 30 9 Acknowledgment 31 10 References 32 11 Appendix 34 ii 1 The development of the industry To grasp the current state of manufacturing some historical information about the field is essential. During the 18th century the first real change in production began. Before this time most goods were produced by independent craftsmen without collaboration except for the few orders that could be placed by the military or the nobles. These workers created for their local market, which often was limited by city borders. Nations often imposed limitations on the establishment of new producers on positions already occupied to restrict competition, therefore resulting in less competition in existing industries. In extension, they also made sure that none of the producers gained a monopoly. This all changed with the first industrial revolution that started in 1740 in England (Encyclopedia 2017). The challenges of today's industries are rooting from the changes that have influenced both customers and companies during the last century. The customers want cheap wares of good quality that at the same time can fit their specific needs. We are entering what the Germans call the fourth industrial revolution, the digitalization off the production industry. There exist difficulties to adapt these new technologies for a business that has a clear paradigm and a way of work regarding incremental innovation compared to the more radical changes of digitalization. According to PwC, 33 % of the industrial companies today see themselves at an advanced level of digitalization. By the year of 2020 at least 72 % of all industrial companies want to reach this grade of digitalization. In today’s industries only half of the companies are collecting data and big data analytics as a base for their decisions. These numbers are expected to grow to 8 out of 10 of all companies will use big data for their decisions in the next five years. (R. Geissbaur 2016). The benefits of becoming a digital industry may seem far off but from the nine researched industries the amount invested would come close to 900 b.n $ for the coming five years. This number may seem daunting but they expected an annual return on at least 490 b.n $. The economic advantages to motivate a change in the industry and to integrate digital solutions in their production exists. The differences that exist compared to the IT industry is that in a completely digital environment the costs regarding the collecting and storing of all the data are minimal. In production, the need for sensors and connectivity to gather all the different production variables is great. The problems lie in the change from our current production lines that dates back to the start of the automation era which are based further back in the non- complexity of Henry Ford assembly lines. It might be possible to implement smart sensors in current machines to gather all the data required for better decisions. There are challenges ahead with both opportunities of greater revenue and the problems of changing the way industry act and think in a global competitive environment. (R. Geissbaur 2016) (Kunzmann et al. 2005) During the last thirty years the changes in automation has created an environment in manufacturing where the operators’ roles have been vastly modified. From working as the actual producer that is transforming the raw material into wares, they are in increasing extent monitoring machines that are executing the actual physical work. To measure and analyze the factors from the production to evaluate problems and errors has become the reality for most operators in larger factories. How the operators can help working towards digitalization of their workplace is a pressing mater. 1 In present day, manufacturers are following the large amount of IT that is becoming an integrated part of production and measurement. The previous challenges to only maximize output are moving towards an interest in producing the greatest quantities of wares with the least amount of raw materials. Problems such as constant machine uptime, zero vision of defects and customizable products to specific need are all parts of the future challenges in manufacturing. Following these requirements, the problems of the future becomes clearer. 1.1 Complexity in modern manufacturing Henry Ford’s breakthrough with zero complexity production has ended. Since the production of the T-Ford many manufacturers have competed by reducing complexity in their production, which have been successful. But those methods are insufficient to deal with the challenges of the future (ElMaraghy et al. 2012). Global competition and higher demands from customers have driven up the product and manufacturing complexity. The challenges today are characterized by design complexity that must be matched with flexible and complex manufacturing systems. Complexity is driven by customer demands and expectations as well as global competition. The customers’ expectations of new and better products as well as services compels manufacturers to develop advanced products that is harder to produce and has higher demands on tolerances. To manage this the production methods will get more complex. In addition, global competition drives down the prices. Therefore, the manufacturing process must be cheaper, faster and strive to produce zero defect products. Manufacturing companies operates in an uncertain and changing environment driven by changes in customer demands, product design and processing technologies. This increases the complexity in the manufacturing systems and is one of the main challenges for future production. The worlds private and public sector leaders believe that a rapid escalation of complexity is the biggest challenge confronting them. Their enterprises today are not ready to cope effectively with this complexity (Palmsiano 2010). Due to the rising complexity in manufacturing there is a greater need of real-time data and knowledge of the processes. This data and knowledge can be used to anticipate and prevent problems in the process. According to Davis and Edgar smart manufacturing will lead to that production goes from response to prevention (Davis and Edgar 2008). On page 14 they wrote: “…Response to Prevention addresses how sensors and knowledge-enabled capabilities will be organized and oriented. Every component of the enterprise will operate in a dynamic, proactive environment enabled by intelligent, model-based systems that are vigilant in monitoring plant and asset status. Any deviations from expected norms will be noted and if adverse trends are detected, the intelligent control systems will gather needed information and autonomously take preventive actions and in so doing exhibit high a high degree of fault tolerance.” Intelligent and connected systems will change production and the way value is created.
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