OPTIMOSPRIME:OrganisingProduc,onTechnologyIntoMOstResponsive
States-3DPRIntMachineEnabledNetworksDuncanMcFarlane,RonanDaly,Maurizio
Tomasella,RengarajanSrinivasan,AlanThorne,AlenaPuchkova,MudassarAhmed
3DP–RDMWORKSHOP
Cambridge,14January2016
Contents
• Introduc,on• Aims,Objec,ves,Approach• IndustrialPrac,ces• AcademicLiterature• ControlRequirements&Architectures• ExperimentalStudy• GoingForward
Introduc,on• Challengesindistributedmanufacturingsupplynetworks:– Leanforcostandefficiency– Responsivenesstodisrup,ons
• Increasingneedtoevaluateaddi,vemanufacturingcapabilityfor:– Flexibilityandresponsiveness– Reconfigurability– Customisa,on– Understandingtheabilitytointegratewithconven,onalmanufacturingsystems
Contents
• Introduc,on• Aims,Objec,ves,Approach• IndustrialPrac,ces• AcademicLiterature• ControlRequirements&Architectures• ExperimentalStudy• GoingForward
AimsandObjec,ves• Howcan3Dprintenableddistributedmanufacturingenvironmentproviderapidresponsecapability?– Howeffec,velycan3Dprin,ngbeusedtoaddrapidresponsecapabili,estoconven,onalproduc,on?
– Howcan3Dprin,ngsupport3rdpartysparesandrepairservicesintandemwithaproduc,onfacility?
– Howcanlatecustomisa,oncarriedoutbyretailerbepartofanintegratedproduc,onprocess?
– (iv)Howcandistribu2onofproduc2onfacili2esbemanagedwithinasingle[cloudbased]produc2oncontrolsystem?
ApproachLiteratureReview
• Compare3Dprin,ngwithconven,onalmanufacturing
• Impactof3DPinenablingresilientsupplychainopera,ons
• Controlandautoma,onrequirements
• Technicalrequirementsfor3DP
• Measuringthebenefitsofopera,onalbenefits
Developmentofpoten,alapplica,onscenariosfor3DPindistributedmanufacturing
Developmentofautoma,onandcontrolcapabilityfor3DP
Simula,onmodel
DevelopmentofDistributedLabDemonstrator
Outputs• Feasibilityofemployingdistributed3DPinconven,onalmanufacturingenvironments
• Evalua,onofcontrolprinciplesandopera,onalefficiencies
• ChallengesandFutureResearch
ApproachLiteratureReview
• Compare3Dprin,ngwithconven,onalmanufacturing
• Impactof3DPinenablingresilientsupplychainopera2ons
• Controlandautoma,onrequirements
• Technicalrequirementsfor3DP
• Measuringthebenefitsofopera2onalbenefits
Developmentofpoten,alapplica,onscenariosfor3DPindistributedmanufacturing
Developmentofautoma2onandcontrolcapabilityfor3DP
Simula,onmodel
DevelopmentofDistributedLabDemonstrator
Outputs• Feasibilityofemployingdistributed3DPinconven,onalmanufacturingenvironments
• Evalua,onofcontrolprinciplesandopera,onalefficiencies
• ChallengesandFutureResearch
Contents
• Introduc,on• Aims,Objec,ves,Approach• IndustrialPrac,cesReview• AcademicLiterature• ControlRequirements&Architectures• Applica,onStudy• GoingForward
IndustrialPrac,cesOverview
• Focusonlyonaspectsoftodaysdevelopments&prac,ceswhichimpacton– Integra,on– Automa,on– Controllability
• Notacomprehensive3DPreview!
AMApproaches&Integratability
[InkjetResearchCentre,IfM]
Adaptedfromwww.ul,maker.com
ExtrusionJedng
[A.Wheeler,"CloudDDM'sNewStrategicEnd-of-Runway3DPrin,ngService",Engineering.com,July30th2015.]
