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FLEXIBLE MANUFACTURING SYSTEMS: INDUSTRY 4.0 SOLUTION

Article  in  DEStech Transactions on Engineering and Technology Research · March 2018

DOI: 10.12783/dtetr/icpr2017/17583

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 FLEXIBLE MANUFACTURING SYSTEMS: INDUSTRY 4.0 SOLUTION

I.P. Gania, A. Stachowiak, J. Oleśków-Szłapka

Poznan University of Technology, Faculty of Engineering Management, Chair of Production Engineering and Logistics,
Strzelecka Str. 11, 60-965 Poznan, Poland

Abstract: The development of flexible manufacturing systems (FMSs) and solutions based on flexibility idea
(flexible assembly systems, flexible selection and picking systems, automated warehouses) began in the
eighties of the last century. The process of planning, designing and FMS implementation is not an easy in
many traditional companies. The authors of this paper presented some remarks on conventional and flexible
manufacturing systems, listing positive and negative premises and consequences of FMS implementation.
The paper briefly discusses the idea of flexible manufacturing system and automation, as the solution typical
for the Industry 4.0, recognizes the approach of polish enterprises towards the approach and some of the
trends that seem to be the future of the FMS solutions.

Keywords:
Flexible manufacturing systems, industry 4.0, production systems.

