The dark factory and the future of manufacturing: a guide to operational efficiency and competitiveness

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]

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)