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(Download PDF) Digital Manufacturing and Assembly Systems in Industry 4 0 1St Edition Kaushik Kumar Editor Online Ebook All Chapter PDF
(Download PDF) Digital Manufacturing and Assembly Systems in Industry 4 0 1St Edition Kaushik Kumar Editor Online Ebook All Chapter PDF
(Download PDF) Digital Manufacturing and Assembly Systems in Industry 4 0 1St Edition Kaushik Kumar Editor Online Ebook All Chapter PDF
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Digital Manufacturing
and Assembly Systems
in Industry 4.0
Science, Technology, and Management Series
Series Editor, J. Paulo Davim
Edited by
Kaushik Kumar
Divya Zindani
J. Paulo Davim
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts
have been made to publish reliable data and information, but the author and publisher cannot assume
responsibility for the validity of all materials or the consequences of their use. The authors and publishers
have attempted to trace the copyright holders of all material reproduced in this publication and apologize
to copyright holders if permission to publish in this form has not been obtained. If any copyright material
has not been acknowledged please write and let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced,
transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter
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Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe.
Preface..................................................................................................................... vii
Editors.......................................................................................................................xi
Contributors.......................................................................................................... xiii
Section I Overview
3. Industries of Future...................................................................................... 59
Hridayjit Kalita, Divya Zindani, and Kaushik Kumar
Section II Applications
Index...................................................................................................................... 161
v
Preface
The editors are pleased to present the book Digital Manufacturing and
Assembly Systems in Industry 4.0 under the book series Science, Technology,
and Management. The book title was chosen by looking at the present trends
and shifts in the industrial world and the future of the same.
Industrial revolutions were the giant steps for mankind toward global
development and prosperity. The industrial revolution started in around
1750 with industry 1.0 (the first industrial revolution) where human and
animal power was replaced by mechanical power systems like the steam
engine, spinning wheel, and water wheel, resulting in an enhancement and
betterment in productivity. It took about a century to introduce electricity,
assembly lines, conveyor belts, etc., and initiation toward mass production
was made. This was designated as the second industrial revolution (industry
2.0). In the nineteenth century, under the third industrial revolution (indus-
try 3.0), integrated manufacturing with electronics provided automated pro-
duction machinery.
Presently, with globalization and an open market economy, the market has
become consumer driven or customer dictated. This has given rise to the
fourth industrial revolution or industry 4.0. This has initiated the amalga-
mation of the internet, information and communication technologies (ICT),
and physical machinery with coinage of words, such as Internet of Things
(IoT), Industrial Internet of Things (IIoT), collaborative robot (COBOT), big
data, cloud computing, virtual manufacturing, and 3D printing, which have
marked their presence into our daily lives. Industry 4.0 has been designed
toward development of a new generation of smart factories or currently
coined as “customized or tabletop factories” with increased production flex-
ibility allowing personalized and customized production of articles in a lot
as small as a single unique item. Hence, today’s facilities are to be provided
to a customer situated at one side of the globe to control and monitor his
product being produced in a manufacturing unit available on the other side
of the world.
This book is primarily intended to provide researchers and students with an
overview of digital manufacturing and assembly systems, a vital component
of the buzzword “industry 4.0.” Digital manufacturing and assembly systems
are modularly structured with cyber-physical systems (CPS), as “convertible
machines,” “smart assembly stations,” and “smart part logistic.” These ele-
ments communicate and cooperate with each other in real time, integrat-
ing the physical processes with virtual information in an augmented reality
fashion to eliminate errors and maximize the production process efficiency.
Furthermore, aided assembly improves the duration and safety of fastening
and picking activities through several technologies, as internet, ICT, IoT, IIoT,
vii
viii Preface
The chapters here are categorized in two parts namely: Section 1: Overview
and Section 2: Applications
Section 1 contains Chapters 1 through 3, whereas Section 2 has Chapters 4
through 6.
Section 1 starts with Chapter 1, which provides a general overview of intel-
ligent manufacturing, smart factories, and industry 4.0, taking the attention
of the reader to possible methods, methodologies, business models, and
progress (trends) along these lines. Information about a general framework
and a reference model has also been explained. The chapter also provides
a roadmap for managing a healthy transformation from the machine-
dominant industry to knowledge-powered manufacturing suites. A set of
references have been provided to support the readers for their own research
and studies.
