TY - BOOK AU - Gisi, Philip J TI - The dark factory and the future of manufacturing: a guide to operational efficiency and competitiveness SN - 9781032687476 U1 - 658.5 PY - 2024/// CY - New York PB - Routledge KW - Manufacturing industries--Data processing N1 - Table of content: 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 [https://www.routledge.com/The-Dark-Factory-and-the-Future-of-Manufacturing-A-Guide-to-Operational-Efficiency-and-Competitiveness/Gisi/p/book/9781032687476?srsltid=AfmBOopAKY5SrlwADzMxqdLF581RhB1LHoZLM9CN0kZO10u7GvwnkwWg] N2 - 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. (https://www.routledge.com/The-Dark-Factory-and-the-Future-of-Manufacturing-A-Guide-to-Operational-Efficiency-and-Competitiveness/Gisi/p/book/9781032687476?srsltid=AfmBOopAKY5SrlwADzMxqdLF581RhB1LHoZLM9CN0kZO10u7GvwnkwWg) ER -