1st Edition
The Dark Factory and the Future of Manufacturing A Guide to Operational Efficiency and Competitiveness
The world of manufacturing is undergoing significant changes driven by various factors and technological advancements. Automation and robotics technologies are revolutionizing manufacturing processes. Robotic systems are being increasingly used for repetitive and precise tasks, improving efficiency, quality, and safety. The Internet of Things (IoT) is enabling connectivity and data exchange between devices and systems. Manufacturing generates vast amounts of data and is leveraging this data through advanced analytics, providing valuable insights to optimize production processes, predict maintenance needs, and improve supply chain management.
Additive Manufacturing has also gained significant traction in manufacturing. It enables the creation of complex parts and prototypes, customization, and rapid prototyping. Supply chains are becoming more interconnected and digitally integrated. Technologies such as blockchain enable transparent and secure transactions, traceability, and efficient inventory management. These trends and others are reshaping the manufacturing industry, promoting increased efficiency, agility, and sustainability. Manufacturers must be aware, understand, and embrace these changes to stay competitive and meet the evolving demands of customers in the modern era.
This book enhances the awareness and understanding of these core technologies by explaining what they are and how they are being used in manufacturing. In addition, it provides practical suggestions on how to advance manufacturing in light of these changes. The book provides a view into the future and direction on how to navigate the journey to a more automated, smarter, and continuously learning factory. This book consolidates the major elements of the fourth industrial revolution and describes them in clear terms within the context of integrated manufacturing. It creates awareness and a fundamental understanding of the advanced technologies that are coming together to facilitate highly automated, smarter, agile, and sustainable operations.
Contents
A Dark Factory: The Future of Manufacturing
Preface
Acknowledgements
About the Author
Introduction
Overview
Industry 4.0
Figure I.1: Industrial Revolutions
The Digital Age
Figure I.2: The Digital Age
Book Contents
Part I - Factory of the Future
Overview
Chapter 1.1 - The Dark Factory
What is a Dark Factory?
Factory of the Future
Figure 1.1.1: Factory of the Future
Realizing a Future Factory
Design for Manufacturing
Industrial Automation
Automation System Structure
Field Devices
Controllers
Information Management
Figure 1.1.2: Automation System Structure
Human-machine interface (HMI)
Industrial Automation - Implementation
The Automated Factory
Warehouse Automation
Process Automation
Robotic Process Automation (RPA)
The Human Factor
Roadmap / Strategy
Key Points
Chapter 1.2 - Industry 4.0: The Digital Age
Overview
Figure 1.2.1: Smart Factory
Internet of Things
Data Analytics
Digital Twin
Block Chain
Applications (Apps)
Cloud Computing
Wireless Connectivity
Big Data
Figure 1.2.2: The 3 V's of Big Data
Mobile Devices
Cognitive computing
Cybersecurity
Key Points
Chapter 1.3 - Digital Transformation
Overview
Figure 1.3.1: Digital Transformation
Physical versus Digital World
Smart Factory
Side Bar: What Makes a Smart Factory Smart?
Remote Experts
Augmented Reality and Virtual Reality
Mixed Reality
Extended Reality
Artificial Intelligence
Machine Learning
Side Bar: Digital Maturity Model
Key Points
Chapter 1.4 - The New Manufacturing Mindset
Overview
Figure 1.4.1: The New Manufacturing Mindset
Manufacturing Agility
Simplicity
Side Bar: Lean Manufacturing Principles
Manufacturing Process Reliability
Manufacturing Equipment Reliability
Modularity
Figure 1.4.2: Workstation Load/Unload Design Variants
Scalability
Figure 1.4.3: Example of Scalability
Ergonomics
Reusability
Energy Efficiency
Sustainability
Additive Manufacturing (3D Printing)
Side Bar: Tips for 3D Printing.
Early Adoption of New technologies
Key Points
Part 2 - Strategic Product Line Design, Development & Installation.