1. INTRODUCTION chain, business models, services and work environment.”

The development of flexible manufacturing systems [8]
(FMSs) and solutions based on flexibility idea (flexible The paper briefly discusses the idea of flexible
assembly systems, flexible selection and picking systems, manufacturing system and automation, as the solution
automated warehouses) began in the eighties of the last typical for the Industry 4.0, recognizes the approach of
century. The reason for interest in solutions representing polish enterprises towards the approach and some of the
such a high level of technical sophistication and the high trends that seem to be the future of the FMS solutions.
level of investment required at the investment stage of the
unit was cost pressureperceived by industry leading 2. STAGESOF DEVELOPMENT OF FLEXIBLE
countries around the world and resulting from the MANUFACTURING SYSTEMS
differentiation of customer needs [1,2,3,4]. Hence, the
change was customer-driven and led to excessive and The manufacturing system is influenced by many different
fast changes in the assortment of assembled products, factors, which are ‘types of operations’, ‘number of
manufactured parts or completed shipments. In workstations’, ‘automation level’, and ‘system flexibility’.
traditionally organized production units, the consequence Based on these factors, six general types of a
was the necessity to shift from production in economic lot manufacturing system are defined as ‘single-station
sizes, launched more often than justified by retrofitting manned cells’, ‘single station automated cells’, ‘manual
schedules, decrease in effective machine load (increase assembly system’, ‘automated assembly system’, ‘cellular
in setup time), ie increase in manufacturing costs, manufacturing system’ and ‘flexible manufacturing
resulting from required increase in capabilities of machine system’ [9] Besides these six typical manufacturing
operators, increase of salaries and training costs. The systems, there are many other manufacturing systems
above mentioned factorsforced the industry to start defined by engineers, such as computer-integrated
searching for ways to reduce production costs. Flexible manufacturing system, reconfigurable manufacturing
automation has emerged as a dominant trend. system, etc. With these fundamental manufacturing
The trend and solutions were recognized as having a systems, the Industry 4.0 has been conceived.
great potential. However, they could not face challenges Flexible solutions differ on account on flexibility they
of contemporary market environment as separate ideas, provide. Some focus on organizational aspects, and are
so they were integrated into Industry 4.0, Germany’s based on implementing management solutions resulting
policy answer [5] to increasing complexities of in flexibility of operating time available, flexibility of
manufacturing systems and mounting external competencies and operators skills (multi-skilled
environmental challenges [6]. Industry4.0 was proclaimed operators), as well as general flexibility of resources
as the fourth industrial revolution, and became both, benefiting from sharing resources. The others embrace
paradigm and strategy, and what is more a novel modern technologies to, in the end, obtain similar results:
approach to thinking on manufacturing and the way of flexibility of time, operation and resources in general.
“how-to” transition from traditionally centralized control In the literature, the most important and often discussed
structures to decentralized ones [5]. In essence, Industry solutions are identified as:
4.0 is the intelligent real-time, horizontal and vertical  Solutions based on Japanese approach, such as
integration of humans and machines with objects and linear work-in-progress flow or „zero inventory”
information and communication technology systems idea [10, 1, 7, 11],
(“digitalization”) to enable a flexible and dynamic  Humanization of work environment – work in
management of complex systems [7]. More specifically, autonomous teams, work broadening and
Industry 4.0 can be defined as the “[…]integration of enriching, flexible working time and flexible
cyber-physical-systems in production and logistics as well employment forms(freelancing) [1],
as the application of Internet of Things in industrial  Flexible automation [12, 13, 1, 5],
processes. This includes the consequences for the value In the present-day practice of the Polish machining
industry, trends corresponding to all three above
mentioned classes of solutions are being successfully with predictive health monitoring, while the production
applied. Each of them, however, is subject to certain system perspective benefits from worry-free productivity.
restrictions. The limitation of the "zero inventory" method The differences are substantialand result in necessity to
is its low flexibility and low dissemination, in authors’ implement completely different approach to production
opinion resulting from the fact that its implementation is system design.
not well recognized among managers. In the case of Examples for Industry 4.0 could be machines which can
flexibility of employment, the constraint is the resistance predict failures and trigger maintenance processes
of employees, especially against flexible working time and autonomously or self-organized logistics which react to
flexible forms of employment [3]. On the other hand, in the unexpected changes in production. Cyber-Physical
case of flexible automation, the most frequently identified Systems (CPS) are integrations of computation and
and obvious barrier is its high costs, to implement the physical processes [18, 19]. The basic principle of
solution, investments need to made [14]. Industry 4.0 is that by connecting machines, work pieces
Over the 30 years of development of flexible and systems, businesses are creating intelligent networks
manufacturing, assembly, and logistics systems, most of along the entire value chain that can control each other
the problems associated with their design, implementation autonomously. This is the reason why we also call the
and operation in the enterprise have been successfully Industry 4.0 in terms like “factory 4.0” (Factory, 2015) or
solved, resulting in flexible production systems and “smart factory” [20]. This designation is a continuation of
