Simulation Approach Towards Energy Flexible Manufacturing Systems

This authored monograph provides in-depth analysis and methods for aligning electricity demand of manufacturing systems to VRE supply. The book broaches both long-term system changes and real-time manufacturing execution and control, and the author presents a concept with different options for improved energy flexibility including battery, compressed air and embodied energy storage. The reader will also find a detailed application procedure as well as an implementation into a simulation prototype software. The book concludes with two case studies. The target audience primarily comprises research experts in the field of green manufacturing systems.

This book has been written for all those interested in flexible manufacturing systems (FMS) and other forms of computerized manufacturing systems (CMS). It deals with many aspects of the design, operation, and simulation of FMS and explains the origins of FMS.

One critical barrier leading to successful implementation of flexible manufacturing and related automated systems is the ever-increasing complexity of their modeling, analysis, simulation, and control. Research and development over the last three decades has provided new theory and graphical tools based on Petri nets and related concepts for the design of such systems. The purpose of this book is to introduce a set of Petri-net-based tools and methods to address a variety of problems associated with the design and implementation of flexible manufacturing systems (FMSs), with several implementation examples.There are three ways this book will directly benefit readers. First, the book will allow engineers and managers who are responsible for the design and implementation of modern manufacturing systems to evaluate Petri nets for applications in their work. Second, it will provide sufficient breadth and depth to allow development of Petri-net-based industrial applications. Third, it will allow the basic Petri net material to be taught to industrial practitioners, students, and academic researchers much more efficiently. This will foster further research and applications of Petri nets in aiding the successful implementation of advanced manufacturing systems.

This book provides for the first time an overview on the current approaches and applications of energy aspects in production and logistics by the use of simulation techniques. During the last decade, the importance of energy in the material flow processes has become more and more important. The pressure to reduce the environmental footprint of production and logistics systems will even intensify in future. Therefore, enterprises have started to integrate the use of energy into their planning processes much more than before, even designing feedback loops, e.g., from energy control to production control. This receives additional attention with the increasing use of renewable, but less reliable, energy sources. Care must be taken to establish processes that aim to use energy when it is available. As an example, many industrial processes like melting or coating have significant energy demands, but could vary the point of time of its consumption within specific limits, leading to a very high complexity. ​ It discusses the construction and application of energy-specific performance indicators and analyzes the input information that needs to be acquired before implementing suitable models. On this basis, concrete technical solutions are introduced.

This book includes the introduction of emerging manufacturing technologies and planning cases with established technologies. The planning of eco-efficient process chains is crucial for manufacturing companies. However, in the state-of-the-art planning, various barriers exist towards the integration of the environmental dimension. Against this background, a concept for the integration of classic lean and environmental criteria into the three planning phases of process chains is presented. During concept planning, the Technology Assessment Tool supports planners in the identification of eco-efficient technologies. During rough planning, the Value Stream Design Tool enables the derivation of a production line based on workpiece characteristics. For detailed planning, tools for eco-efficient machine and process chain configuration are provided. Three case studies from large-scale automotive component manufacturing with established and emerging technologies demonstrate the tool applicability.

The importance of the energy and commodity markets has steadily increased since the first oil crisis. The sustained use of energy and other resources has become a basic requirement for a company to competitively perform on the market. The modeling, analysis and assessment of dynamic production processes is often performed using simulation software. While existing approaches mainly focus on the consideration of resource consumption variables based on metrologically collected data on operating states, the aim of this work is to depict the energy consumption of production plants through the utilization of a continuous simulation approach in combination with a discrete approach for the modeling of material flows and supporting logistic processes. The complex interactions between the material flow and the energy usage in production can thus be simulated closer to reality, especially the depiction of energy consumption peaks becomes possible. An essential step towards reducing energy consumption in production is the optimization of the energy use of non-value-adding production phases.

This 4-volume set, IFIP AICT 689-692, constitutes the refereed proceedings of the International IFIP WG 5.7 Conference on Advances in Production Management Systems, APMS 2023, held in Trondheim, Norway, during September 17–21, 2023. The 213 full papers presented in these volumes were carefully reviewed and selected from a total of 224 submissions. They were organized in topical sections as follows: Part I : Lean Management in the Industry 4.0 Era; Crossroads and Paradoxes in the Digital Lean Manufacturing World; Digital Transformation Approaches in Production Management; Managing Digitalization of Production Systems; Workforce Evolutionary Pathways in Smart Manufacturing Systems; Next Generation Human-Centered Manufacturing and Logistics Systems for the Operator 5.0; and SME 5.0: Exploring Pathways to the Next Level of Intelligent, Sustainable, and Human-Centered SMEs. Part II : Digitally Enabled and Sustainable Service and Operations Management in PSS Lifecycle; Exploring Digital Servitization in Manufacturing; Everything-as-a-Service (XaaS) Business Models in the Manufacturing Industry; Digital Twin Concepts in Production and Services; Experiential Learning in Engineering Education; Lean in Healthcare; Additive Manufacturing in Operations and Supply Chain Management; and Applications of Artificial Intelligence in Manufacturing. Part III : Towards Next-Generation Production and SCM in Yard and Construction Industries; Transforming Engineer-to-Order Projects, Supply Chains and Ecosystems; Modelling Supply Chain and Production Systems; Advances in Dynamic Scheduling Technologies for Smart Manufacturing; and Smart Production Planning and Control. Part IV : Circular Manufacturing and Industrial Eco-Efficiency; Smart Manufacturing to Support Circular Economy; Product Information Management and Extended Producer Responsibility; Product and Asset Life Cycle Management for Sustainable and Resilient Manufacturing Systems; Sustainable Mass Customization in the Era of Industry 5.0; Food and Bio-Manufacturing; Battery Production Development and Management; Operations and SCM in Energy-Intensive Production for a Sustainable Future; and Resilience Management in Supply Chains.

Energy consumption is of great interest to manufacturing companies. Beyond considering individual processes and machines, the perspective on process chains and factories as a whole holds major potentials for energy efficiency improvements. To exploit these potentials, dynamic interactions of different processes as well as auxiliary equipment (e.g. compressed air generation) need to be taken into account. In addition, planning and controlling manufacturing systems require balancing technical, economic and environmental objectives. Therefore, an innovative and comprehensive methodology – with a generic energy flow-oriented manufacturing simulation environment as a core element – is developed and embedded into a step-by-step application cycle. The concept is applied in its entirety to a wide range of case studies such as aluminium die casting, weaving mills, and printed circuit board assembly in order to demonstrate the broad applicability and the benefits that can be achieved.