Challenges in the engineering of adaptable and flexible industrial factories

Transcription

1 Ina Schaefer, Loek Cleophas, Michael Felderer Ina (Eds.): Schaefer Workshops et. al. (ed.): at Modellierung Modellierung 2018, 2018, Modellierung Lecture dernotes Entwicklung Informatics von kollaborativen (LNI), Gesellschaft egebetteten für Informatik, Systemen Bonn (MEKES) Challenges engeerg Bir Böhm 1, Marc Zeller 2, Jan Vollmar 1, Stefanie Weiß 3, Kai Höfig 2, Vcent Malik 4, Stephan Unverdorben 1 Constant Hildebrt 5 Abstract: To encounter challenges faster changg markets growg dividualization customer requests as well as to efficiently deal with ternal disturbances like mache failures, an enhanced adaptability flexibility is required. In this paper, challenges engeerg are highlighted, which rema unsolved from an pot view. For this purpose, some general challenges are derived from Industry 4.0 application scenarios seamless dynamic engeerg production systems factory. Selected general challenges are detailed based on typical engeerg tasks rangg from design a new production system engeerg its self-orchestration capabilities to safety product quality aspects. Solutions for se challenges will be essential for future. Keywords: Engeerg challenges, factory, Industry 4.0, application scenarios, simulation, self-orchestration, safety, process FMEA 1 Introduction Major trends manufacturg sector are growg dividualization products volatility product mixes. This results an creased amount disturbances production system, thus, requires easy changeability se production systems. In general, disturbances can be divided ternal external disturbances [SS90]. Internal disturbances production system are, for example, mache failure or matenance while external disturbances represent changes existg products, troduction new products that have to be manufactured due to new customers or a changg market structure or changes order parameters (lot size, lead times, etc.). While external disturbances require an adaption production system to new requirements ternal disturbances reduce availability factory, both disturbances result creasg cost manufacturg. Due to a growg amount external ternal disturbances, have to be designed to be easily changeable, which means that should be. 1 Siemens AG, CT RDA SSI EMT, Günr-Scharowsky-Str. 1, Erlangen, {firstname.name}@siemens.com 2 Siemens AG, CT RDA SSI DAM, Otto-Hahn-Rg 6, München, {firstname.name}@siemens.com 3 Siemens AG, CT RDA SSI EMT, Günr-Scharowsky-Str. 1, Erlangen, weiss.stefanie@siemens.com 4 Siemens AG, CT RDA AUC MSP, Otto-Hahn-Rg 6, München, vcent.malik@siemens.com 5 Helmut-Schmidt-University, Institute for Automation Technology, Holstenhweg 85, Hamburg, c.hildebrt@hsu-hh.de

2 102 Bir Böhm, Marc Zeller, Jan Vollmar, Stefanie Weiß, Kai Höfig, Vcent Mali, Stephan 16 Bir Unverdorben, Böhm et al. Constant Hildebrt Accordg to [VDI17] adaptability flexibility are defed as follows: Adaptability refers to ability to change volvg structural changes to system [VDI17]. For stance, if a new product is troduced, production system s hardware stware structure might have to be changed order to meet new requirements. While process changg structure hardware /or stware is called reconfiguration, ability production system to be economically changed to se new requirements its hardware stware structure is called adaptability. Flexibility refers to ability to change without structural changes [VDI17]. An example is possibility to produce new products without changg production system its structure. This can be achieved by re-parameterization existg stware functions. Hence, hardware stware structure is not changed. In this paper, selected technical challenges engeerg are described. The remader this contribution is as follows: In section 2, general challenges are described based on Industry 4.0 application scenarios [Pl16], whereas section 3, selected challenges are detailed based on typical engeerg tasks. Concludg, section 4 provides a summary cludg an outlook on future work. 2 Challenges derived from exemplary Industry 4.0 application scenarios Based on typical value chas, platform Industry 4.0 identified so-called application scenarios which describe challenges that users are gog to face through digitizg manufacturg busess operations [Pl16, Pl17]. Ma focus application scenarios are busess value network connected challenges. With respect to value network, followg ma value-added processes were identified for manufacturg [Pl16, Pl17]: product lifecycle management, production system lifecycle management, supply cha management, service with respect to product production system. Fig. 1 gives an overview application scenarios related to se value-added processes. It is obvious, that application scenarios related to production systems, as shown Fig. 1, are particularly terest for derivg challenges on production system. Therefore, application scenarios seamless dynamic engeerg production systems factory are used as a basis for derivg concrete challenges followg.

