Faunhofer Project Center for Production Management and Informatics PMI

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Publication

Robotisiertes Laser-Fernschweißen

2016 , Monostori, László

Das Ziel des Projekts ist die Verbesserung der Bearbeitungsgeschwindigkeit, die Erhöhung der Prozessflexibilität und der Energieeffizienz. Zudem sollen die realen und virtuellen Prozesse verknüpft werden, um eine Remote-Offline-Programmierung zu ermöglichen.

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Cyber-physical systems in manufacturing

2016 , Monostori, László , Kádár, Botond , Bauernhansl, Thomas , Kondoh, Shinsuke , Kumara, Soundar R. , Reinhart, Gunther , Sauer, Olaf , Schuh, Günther , Sihn, Wilfried , Ueda, Kanji

One of the most significant advances in the development of computer science, information and communication technologies is represented by the cyber-physical systems (CPS). They are systems of collaborating computational entities which are in intensive connection with the surrounding physical world and its on-going processes, providing and using, at the same time, data-accessing and data-processing services available on the Internet. Cyber-physical production systems (CPPS), relying on the latest, and the foreseeable further developments of computer science, information and communication technologies on one hand, and of manufacturing science and technology, on the other, may lead to the 4th industrial revolution, frequently noted as Industrie 4.0. The paper underlines that there are significant roots in general - and in particular to the CIRP community - which point towards CPPS. Expectations towards research in and implementation of CPS and CPPS are outlined and some case studies are introduced. Related new R&D challenges are highlighted.

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Planning of remote laser welding processes

2013 , Erdös, Gábor , Kemény, Zsolt , Kovács, András , Váncza, József

The paper discusses the technical background of the remote laser welding (RLW) technology, its novel opportunities and implications for planning processes. Our ultimate goal is to develop a complete off-line programming toolbox for RLW which can provide an automated method for computing close-to-optimal robot programs. We suggest a workflow for the complete planning process, and propose new models and algorithms for solving the sequencing of welding tasks in conjunction with path planning, as well as for generating the inverse kinematics of the robot. The paper summarizes results of first computational experiments in an automotive case study using an industrial robot. The proposed method leads to a substantial reduction in the cycle time of the welding operation compared to an earlier approach.

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Publication

Uniform Data Structure for Production Simulation

2012 , Popovics, Gergely , Kardos, Csaba , Kemény, Lorinc , Gyulai, Dávid , Monostori, László

One of the most widespread techniques to evaluate various aspects of a manufacturing system is discrete-event simulation (DES). However, building a simulation model of a manufacturing system is a difficult task and requires special competence. The majority of simulation studies aimed at analyzing a certain problem by a specific simulation model created by experts. This approach requires relatively high financial expenditures. The paper introduces an ongoing research aimed at developing an application to reduce the costs of a draft simulation study. The input of the simulation models in the proposed methodology is based on ISA-95 standardized data structure. The instantiated input data set can be stored both in MS Excel, XML files or an SQL database. Having the complete input a simulation model can be created automatically without simulation expertise.

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Complementary research and education opportunities - a comparison of learning factory facilities and methodologies at TU Wien and MTA SZTAKI

2016 , Kemeny, Zsolt , Nacsa, János , Erdos, Gábor , Glawar, Robert , Sihn, Wilfried , Monostori, László , Ilie-Zudor, Elisabeth

Typical learning factories are characterized by selective simplification or scaling-down of complex and large-scale production processes, while also safely containing risks in the case of process failures inherent to experimental and didactic activities. The variety of aspects preserved by these scaled-down environments allow different approaches to be taken in research and education. The paper compares two facilities, at TU Wien and at MTA SZTAKI in Budapest, respectively, and highlights differences in their modes of operation, the resulting variations of course-based vs. project-based didactic approaches, as well as their place in technical higher education.

