A new Simulation-Based Approach in the Design of Manufacturing Systems and Real-Time Decision Making
Romão Santos, César Toscano, Jorge Pinho de Sousa
Abstract
The principles and tools made available by the Industry 4.0, smart factories, or the Internet of Things (IoT), along with the adoption of more comprehensive simulation models, can significantly help the industry to face the current, huge external and internal challenges. This paper presents a new simulation-based approach to support decision making in the design and operational management of manufacturing systems. This approach is used to evaluate different layouts and resources allocation, and help managing operations, by integrating a simulation software with real-time data collected from the production assets through an IoT platform. The developed methodology uses a digital representation of the real production system (that may be viewed as a form of a digital twin) to assess different production scenarios. A set of key performance indicators (e.g. productivity) provided by the simulation can be used by the Manufacturing Execution System (MES) to generate production schedules. The developed approach was implemented and assessed in a real case study, showing its robustness and application potential. Its extension to other industrial contexts and sectors seems, therefore, quite promising.