Chapter 2 concentrates on the history of the development of technology-
based industrialization with special emphasis toward digital transforma-
tion and industry 4.0 with a special concentration on Turkey’s technological
outlook. Turkey, with its geopolitical position, dynamic private sector, and
demographic and economic potential has always been an important country
Preface ix
for the global business world. This chapter points out the importance of
industry 4.0 for Turkey and aims to suggest a roadmap for the needed adap-
tation strategies to industry 4.0 for various Turkish sectors.
Chapter 3, the last one in Section I, speculates about the future factories
in tune to the development of digitalization and customization. For custom-
ized and high-demand products, the flexible manufacturing has become the
need of the market and time. Lack of flow of information between the pro-
ducers and the customers was a big issue and needed to be solved entirely.
The solution was provided with improvement in the digital technology and
its integration with the information technology, which ensured flow of data
from machine to machine or across company boundaries, sophisticated algo-
rithms incorporated to optimize the information in the network and com-
municate with the CPS, or the machines for the best possible solution to any
operational problem. In this chapter, the general overview of the manufac-
turing world in the future (or the future industries), their fundamental tech-
nologies, their future ethics and laws to be followed, their characteristics,
and their impact on the socioeconomic–political domain has been discussed
in detail.
In the previous chapter, the usage of sophisticated algorithms was identi-
fied. In Chapter 4, the first one in Section II, the Theory of Constraints (TOC)
was applied to a complex manufacturing environment of the case company
Futur Décor in order find bottlenecks in their production processes and
develop ways to eliminate them and improve organizational performance.
After exploiting these constraints and successfully breaking the bottlenecks,
the cycle time of the primary and secondary constraint processes were
reduced and, thereby, improved factory processes. Companies facing similar
challenges in similar industries, to improve their performance as well, could
apply the methods used in this chapter.
Chapter 5 also presents the application of an intelligent algorithm.
The chapter provides a generic solution for the heuristic tool path
optimization of complex sculptured surface CNC machining. The three-
objective optimization problem is established as an integrated automation
function involving the criteria mentioned, as well as the existing objects of
a cutting-edge Computer-aided manufacturing (CAM) system and solved
by adopting the Pareto multi-objective approach. The automation function
is handled by an intelligent algorithm. The proposed approach for heuris-
tic sculptured surface CNC tool path optimization has been validated by
comparing the results obtained from actual five-axis cutting experiments
conducted, to those available by existing methods in literature for the same
problem. It was shown that the proposed approach not only can outperform
those methods in terms of high-precision cutting but may also constitute
a practical environment for profitable, reliable, and flexible intelligent tool
path selection to machine-complex-sculptured surfaces.
Chapter 6, the last chapter of the section and the book, describes computer
simulation models, developed to imitate a real-world automobile component
x Preface
assembly line in order to analyze the cycle time and calculate efficiency of
the assembly line. The model has been developed under WITNESS PwE
RELEASE 3.0 simulation software. Two assembly lines have been chosen for
the study. The use of industrial engineering tools like work study, method
study, line balancing, two handed process charts and 5S are being used to
recoded the data and identify alternatives for productivity improvement of
assembly line. Based on the result of this study, the total cycle of Assembly
Line 1 has been reduced, and the production rate has increased for both
cases. Simulation methodology has been conducted to verify and validate
the model before applications to the case study.
First and foremost, we would like to thank God for giving us power to
believe in our passion and pursue our dreams. We could never have done
this without the faith we have in you, The Almighty.
We would like to thank our grandparents, parents, and relatives for allow-
ing us to follow our ambitions. Our families showed patience and tolerated
us for taking yet another challenge that decreased the amount of time we
could spend with them. They were our inspiration and motivation. Our
efforts will come to a level of satisfaction if the professionals concerned with
all the fields related to industry 4.0 are benefitted.
We also thank all the contributors, our colleagues, and friends. This book
not only was inspired by them but also directly improved by their active
involvement in its development.
We owe a huge thanks to all of our technical reviewers, editorial advisory
board members, book development editor, and the team of CRC Press per-
sonnel for their availability on this huge project. All of their efforts helped
to make this book complete, and we couldn’t have done it without their con-
stant coordination and support.
Last, but definitely not least, we would like to thank all individuals who
had taken time out and helped us during the process of editing this book.
Without their support and encouragement, we would have probably given
up the project.