3 Challenges Challenges engeerg engeerg Fig. 1: Product production system-related Industry 4.0 application scenarios with respect to value-added processes as described [Pl16] 2.1 Application scenario seamless dynamic engeerg production systems This application scenario assumes that need to change future rar ten, thus, all partners volved engeerg, operation, service should work on an tegratg model production system to avoid consistencies errors. Such an tegratg model should be kept up to date support also evaluation impact past future decisions. In addition, it should be enriched with lifecycle formation, constrats, context formation, possible variants [Pl16, Pl17]. Technical challenges derived from this application scenario are especially [Pl16, Pl17]: setup an tegratg model across organizational boundaries throughout lifecycle, considerg data tegrity, tellectual property, data analysis, usage, methods for model analysis which enable, for example, evaluation impact decisions, analysis prerequisites for modules which have to be tegrated (e.g. risks), planng future capabilities factory its evolution, assessment a new configuration terms functionality, reliability, availability, safety, adequate tool support.

4 104 Bir Böhm, Marc Zeller, Jan Vollmar, Stefanie Weiß, Kai Höfig, Vcent Mali, Stephan 18 Bir Unverdorben, Böhm et al. Constant Hildebrt 2.2 Application scenario factory The application scenario factory addresses adaption capacities capabilities a production system to changg customer as well as market dems focuses on physical changes factory. In particular, adaption production system should be automated as far as possible. In order to create a plug&produce environment, this application scenario suggests a modular design for manufacturg as well as self- highly-teroperable modules based on stardized terfaces [Pl16, Pl17]. Technical challenges derived from this application scenario are particular [Pl16, Pl17]: design creation self- highly-teroperable modules, which implies platform-based modules with teroperable terfaces, system architecture for production system which enables a plug&produce environment for such modules startg from physical connection up to tegrated operation manufacturg execution systems: self-description module capabilities propagation control-related changes to facilitate tegration rearrangements production systems, cludg also e.g. safety aspects, tegration concepts for modules for central services such as visualization, archivg, alarms, or manufacturg execution systems, e.g., self-description modules for visualization, access to all formation at field level for manufacturg execution visualization, reconfiguration a versatile production le without programmg or engeerg effort, e.g. also by usg self-orchestration mechanisms, runtime location stware components should be changeable to e.g. enhance reliability availability. 3 Engeerg challenges concerng Based on Industry 4.0 application scenarios described section 2, four general engeerg tasks high terest for are used to derive specific challenges for engeerg such. Durg lifecycle an factory from design or concept phase up to its retirement [ISO10], a lot engeerg tasks have to be performed which are very