complementary solutions becoming an integral part of the the term “digital factory” in previous years.
industrial systems in high-developed countries [13,15, 1,
16]. Companies have been forced not only to introduce The value added processes in the “factory of the future”
new forms of production organization or new technologies are transparent and flexible. That also means that the
and new production techniques, but also to move towards production workflows, including preparation and set up
modernizing their resources. Examples of such activities time can be calculated with pinpoint precision so that free
are the solutions that allow proper allocation of functional capacity can be identified, accurately measured and
subsystems (manufacturing, storage, transport) and their consistently used. However a new generation of
interconnection, providing a free and fast flow of material, machines is required to benefit from these new
according to FMS requirements. opportunities. The production plant of the future will house
In contemporary manufacturing enterprises, disregarding multifunctional machinery as well as adjustable and
whether they are flexible or conventional, integration of intelligent production facilities.
the individual functional areas of an enterprise into an 2.1.Design framework
integrated computer-aided system seems to be crucial.
Such integration enables through automation realization The basis for the design of each production system is the
of almost all of the company's functionsby computers or assortment produced and complexity of production
devices operating under their supervision. This eliminates processes (both basic/core and auxiliary) to be carried
human participation in the implementation of technological out therein that is emerging from products structure and
and auxiliary operations such as manufacturing, transport, characteristics.
storage, manipulation thanks to numerically controlled Realization of production processes depends on material
devices, and implementing information systems to control flows and the associated information streams flow
and monitoring processes [12, 2]. realization in the company. These, in turn, depend
Implementation of automated and numerical solutions primarily on the type of assortment produced in the
brings companies closer to Industry 4.0 requirements. enterprise. In each production system, sets composed of
The differences between contemporary manufacturing a number of flow subsystems can be identified , and in
companies and industry 4.0 company arerefer to the level each set there can be subsets of tasks, processes and
of component, machine and production systems [17]. their components extracted together with their space
As far as the component is considered, contemporary requirements. Correct design of the production system
companies benefit from sensors and strive for precision requires a number of factors to be taken into account and
that can be obtained with technologies such as smart concerning production assortment, which is a reference to
sensors and fault detection. the layout of the production system being developed and
The machines are controlled with controllers that focus on the list of the production process of all functional
producibility and performance. The technologies subsystems of the flexible production system together
implemented for machines management and with their allocation on the facility floor [14,21].
maintenance are condition-based monitoring and  Designing production subsystem.
diagnostics. The manufacturing subsystem includes workstations that
Production systems in contemporary companies are perform technological operations, as well as washing,
networked, and their most important attributes are inspection, changeover, etc. operations. The workstations
productivity and OEE (Overall Equipment Efficiency). are of various character/capabilities and include
Nowadays it is believed that they can be obtained with machining, preparatory, auxiliary and control stations. The
lean approach to manufacturing and management and basic factor determining the way a FMS is designed is an
waste reduction. assortment of manufactured products that has a decisive
The Industry 4.0 companies focus on different attributes, impact on the solutions used not only in the
namely: manufacturing subsystem but also in the manipulation,
 Self-awareness, transport and storage subsystems, which in turn
 Self-prediction, determines the layout of the production system [3, 14, 22
 Self-comparability, ].
 Self-configuration,  Designing transportation subsystem
 Self-maintenance, The transport subsystem in flexible production systems
 Self-organization. has a number of functions that enable both the transport
The technologies applied for components management of raw materials and materials necessary for the
include degradation monitoring and remaining useful life production process, as well as the transport of tools that
prediction, those referring to machines include up time ensure the implementation of the manufacturing process,
workshop equipment, post-production waste, etc. The (CAM), computer aided quality (CAQ). The relations are
implementation of these functions is possible through the presented in the figure 1.
use of various types of means of internal (inbound)
transport, which have a significant impact on the layout of
the developed system, including:
- numerically controlled gantry cranes for transport and Management
handling, without the need to expand the facility floor Information System
space, (MIS)
- hanging conveyors, which are used for steady flow of
materials, do not interfere with the production unit
space and deliver materials directly to the workspace CAD, CAE, CAPP, computer aided
of the workstation, however requiring the adaptation of CAQ manufacturing CAM
the facility building and working space,
- Induction carts, the most flexible means of transport
used in flexible production systems, but requiring Fig.1. Integration of CAD/CAE/CAPP/CAM systems within
adaptation of the facility to the specific requirements of an information system of a company. Source: prepared on
the solution. the basis of [3].
The result is determination of the type of mean of
transport to be used (based on its characteristics and its Unquestionable are also the benefits resulting from the
