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Smart Manufacturing: Operations Planning Perspective

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The combination of sensors and computational infrastructure is becoming increasingly pervasive on the industry shop-floor. This is enabling automation of more and more industrial practices under the banner of Industry 4.0. Such developments are driving the need to replace conventional planning tools with schemes that can utilize the capabilities of Cyber-Physical Systems (CPS) and Industrial Internet of Things (IIoT). The future is a place where intelligence is endowed to every entity on the shop floor. It is necessary to develop new schemes that can unlock the potential of decentralized data observation and decision-making. Due to the huge diversity of industrial assets in terms of structure, operation and automation level, in addition to the shallow penetration of embedded-sensor technology into the existing systems, existing development model do not suffice the adequacy of Industry 4.0, thus making deployment of such CPS a bottle-neck. To overcome this bottle-neck, an event-based approach is developed for creation of a transient system, ‘cyber-twin,’ for industrial assets expediting the development of CPS for Industry 4.0 realization. Integration of the proposed cyber twin with existing communication standards like MTConnet is also studied. Utilizing the concept of cyber twins, a distributed algorithm is developed for the first time that performs intelligent maintenance planning for identical parallel multi-component machines in a job-shop manufacturing scenario. The results are encouraging in terms of computation time, quality of solution and scalability. The supremacy of the devised algorithm is demonstrated over conventional centralized heuristics such as Memetic Algorithm and Particle Swarm Optimization. We believe that such distributed algorithms will give new research directions to conventionally done centralized operations planning approaches in the industry. Further, it becomes an integral and a very important part for any Industry 4.0 implementation. Furthermore, a generic, self-sustained, system and method for autonomous and goal-oriented communication between cyber-twins is proposed in-detail, forming the bedrock concept for creation of a Social Network of Machines. In essence, the talk will highlight about the development of a system and method for systematic implementation of Industry 4.0 in manufacturing industries irrespective of the readiness of their current infrastructure.

This talk is part of the DIAL seminars series.

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