Kaushik Kumar
Divya Zindani
J. Paulo Davim
Editors
xi
xii Editors
guest editor of journals, editor of books, series editor of books, and scientific
advisor for many international journals and conferences. At present, he is
an editorial board member of 25 international journals and acts as reviewer
for more than 80 prestigious Web of Science journals. In addition, he has also
published as editor (and co-editor) for more than 100 books and as author
(and co-author) for more than 10 books, 80 book chapters, and 400 articles in
journals and conferences (more than 200 articles in journals indexed in Web
of Science/h-index 45+ and SCOPUS/h-index 52+).
Contributors
xiii
xiv Contributors
Overview
14 Digital Manufacturing and Assembly Systems in Industry 4.0
FIGURE 1.7
The solution space for membership functions given in Figure 1.5.
prices satisfying these four fuzzy variables. That is to say that any
price value that has a membership value inside the shaded area rep-
resents a price that is high, low, around, and near $22.
• Defuzzification: Generating a crisp value to indicate a solution.
There are various defuzzification methods. The most common one
is assigning the domain variable to the one that has the biggest
membership function. In Figure 1.7, the price value of 22.75 with a
membership value of 0.5 (the possibility of being high, low, around,
and near 22) is assigned as the solution.
Detailed information on fuzzy logic and its applications can be found
in Cox (1999).
With the introduction of intelligent robots, utilizing more than one
AI method to perform intended actions became necessary. This is
empowered intelligent agents, which are very popular nowadays due
to their capability of handling dynamic and complex events as well
as working on hardware. Note that an agent is defined as a computa-
tional system that is situated in a dynamic environment and is capable
of exhibiting autonomous and intelligent behavior. They can work
independently. This makes it easy to implement expected functional-
ities. Intelligent agents can learn, prioritize, and focus their attention
on important events. The general architecture of an agent is given in
Figure 1.8. As illustrated, there are three main components:
• Perception: Receiving input from the environment and performing
preprocessing on that.
• Cognition: Processing the knowledge perceived and perform rea-
soning by using respective intelligent knowledge processing meth-
odologies, some of which are explained above. This component
should also be capable of adapting knowledge changes. Immediate
response can be generated.
• Action: Producing respective responses to knowledge perceived
and processed.
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Though the old lady’s kirk was four miles off—probably eight
English miles—she went to worship every Sunday. She was glad to
get some snuff, which is the luxury of a Highland cottage. In one
village of three huts, Dr. Johnson found a chimney and a pane of
glass.
Beside his road-making, with stone and concrete, General Wade
had notable success in dealing with the peculiar variety of human
nature that was so marked in the Celtic Highlanders. He so won his
way into their hearts that, with the tact that came of thorough
acquaintance with his subject, he slowly but surely disarmed the
clans. Turbulence and habitual brawls ceased, for the most part, and
there came an era of civilization and peaceful life, contrasting
amazingly with the state of affairs in Scotland before 1745. To the
Irish General Wade the world awards the title promised of God by
the prophet Isaiah, “The restorer of paths to dwell in.”
It was in 1745 that the road-builder in the Highlands, Wade, then
a field marshal, but in poor health and seventy years of age, when
attempting to deal with the insurrection of the Jacobites, was utterly
baffled by the perplexing rapidity of Prince Charles’s marches. He,
therefore, most patriotically, resigned in favor of the Duke of
Cumberland, the “Bluff Billie” of fame and story.
Though Wade won great victories in war, his greatest renown
was gained not on the field of blood, but in this peaceful triumph over
the Highlanders. In this, he gave an inspiring precedent to those of
our own American officers of the army and navy, who have done
such noble work in preventing riot and other outbreaks of violence
among the races in our composite nation, or who, by persuasion,
instead of bloodshed, have induced Indians to submit to law. In
digging canals, in achieving hygienic mastery over disease, in
surmounting natural obstacles, in ministering to the needy, sick, and
hungry upon the frontiers, and in time of pestilence, calamity, and
devastation, by storm and earthquake, they have shown their
heroism. May the time soon come when society and the world at
large will honor the heroes of peace and mark their bloodless
triumphs, no less renowned in peace than in war. Admirable in the
highest degree is now the Scottish camaraderie of Highlander and
Lowlander, but none, to gain it, would in these more enlightened
days, pay again the awful price at which it was won.
CHAPTER XVII
HEATHER AND HIGHLAND COSTUME