suitability for the system) in the developed FMS. applied systems, like [3]:
 Designing storage subsystem  diminishing labor consumption of the designed
Storage subsystem in flexible manufacturing systems has products,
many functions. The basic function is to store item, but  product and solution quality improvement,
there are also auxiliary functions that include:  possibility of optimization methods usage.
• storage of workshop and facility equipment Integration of computer aided systems in design may be
(pallets, tools, handles), used doubly:
• storage of auxiliary  In the first version the result of work of one of the
• storage of post-production materials. subsystems may be passed to next systems using
The components of this subsystem are storage devices available IT systems e.g. LAN (local area network).
(central production warehouse, local warehouses and So it is necessary for all subsystems to be available
storage areas allocated at workstation etc.). for mutual data collection.
Flexibility in storage system is the more important, the  The second version consist of joining the abilities to
more corporate processes are stochastic and inordinately do different design activities within one system by
complex, resulting in uncertainty of quantity and quality of using work outcome of one system by the other one
material flows companies need to deal with [23]. e.g. integrated construction design system.
The very important aspect in the design of the storage Computer aided design systems (CAD, CAE, CAP, CAM,
subsystem is the selection of equipment of the subsystem CAQ) are an inseparable element of the informational
to improve the flow rate, which includes the flow of system of the whole company and have a significant
materials, raw materials, finished goods, tools and post- influence on the functioning of other parts of the company,
production waste in a flexible system. Such solutions like [3]:
include automatically controlled racks or automatic shelf  marketing,
storage.  sales,
 Designing handling subsystem  supplies,
The overriding task of the handling subsystem is to move  bookkeeping,
and allocate materials, manufactured articles, pallets with
 finance
WIP, tools necessary for processing between and into
 production abilities of the company,
workstations or storage and transport equipment.
At the design stage, the selection and allocation of the  human resources management.
handling subsystem components is defined, in order to
enable transfer of cargo between the technological, Nowadays in the known by the authors companies of
storage and transport equipment. The components of this mechanical engineering industry, flexible manufacturing
subsystem are manipulators (robots, manipulators, pallet systems are applied in the process of simple product
changers, etc.) [3]. production. Such situation narrows down the production
The handling subsystem is a bridge between production, preparation to constructional and technological
transport and storage subsystems, and depends on the preparation and permits to omit the research stage.
performance of other functional and logistic subsystems. Also a unit and low-volume production type in
The subsystems listed above constitute the subsystem of conventional systems causes that the scope of activities
material flow. The components of this subsystem are the which need a technical production preparation is on the
locations of issuing and receiving of various types of one hand very narrowed down or on the other it doesn’t
loads, from tools through raw materials, materials to post- appear at all.
production waste, moving according to the technological In turn flexible manufacturing systems encompassing a
process route. wide range of automation and auxiliary production
operations require, in comparison with conventional
2.2. Integration of CAD/CAM systems vs. production systems, a wider range of work connected with
effectiveness of company functioning production preparation i.e. more detailed work.
As it was mentioned above in technical production
preparation of flexible manufacturing systems the key role
plays an integration of computer aided design (CAD),
computer aided engineering (CAE), computer aided
process planning (CAPP), computer aided manufacturing
4. ANALYSIS OF BENEFITS RELATED TO THE to incur considerable investment costs, much higher than
IMPLEMENTATION OF FLEXIBLE PRODUCTION in conventional production systems that prevents
SYSTEMS IN POLAND companies from implementing the flexible solution.
4.1. Positive premises for using flexible Because the high capital investment factor, significantly
manufacturing systems higher than conventional production systems, is the most
In general, each production system should meet the commonly quoted in the literature FMS restriction, its logic
following objectives: be able to deliver the right products is presented below, in a simplified, cost-only, industry-
at the right time, in the required quantity, at the specified based example.
quality level and at the acceptable production costs. Considering two variants:
These goals can be achieved by using flexible A) conventional system – lathe
manufacturing systems, which in addition provide [22]: - purchase price of universal lathe: about PLN 40
 productivity growth - productivity of flexible 000
production systems is significantly higher than the - employee - net salary of about PLN1,500/a
one of conventional production systems equipped month
with the same number of machines, - income derivatives (social security, health
 decreased demand for space - high productivity of insurance contributions) about PLN 850/a month.
flexible production systems reduces the number of - salary with derivatives per year about
machines installed and thus the demand for space PLN28 200
compared to conventional production systems that Total expenses under the assumption
perform the same production tasks, a 6-year depreciation cycle account for about
 reduced direct labor costs - centrally controlled PLN 209 200
machines do not require a permanent operator B) automated system - numerically controlled lathe
presence, OKUMA
 reduction of work in progress and shortening - the purchase price of a numerically controlled
production cycles by up to 80% compared to lathe is about PLN250 000
performing the same tasks in conventional - salary with derivatives per year - assuming