[www.cloudddm.com]
• ManychallengesspecifictoeachAMtechniqueinmaterialmanagement,componentremoval/transfer,post-processing,valida2on
• Fixturing/Sensingcapabili,estotrackopera,ons• supportmaterialin3Dprintedparts->impactonautoma,on• Ongoingmovestosupportdistributedmanufacturingbyautoma2on:
“ThreeSignsthattheFullyAutomated3DPrin2ngFactoryIsComing”DavideSher,3DPrin,ngIndustry,2015“Louisvillefactory:100printers,3employees”ParijaKavilanz,CNNMoney,2015.“HowCloudDDMIsPuSngSpeedandAutoma2onInto3DPrin2ng”JoshMings,SolidSmack,2015
Automa,onReadiness
Comms&ControlPoten,al
• Needfornetworking/communica,onfacility• Abilitytocommunicatewithinandoutsideorganisa,onalboundaries(inter/intranetworkcapability)
• Needforstandardinterfacesforcommunica,on(TCP/IP,EtherCatetc)tointegratewithconven,onaldevices/technologies
Communica,on
• Limitedcapabilityforsomwaredevelopment/controlinterfacestoexecuteandmonitortasksin3DP
• ConversionofCADrelatedfilesinto3Dprinterenabledg-codesarenotstandardisedLimitedAbilitytocontrol/communicatewith3Dprintervariesbetweenmanufacturers(opensourcedevelopmentVsproprietarytools)
Interfaces/Control
Contents
• Introduc,on• Aims,Objec,ves,Approach• IndustrialPrac,ces• AcademicLiterature• ControlRequirements&Architectures• Applica,onStudy• GoingForward
LiteratureOverview
• Vastliteratureon3DP/AMtechnologiesandcapabili,esc.f.conven,onal
• Lioleornoliteratureoncontrol/automa,onof3DP/AMtechnologies
• Lioleornoliteratureonintegra,onof3DPwithconven,onalmanufacturing
• Significantliterature[not3DPspecific]on– distributedproduc,onnetworkdesign– Distributedproduc,oncontroland– Leanv/resilienceindistributedsupplychains
Prac,ceslightlyaheadofliterature
Op6maldesignofdistributednetworks[including3DPfacili6es]
Loca6on:offshoringvsreshoring
[4]DaSilveira,G.J.C.(2014).Anempiricalanalysisofmanufacturingcompe66vefactorsandoffshoring.Interna'onalJournalofProduc'onEconomics150,163–173.[5]Gylling,M.,Heikkilä,J.,Jussila,K.,andSaarinen,M.(2015).Makingdecisionsonoffshoreoutsourcingandbackshoring:Acasestudyinthebicycleindustry.Interna'onalJournalofProduc'onEconomics162,92–100.[6]Ellram,l.M.,Tate,W.L.,andPetersen,K.J.(2013).OffshoringandReshoring:AnUpdateontheManufacturingLoca6onDecision.JournalofSupplyChainManagement49(2)[7]DeTreville,S.,Trigeorgis,L.(2010).Itmaybecheapertomanufactureathome.HarvardBusinessReview88,84–87.
Op,malnumberandloca,onofresources
[8]Kalaitzidou,M.A.,Longinidis,P.,Tsiakis,P.,andGeorgiadis,M.C.(2014).Op,malDesignofMul,echelonSupplyChainNetworkswithGeneralizedProduc,onandWarehousingNodes.Industrial&EngineeringChemistryResearch:53(33),13125-13138.[9]Pasandideh,S,H.R.,Niaki,S.T.A.,andAsadi,K.(2015)Op,mizingabi-objec,vemul,-productmul,-periodthreeechelonsupplychainnetworkwithwarehousereliability.ExpertSystemswithApplica2ons42(5),2615-2623.
Op,malflowinthenetwork
[10]Ventuta,J.A.,Valdebenito,V.A.,andGolany,B.(2013).Adynamicinventorymodelwithsupplierselec,oninaserialsupplychainstructure.EuropeanJournalofOpera2onalResearch230(2):258-271.