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An inverse economic lot-sizing approach to eliciting supplier cost parameters

2014 , Egri, Péter , Kis, Tamás , Kovács, András , Váncza, József

Recent literature on supply chain coordination offers a wide range of game theoretic and optimization approaches that ensure efficient planning in the supply chain, but assume that the involved parties have complete information about each other. However, in reality, complete information is rarely available, and those models alone do not present any incentive for the parties to reveal their private information, e.g., the cost parameters that they use when solving their planning problems. This paper proposes an inverse lot-sizing model for eliciting the cost parameters of a supplier from historic demand vs. optimal delivery lot-size pairs, gathered during repeated earlier encounters. It is assumed that the supplier solves a single-item, multi-period, uncapacitated lot-sizing problem with backlogs to optimality to calculate its lot-sizes, and the buyer is aware of this fact. The inverse lot-sizing problem is reformulated to an inverse shortest path problem, which is, in tu rn, solved as a linear program. This model is used to compute the ratios of the supplier's cost parameters, i.e., the setup, the holding, and the backlog cost parameters consistent with all the historic samples. The elicited cost parameters can be used as input for various game theoretic or bilevel optimization models for supply chain coordination. Computational experiments on randomly generated problem instances indicate that the approach is very efficient in predicting future supplier actions from the historic records.

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Methodology and data-structure for a uniform system's specification in simulation projects

2013 , Kardos, Csaba , Popovics, Gergely , Kádár, Botond , Monostori, László

In the last few decades the evaluation and analysis of manufacturing systems' behavior and their performance became very important. Digital enterprise technologies, as for example discrete-event simulation (DES), are effective tools both in production related decision making processes and in structure and performance analysis of manufacturing systems. However, building a discrete-event based simulation model of a manufacturing system is a difficult task and requires special competence. The majority of simulation studies are aimed at analyzing a certain problem by a specific simulation model created by experts with a relatively high financial expenditure. The paper introduces an ongoing research aimed at developing a framework to reduce the efforts spent on draft simulation studies by simplifying and accelerating the process of model building. The proposed modeling methodology uses a uniform data structure which is a production oriented implementation of the ANSI/ISA-95 standard and supports the creation of models without simulation software specific knowledge. The supporting data structure enables the development and application of proprietary simulation engines tailored for specific problems. The paper compares the traditional and the proposed methodologies and also introduces the first experiments gained on specific test -cases. In our approach the simulation models are created automatically and independently from simulation tools which will be presented through the examples of both commercial and self-developed applications.

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A holistic approach for quality oriented maintenance planning supported by data mining methods

2016 , Glawar, Robert , Kemeny, Zsolt , Nemeth, Tanja , Matyas, Kurt , Monostori, László , Sihn, Wilfried

Appropriate maintenance measures, which are carried out at the right time are a key factor to secure plant availability, product quality and process efficiency in modern manufacturing systems. Established maintenance strategies oftentimes lack in combining these strongly related aspects. They are not capable to anticipate in a holistic way and therefore lead to unnecessarily high maintenance efforts, wasted resources and the occurrence of quality and availability impairments. In order to realize a holistic and anticipatory approach for maintenance planning, a methodology which consistently compiles and correlates various data via ""cause and effect"" coherences is depicted. By breaking down the production facilities on component level a basis is set to link condition monitoring data, wear data, quality and production data by using data mining methods. This framework enables the identification of maintenance-critical conditions and the prediction of failure moments and quality deviations.

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Publication

Capacity management for assembly systems with dedicated and reconfigurable resources

2014 , Gyulai, Dávid , Kádár, Botond , Kovács, András , Monostori, László

Managing changes and disturbances resulted by fluctuating order streams and diverse product portfolios requires efficient capacity management decisions and production planning strategies. High volume products can be produced cost efficiently on dedicated assembly lines, while the assembly of low runners is more efficient on reconfigurable lines. In the paper a hierarchical planning decision workflow is introduced to assign the products to dedicated and reconfigurable lines, and to optimize the system configuration and the production plan of the reconfigurable system in an integrated way. The proposed solution is demonstrated through the results of an industrial case study.

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Designing cooperation mechanisms for supply chains

2012 , Váncza, József , Egri, Péter

The paper defines generic requirements towards cooperative planning in the nucleus of any supply network that is constituted by a pair of autonomous manufacturer and supplier who possess asymmetric information on demand forecast and costs, respectively. Then a novel way is suggested for investigating this problem by means of the apparatus of mechanism design. The analysis results in some provable generic properties as for efficiency and truthfulness, and shows the impossibility of fair cost and profit sharing. Further on, design principles towards a payment scheme are devised that provide incentive for the partners to cooperate in order to minimize costs. This payment can be considered the price for a flexible supply service. As examples, the generic framework is instantiated with two particular cooperative supply mechanisms.

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