5 Challenges Challenges engeerg engeerg specific for such are still challengg. These engeerg tasks can be related to one Industry 4.0 application scenarios which address some basic challenges engeerg. These tasks clude, e.g., design a new production system, self-orchestration functional safety a production system durg operation, accordance to required quality production process as well as resultg product. These tasks are described more detail followg. 3.1 Designg a new production system To design a new factory, it is necessary to fd an optimal system configuration for given production scenarios. The possible configurations consistg production modules, entire production system, schedule, product mix can be simulated advance order to fd best possible system configuration. The production system has to ensure manufacturability avoid possible failures such as bottlenecks, missg capabilities, or suboptimal layout. The production system has to be designed under consideration given requirements. The important parts design production system are design production process detailed design technical system. The production system may consist several production modules which can be manual, hybrid, or even fully automated production modules. Each production modules consists several submodules. A production module has ability to hle varyg tasks, has to be designed to correspond to requirements, can act dependently or modules. Production simulation can be used to design optimize an factory. The layout, a production sequence, even frastructure production hall have to be taken to account. The modular production system has to be simulated with consideration a layout. The production sequence aspect can be covered by modelg cells modular production systems with respect to reusability stallations. The frastructure production hall has to be optimized with respect to qualities new production systems such as different power consumption for needs a changed formation communication behavior. To create simulation such a factory, a lot challenges have to be managed. Not all possible variants product can be defed a Computer-Aided Design (CAD) environment durg engeerg a new production system. The production simulation can be used to ensure needed flexibility by modelg relevant product variants. It has to be done with respect to module configuration cycle times even necessary change layout a production system has to be considered. To simulate high flexibility production system, models collaborative production modules are needed. To create a simulation a plug&produce environment, modelg self-

6 106 Bir Böhm, Marc Zeller, Jan Vollmar, Stefanie Weiß, Kai Höfig, Vcent Mali, Stephan 20 Bir Unverdorben, Böhm et al. Constant Hildebrt modules based on stardized terfaces is essential. The communication between modules has to be implemented simulation. As a result, this will lead to a valid production simulation with time evaluation necessary module layout reconfigurations. The simulation results have to be analyzed under consideration given Key Performance Indicators (KPIs). In case valid simulation production system, output is system configuration validated control concept. The simulated production system has to meet all relevant production constrats such as lead times quality. The simulation provides an optimal system configuration ensures that all required production capabilities are able to produce product accordg to its production bill material as well as bill process. The KPIs for a factory s output are ensured by simulative optimization factory. Designg a new production system for is related to application scenario seamless dynamic engeerg production systems which implies an tegratg production system model across organizational boundaries throughout lifecycle production system which is also used for assessg future configurations. Such an tegratg model should be set up already design phase, thus, can be used for any necessary simulations. 3.2 Engeerg production systems with self-orchestration capabilities An factory needs to cope with various disturbances durg operation. These clude both ternal as well as external disturbances, see section 1. In order to tackle se challenges future to respond to creasg trend towards dividualization products, one possible solution can be self-orchestration a production system at runtime. Dependg on type disturbance, system needs to perform eir structural changes (e.g. reconfiguration) or non-structural changes (e.g. parameterization). Self-orchestration mechanisms may be required, for example, if re is a change product requirements or production parameters. If production system is able to successfully self-orchestrate itself, it can also deal with unexpected changes, e.g. by reconfiguration re-parameterization or an autonomous re-schedulg execution production workflows. The boundaries which system can orchestrate changes are determed beforeh by engeerg durg design phase. In case that system fails to self-orchestrate at runtime, a report with reasons for failure (e.g. missg capabilities) could be issued tasks could be proposed which are needed to be done manually by a technician. There are several challenges that need to be addressed with respect to self-orchestration mechanisms: First all, production system needs to be equipped with various skills. These clude self-management capabilities like self-awareness its own manufacturg/process capabilities its status, awareness its context as well as ability to communicate teract with or systems order to negotiate collaborate.

