A digital twin-driven production management system for production workshop
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ORIGINAL ARTICLE
A digital twin-driven production management system for production workshop Jun Ma 1,2 & Huimin Chen 3 & Yu Zhang 4 & Hongfei Guo 5,6 & Yaping Ren 5,6 & Rong Mo 1,2 & Luyang Liu 7 Received: 17 April 2020 / Accepted: 17 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract With the rapid development of smart manufacturing, some challenges are emerging in the production management, including the utilization of information technology and the elimination of dynamic disturbance. A digital twin-driven production management system (DTPMS) can dynamically simulate and optimize production processes in manufacturing and achieve real-time synchronization, high fidelity, and real-virtual fusion in cyber-physical production. This paper focuses on establishing DTPMS for production life-cycle management. First, we illustrate how to integrate digital twin technology and simulation platforms. Second, a framework of DTPMS is proposed to support a cyber-physical system of production workshop, including product design, product manufacturing, and intelligent service management. Finally, the proposed DTPMS is applied to the production process of a heavy-duty vehicle gearbox. The experimental results indicate that the defective rate of products and the in-process inventory are reduced by 34% and 89%, respectively, while the one-time pass rate of product inspection is increased by 14.2%, which demonstrates the feasibility and effectiveness of the DTPMS. Keywords Production management . Digital twin . Smart workshop . Heavy-duty vehicle gearbox
1 Introduction
* Hongfei Guo [email protected] * Yaping Ren [email protected] 1
Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University, Xi’an 710072, China
2
Chongqing Tiema Industries Group Co. Ltd, Chongqing 400050, People’s.Republic of Chongqing, China
3
Institute of Computer Science, the University of Hong Kong, Hong Kong 999077, China
4
Guangzhou CreateView Education Technology Co. Ltd, Guangzhou 510000, China
5
School of Intelligent Systems Science and Engineering, Jinan University, Zhuhai 519070, China
6
Institute of Physical Internet, Jinan University, Zhuhai 519070, China
7
School of Engineering, the University of Hong Kong, Hong Kong 999077, China
“Industry 4.0” combines information communication technology and cyber physical system to support decision-making in smart production and manufacturing. Production workshop is the basis of industry; it is a convergence point with information flow, material flow, and control flow [1]. However, element management, process control, and optimization are dominated by empirical management in many production workshops. Continuous, real-time interaction cannot be accomplished between the physical layer and information layer. Lack of real-time statistics and dynamic feedback mean that we cannot find the abnormity and make adjustments quickly during the production process. In order to remotely monitor machines and an
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