Flexibility(cap’yrealloca,on)
[11]Rosenbaum,I.,Ben-Gal,I.,andYechiali,U.(2013)Nodegenera,onandcapacityrealloca,oninopenJacksonnetworks.IIETransac2onsVol45,Number3,259-272.
e.g.Op,malNetworkDesign
Mainstreamsupplychainnetworkstructure Generalizedstructure
Innova,ons:1)GeneralizedP/Wnodeswhosefunc,onisnotaprioriassumed2)Collabora,onamongP/Wnodes
Contents
• Introduc,on• Aims,Objec,ves,Approach• IndustrialPrac,ces• AcademicLiterature• ControlRequirements&Architectures• Applica,onStudy• GoingForward
ControlRequirementsfor3DPinDistributedProduc,onNetwork
• (R1)Coopera6on—Effec,vecommunica,onb/w3Dprintersonanetworkandabilitytoresolveconflicts
• (R2)Flexibility—Controlfeaturethatoffersliolechange-over,me/effort• (R3)Re-configurabilityofOpera6ons—Changeofopera,onsover,me/order
– Tackledisrup,ons(delaysona3DP)andtheop,ontore-configurethenetworktomeetgoals(delivery,me)
– Priori,sa,on—fulfilsubsequentorders(insteadofwai,ngfor10unitsofplas,cs,makeuseoftheavailable8tomeet2otherordersrequiring3and2unitsonly)
• (R4)Self-organisa6onCapability– Autonomouslyaccommodatesachangeinduedate/rushorder/quickerdelivery/
premiumqualityofsomeparts.– Autonomouslyaccommodateslatecustomisa,onrequestthatcannotbeproduced
byasinglefacilityonitsown.• (R5)Seamlessintegra6on:
– Level1-Distributedopera,onwithincompany– Level2-Distributedopera,oninvolvingmul,plecompanies.
Ini,alSystemArchitecture[SingleOpera,on]
Control
Command
Respon
se
AMQP
CONTROL&MANAGEMENT
RawDataLogicOpera,onalLogic(EventIden,fica,on)
Tracking
DatabasesCo
mmand/Re
spon
se
Capture&
Que
ry
TRACKING
Opera,on/PLCLayer
OPCServer
ResourceLayer
Devicenet
Ethe
rnetIP
LOCALEXECUTION
TargetDistributedSystemArchitecture
Tracking&EventLogic Control1
Databases
AMQP
Execu,onLayer
ResourceLayer
Control2
Execu,onLayer
ResourceLayer
Execu,onLayer
ResourceLayer
Control3
CLOUDSYSTEM
LOCALEXECUTIONSYSTEMS
AGENTBASEDCONTROL
Contents
• Introduc,on• Aims,Objec,ves,Approach• IndustrialPrac,ces• AcademicLiterature• ControlRequirements&Architectures• Applica,onStudy• GoingForward
Applica,onScenariosObjec6ves(i)Howeffec,velycan3DPrin,ngbeusedtoaddrapidresponsecapabili,estoconven,onalproduc,on?(ii)Theextenttowhich3DPrin,ngsupports3rdpartysparesandrepairsservicesintandemwithaproduc,onfacility?(iii)Theextenttowhichlatecustomisa,oncarriedoutbytheretailerforexamplecanbepartofanintegratedproduc,onprocess?(iv)Howcandistribu2onofproduc2onfacili2esbemanagedwithinasingle[cloudbased]produc2oncontrolsystem?