7 Challenges Challenges engeerg engeerg In that regard, it is also necessary to vestigate optimal degree autonomy systems. It needs to be examed wher re is still a central stance required for an overall optimization production or wher several rar loosely-coupled collaboratg systems can manage terplay different production orders without any central coordation. Furrmore, re is challenge predictg a system s behavior after each change enablg adequate testg or even virtual commissiong order to ensure proper functiong production system. Apart from functional testg, also safety product quality aspects need to be considered (see also ). Those challenges are aggravated by fact that fundamental engeerg decisions for an factory are made durg design time without full knowledge factory s context at runtime. Therefore deliberate planng at design time as well as application an tegrated engeerg approach coverg all lifecycle phases are necessary to ensure a suitable economically viable degree flexibility adaptability production systems durg operation. The self-orchestration production systems durg operation is associated to application scenario factory. Self-adaptability modules, propagation control-related changes to facilitate tegration rearrangements production systems as well as reconfiguration production les are mentioned this application scenario form a basis for self-orchestration whole production system. 3.3 Safety production systems In order to ensure functional safety context, mache manufacturers operators Europe are required by law to ensure protection persons environment. The basic requirements for system safety, mache manufacturers or system operators must comply with, are defed safety stards ISO [ISO06] or EN [IEC05] (see Machery Directive 2006/42/EC European Commission [EC06]). Safety stards provide guideles to keep residual risk mache construction operation with tolerable limits. Therefore, a comprehensive risk assessment, if required, risk reduction is performed (e.g. by troducg specific risk reduction measures). The risk assessment provides safety requirements which apply to machery. The machery must n be designed constructed takg to account results risk assessment. The correspondg safety documentation describes assessment prciples resultg measures order to mimize hazards. This documentation also lays foundation for safe operation a mache it proves compliance with machery directive. In context an factory, risk analysis must be conducted after each production system reconfiguration, for each new product, for each path product steps so that safety system group or machery is proven. This is a prerequisite for operatg factory. Therefore, list possible risks w.r.t. hazards

8 108 Bir Böhm, Marc Zeller, Jan Vollmar, Stefanie Weiß, Kai Höfig, Vcent Mali, Stephan 22 Bir Unverdorben, Böhm et al. Constant Hildebrt for humans must be updated automatically durg operation an factory order to have current list risks. The list risks serves as a basis to assess new configuration a factory terms safety every time production process is changed, a new product is produced, or factory configuration is changed. The update must be performed fully automatically order to enable production scenarios, see section 2, to avoid long matenance tervals between changes factory configuration. Today, list risks a production plant is set up manually durg its design phase. To realize above application scenarios, list risks must be synsized automatically durg operation a factory (i.e. when system configuration is modified or a new product is produced). Besides risks each dividual production step also risks to harm a person resultg from specific sequences production steps must be considered. For stance, if a specific work piece is cut by a mache n sharp edges may result. A worker who performs a subsequent production step may be jured by se sharp edges. So eir sharp edges must be deburred an additional process step or worker must be protected (e.g. by wearg specific h gloves), if possible. Ensurg functional safety production systems is associated both with application scenarios seamless dynamic engeerg production systems factory. First, an tegratg production system model is needed to assess functional safety. And second, modules with production system should provide selfdescription module capabilities also related to safety aspects. 3.4 Ensurg product quality In order to ensure quality products produced an factory, each new configuration production process must be assessed. It must be ensured that specified requirements w.r.t. quality production process resultg product are met. This can be done by dynamically creatg a so-called Process- FMEA for each product each system configuration. Failure Modes Effects Analysis (FMEA) [IEC91] is a step-by-step approach for identifyg all possible failures a design, a manufacturg or assembly process, or a product/service. FMEA is a bottom-up, ductive analytical method which may be performed at eir functional or piece-part level. The Process-FMEA is a methodical approach used to identify evaluate potential failures manufacturg assembly processes, where both quality reliability may be affected from process faults. The put for this FMEA is, amongst ors, a work process or recipe current configuration an factory for a specific work piece. By conductg a Process-FMEA failure modes each production step as well as ir effects on process are identified. For each effect a failure, severity this effect is determed. Then, causes ir mechanisms failure mode are identified. Thus, Process-FMEA can be used to select quality assurance measures to add m to production process to ensure target product quality.