Overview
Chapter 2.1 Manufacturing Equipment
Overview
Industrial Robots & Cobots
Collaborative Robots (Cobots)
Robot Deployment
Table 2.1.1: Industrial Robot vs. Collaborative robot
Automated Material-Handling Equipment
Automated Guided Vehicles (AGVs)
Micro AGVs
Smart Glasses
Figure 2.1.2: Examples of Smart Glasses
Sensors & Devices
Automated Conveyors
Key Points
Chapter 2.2 - Line Design, Build & integration Strategy
Introduction
Production Concept
Make or Buy Decision
In-House Equipment Design and Build Activities
Outsourcing Equipment Design and Build Activities
Build Team
Table 2.2.1: Build Competencies and Experience
Test Equipment & Systems
Equipment Build/Tool Shop
Building for the Future
Life Cycle Engineering
Figure 2.2.1: Product Lifecycle Phases
Manufacturing Simulations
Key Points
Chapter 2.3 - Equipment Fabrication
Overview
In-House Equipment Fabrication
Outsourcing Equipment Fabrication
Figure 2.3.1: Equipment Build Activities Checklist
Figure 2.3.2: Equipment Lifecycle Process
Tool Shop Fabrication Capabilities
Equipment Build Standards
Figure 2.3.3: Equipment Design Considerations
Ease of Equipment Maintenance
Side Bar: Equipment Design Guidelines
Key Points
Chapter 2.4 - Production Line Assembly / Integration
Overview
Side Bar: Production Line Assembly Overview
Production Line Concepts
Workstation Concepts
Mixed Line Concept
Decoupling Process Workflow (Buffers)
Manufacturing Floorspace Optimization
Equipment Mobility Optimization
Production Line Material Supply
Side Bar: Karakuri Solution
AGV Ready Production Lines
Manufacturing Operators
Figure 2.4.1: Operator Positioning
Key Points
Chapter 2.5 - Product Line Validation
Overview
Figure 2.5.1: Product Line Validation
Machine Capability
Product Validation Build
Product Validation Testing
Process Validation
Run at Rate
Product Line Acceptance
Key Points
Part 3 - Manufacturing in the Digital Age
Overview
Chapter 3.1 - Process Execution
Overview
Start of Production
Standardization
Standardization Drawbacks
Data Collection and Analysis
Data Collection
Data Analytics
Daily Shop Floor Management
Figure 3.1.1: Daily Shop Floor Management
Key Points
Chapter 3.2 - Process Monitoring & Control
Overview
Figure 3.2.1: Process Monitoring and Control
Key Process Indicators
Side Bar: Improving OEE
Data Visualization and Reporting
Deviation Management
Figure 3.2.2: Deviation Management
Key Points
Chapter 3.3 - Line Maintenance & Equipment Repair
Equipment Reliability
Equipment Reliability Metrics
Predictive Maintenance
Figure 3.3.1: Predictive Maintenance Benefits
Predictive Analytics
Spare Parts Management
3D Printing for Maintenance and Repair
Key Points
Chapter 3.4 - Continuous Improvement
Overview
Figure 3.4.1: Continuous Improvement Methods & Sources of Ideas
Lessons Learned
Tips for Gathering Lessons Learned
Best Practices
Identifying Best Practices
Change Management
Effective Change Control Management
Key Points
Part 4 – Sustainable Manufacturing
Overview
Chapter 4.1 - Resource Efficiency
Overview
Figure 4.1.0: Resource Efficiency
Water Conservation
Tips for Reducing Water Consumption
Energy Conservation
Tips for Energy Conservation
Material Conservation
Alternative Materials
Waste Reduction
Recycling & Reuse
Side Bar: Tips for Reducing Energy Consumption
Key Points
Chapter 4.2 - Pollution Prevention
Overview
Figure 4.2.0: Pollution Prevention
Greenhouse emissions
Tips for Reducing Greenhouse Gas Emissions
Air Pollutants
Tips to Reduce Air Pollution
Toxic Substances
Tips to Minimize / Avoid Toxic Substances
Pollution Control Technologies
Air Pollution Controls
Water pollution controls
Waste Management
Cleaner Production Methods
Waste Management Practices
Key Points
Chapter 4.3 - Renewable Energy
Overview
Figure 4.3.0: Renewable Energy Sources
Solar Energy
Wind Energy
Hydropower Energy
Geothermal Energy
Side Bar: Global Geothermal Resource
Manufacturing Benefits of Renewable Energy
Key Point
Chapter 4.4 - Design for Sustainability
Overview
Figure 4.4.0: Design for Sustainability Tips; What to do & How to do it.
Environmental Footprint
Eco Friendly Materials
Durable, Repairable, and Recyclable Products
Side Bar: What is a Circular Economy?
Supply Chain Management
Sustainable Sourcing Practices
Reduced Transportation Impacts
Ethical Labor Conditions
Chapter 4.5 - Sustainable Manufacturing Culture
A Culture of Sustainable Manufacturing
Employee Awareness and Collaboration
Appendix
A.1 Acronyms
Biography
Philip Gisi, PMP, SSMBB, has over 30 years of experience in the automotive, commercial, and aerospace industries. His areas of expertise include new product development, process technology, quality management, automotive electronics, and manufacturing. He has worked internationally in multicultural environments and is currently involved in manufacturing operations as a manufacturing operations manager at Vitesco Technologies. Phil has a Master of Science in Engineering, a Master’s Certificate in Project Management, Lean Management Certification from the University of Michigan, a Project Management Professional certification, and a Six Sigma Master Black Belt (SSMBB). Phil is the author of the book “Sustaining a Culture of Process Control and Continuous Improvement: The Roadmap for Efficiency and Operational Excellence” and continues to share his experiences in Project Management, Lean Concepts, and Six Sigma Process Improvement as a DePaul University instructor for more than 20 years.