Sparepartmanagementinproduc,on
Reac,vepartreplacement
Customisa,onofproduct
LateCustomisa,onofproduct
All
Scenarios
Example:ProductCustomisa,on• Anorderfortengearboxesarrives• Eightgearboxeswilluseconven,onalgearpairs• Fourofthesearerequiredtohaveacolouredcapaoachedtothe
gearboxwiththeleoerM• Twogearboxeswillusenonstandardgearsets[althoughusual
shamposi,ons]• 3DPacanmanufacturebothrequiredsetofgearsbutisexpensive• 3DPbcanproducethesmallerbutnotthelargergear.• 3DPbcanproducethecolouredcapsrequired• Theproductsarerequiredtobeassembledinoneweek• Thereisnowheretostorethecolouredcapssotheyneedtobe
producedJIT• Thecustomerrequires100%inspec,onofthetwononstandard
gearboxes.
TestImplementa,onatIFM
Machining/ComponentManufacture Assembly
Conven'onalLocalManufacturer
PartsSupplier
RawMaterial
Conven'onalUpstreamSupplyChain
PartsSupplier
RapidResponse3rdPartyManufacturingServiceProvider
Warehouse/Retailer3Dprin,ngserviceProductcustomisa'on
Customer/3rdpartydesigner
Productcustomisa'onRequirements/Designs
CloudBasedDistributedControlofProduc'on
CloudServiceProvider
WAREHOUSE
MAINLAB DESIGNSTUDIO
WORKSHOP
FLUIDSLAB
SERVERWITHINIFM
1 2 3 4 5
T-Bar
A520 M6i M6i
6 7 8
LR Mate
Mazak
Inspection
Trolley
Inspection
Trolley
Shuttles
ProductCustomisa,on
Plas,cormetalgears
CustomisablenameplateOngearbox
Proof-of-conceptDemonstra,on
1 2 3 4 5
T-Bar
A520 M6i M6i
6 7 8
LR Mate
Mazak
Vac-Form
Inspection
Trolley
Inspection
Trolley
Shuttles
Part Manufacture Sub Assembly Final Assembly
3DP
3DP
ProofOfConceptDemonstra,on
• Demonstra,ons– GearPrin,ng– GearBoxAssembly
– LateGearBoxCustomisa,on
ProofOfConceptDemonstra,on
• Demonstra,ons– GearPrin,ng– GearBoxAssembly
– LateGearBoxCustomisa,on
ProofOfConceptDemonstra,on
• Demonstra,ons– GearBoxPrin,ng
– GearBoxAssembly
– LateGearBoxCustomisa,on
DemoControlArchitectureInternet/Cloud
printerYprinterX
a. Selec,onofsuitable3Dprinterfirm/Suppliermanagement
b. Decision/Choicetodecidewhentoorderrushparts
c. Customisa,onmanagement
Conven,onalManufacturingResources
LowLevelDeviceControl–TaskExecu,on
HighLevelControl–Planning/Scheduling/Ordermanagement/Disrup,onmanagement
Tradi,onalManufacturingControlArchitecture• Distributedcontrol• Centralised/Hierarchical
control• Hybrid/Semi-heterarchical
control
1 2 3 4 5
T-Bar
A520 M6i M6i
6 7 8
LR Mate
Mazak
Inspection
Trolley
Inspection
Trolley
Shuttles
3DP–Conven,onal:controlInterface
JADEAgentEnvironment
Webserver(OctoprintS/W)
HTTPmessaging
Serialport/USBcomm
Internet/Cloud
TCP/IP
Conven,onalManufacturingResources
LowLevelDeviceControl–TaskExecu,on
JADEAgentEnvironment
TCP/IP
OPCMessage
Device-net/IO
Tradi,onalManufacturer
Contents
• Introduc,on• Aims,Objec,ves,Approach• IndustrialPrac,ces• AcademicLiterature• ControlRequirements&Architectures• Applica,onStudy• GoingForward
Next Steps
• Further developments of distributed lab demonstrator – Development of distributed intelligent control – Assessment of additional scenarios and operational efficiencies.
• Modelling of resilience in distributed manufacturing environments enabled by 3DP
• Larger proposal to investigate 3DP integration / automation / cloud control requirements & limits
Simulation of 3DP and conventional manufacturing
Conventional manufacturing 3D printing
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