9 Challenges Challenges engeerg engeerg Sce factory s configuration as well as its products constantly change factory scenarios, a Process-FMEA must be performed dynamically durg production each product based on a new configuration. This is necessary to ensure that requirements w.r.t. quality production process resultg product are met. Thus, dynamic Process-FMEA provides feedback if a new configuration meets quality requirements defed for production if residual risk producg products that do not meet given quality requirements is sufficiently low. For stance, a specific production step (e.g. drillg a hole) can be performed by different maches but with a different failure probability for potential failures (e.g. hole drilled too deep, etc.). Then, it is better to test quality work piece after a mache with a high failure probability before performg next production step order to sort out work pieces with an correct drillg depth. However, if hole was drilled by a mache with a very high precision, it could be sufficient to perform test at regular end le. Such scenarios should be considered after each reconfiguration factory order to ensure a target product quality produce a certa amount products for a specific price a given time. Dynamically creatg a Process-FMEA durg operation an factory requires to identify all possible failure modes automatically associate effects dividual failures (e.g. from machery or production steps) with possible effects on specific product. This open challenge must be addressed. Ensurg quality products produced an factory addresses both application scenarios factory seamless dynamic engeerg production systems. As a basis for a Process-FMEA, modules with production system should provide self-description, cludg also possible failure modes ir effects. Consequently, an tegratg production system model is needed to use se self-descriptions modules to assess failure modes each production step ir effects on production process described second application scenario. 4 Summary In this paper, challenges for engeerg are described which are derived from selected Industry 4.0 application scenarios as well as general engeerg tasks durg lifecycle such. It is left to furr research activities to derive concrete requirements from se challenges evolve solutions order to enable design operation future. Sce changes with se are expected to happen rar ten, support engeerg tasks related to production system product changes must be efficient effective order to enhance availability factory. Furr challenges on can be derived from complementary Industry 4.0 application scenarios as well as from or engeerg tasks such

10 110 Bir Böhm, Marc Zeller, Jan Vollmar, Stefanie Weiß, Kai Höfig, Vcent Mali, Stephan 24 Bir Unverdorben, Böhm et al. Constant Hildebrt as check for manufacturability given products, production planng, performance reliability improvements, self-management capabilities production systems. Sce lifecycle may be some decades, addition, migration concepts for existg are highly required. Such migration concepts shall provide a transition path from traditional to based on a step-by-step approach. These challenges have to be analyzed as well order to provide a stable requirements basis for future solutions for. 5 Acknowledgement The work leadg to this paper was funded by German Federal Mistry Education Research under grant number 01IS16043Q Collaborative Embedded Systems (CrESt). Bibliography [Pl17] Plattform Industrie 4.0 Fortschreibung Anwendungsszenarien. accessed: 10/01/2018. [EC06] European Commission: Machery Directive 2006/42/EC, [Pl16] Platform Industrie 4.0 Aspects Research Roadmap Application Scenarios. accessed: 10/01/2018. [IEC05] International Electrotechnical Commission (IEC): IEC Safety machery functional safety safety-related electrical, electronic programmable electronic control systems, [IEC91] [ISO06] International Electrotechnical Commission (IEC): IEC 60812: Analysis Techniques for System Reliability Procedure for Failure Mode Effects Analysis (FMEA), International Organization for Stardization (ISO): ISO Safety machery Safety-related parts control systems Part 1: General prciples for design, [ISO10] International Organization for Stardization (ISO): ISO/IEC TR :2010 Systems stware engeerg Life cycle management Part 1: Guide for life cycle management, [SS90] Sethi, AndreaKrasa; Sethi, SureshPal: Flexibility manufacturg: A survey. In: International Journal Flexible Manufacturg Systems 2, Nr. 4, [VDI17] VDI-Gesellschaft Technologies Life Sciences: VDI Richtlie (VDI 5201), Wlungsfähigkeit Beschreibung und Messung der Wlungsfähigkeit produzierender Unternehmen, 2017.