systems. (which corresponds to actual business
These effects are achieved through [7]: conditions) that employeeoperates three
 high, for some flexible manufacturing systems, machines (multi-station work) accounts for about
degree of product-based specialization leading to PLN9 400
concentrating all the operations on the product Total expenses under the assumption
within the system, of a 6-year depreciation cycle are about
 reduced retrofitting time thanks to reducing the PLN304 400.
number of handlings, Hence, the cost of the automated system is 1/3 higher
 improving production control in the system through than the cost of the conventional system. But the structure
the use of IT support, of the cost is different. While in the case of the
conventional system, personal costs with derivatives
 improving quality of product by limiting operators
account for about 4/5 of all costs, their share for the
errors and by reducing the number of handlings,
automated variant is about 1/6. The rest in both cases is
 increased quantitative flexibility thanks to
depreciation. Depreciation funds remain in the enterprise
possibility of maintenance-free operation of the
and may be used, where appropriate, for ongoing
flexible system during the off hours.
business financing or reinvestment. The problem that the
4.2. Negative premises for implementing flexible
manager needs solve in the presented above, simplified
manufacturing systems
example is the answer to the question "Do you have to
The potential benefits of implementation of flexible
invest more to improve your business in the future?"
manufacturing systems such as high productivity, short
The authors of the paper believe that such problems are
production cycles, inventory reduction, quality growth, or
currently faced by the management of many machinery
rapid deployment to new production are not easy to
companies that are modernizing their production systems.
achieve. Companies in many cases do not make the
They believe that currently the good economic conditions
decision to implement flexible production systems, even if
are suitable for introducing flexible manufacturing systems
there are conditions supporting the decision, because
in enterprises as a competitive solution to the employment
they have difficulty in identifying such opportunities.
of surplus workforce. However, companies do not
Designing flexible solutions requires the involvement of
implement flexible production systems, even if there are
highly qualified staff - specialists in many fields such as
conditions enabling that, because they have difficulty
construction of machines and machine tools, technics and
identifying such opportunities.
technology, IT, electronics, automation and quantitative
methods in production planning and control. A typical
5. INDUSTRY 4.0 IN POLISH ENTERPRISES
machining company usually does not have such a broad
ENTERPRISES
staff of specialists. Companies are also not usually
As it was presented in the previous sections, digitalizing
prepared to solve problems related to the operation of
the production is not a new trend. It started in the 80s and
FMS. Effective use of high performance flexible
spread all over the world and industries, taking the form of
manufacturing systems requires a high level of load.
computer integrated manufacturing (CIM)during the
Which in turn requires increasing the efficiency of sales
early1990s and gaining a significant momentum. CIM
and acceleration of technical preparation of production
rested on the idea of a fully automated production process
(design of construction and technology). Problems can
from procurement and production to distribution without
also arise in the sphere of maintenance and repair of the
necessitating human interaction [24].
flexible system.
CIM implementation in 90s however was not as
As the main reason for the lack of interest in the
successful as expected, mainly due to missing information
implementation of FMS quoted in the literature, is the high
and communication technology(ICT) standards [6],
cost of machines and equipment required to build a
insufficient understanding, human resistance to change,
flexible manufacturing system, it is the consequent need
organizational incompatibilities, and lack of skilled labour human factor and knowledge as key drivers of innovation,
to implement and use CIM [25]. on the other basing innovation on communication.
These constraints or obstacles are nowadays dealt with, Communication between machines and benefiting from
as on the social dimension, industries are experiencing a
the so called Fourth Industrial Revolution – linking
shift from an economy centered on organizations to one
centered on the individual [26], and communication manufacturing and Internet – seem to be the perspective
technology has made a great progress, benefiting from of FMS development.
extensive use of Internet as communication on multiple Currently one of the major technologies supporting the
levels providers (human to human, human to machine, communication process in the context of IoT is RFID
machine to machine). Based on assistive (ambient) (Radio Frequency Identification). In the areas of logistics
systems and sophisticated human-to-machine interfaces and the supply chain, the RFID technology has been
production process flexibility and employees play a key known for decades and is largely used for the tracking
role in Industry 4.0 [6]. On the technology front, wireless and monitoring of goods [29, 30].The items using RFID
communication and the Internet of Things have reached tags are equipped with micro-processors and thus are
industrial maturity [11]. detectable in the environment. It facilitates the processing
of information and the interaction with other devices [31].
Industry4.0 is the strategy or the concept that is widely Other increasingly popular technologies are the NFC and
discussed and willingly implemented as the way to gain Bluetooth Smart, used by beacons (corresponding to
competitive advantage and benefit from solutions tags) - tiny devices consisting of a Bluetooth chip and a
available thanks to technology development. battery. The transmitter sends a specific signal, which is
However, according to Millward Brown research on Polish captured, for example, by the applications installed on
industry, almost 90% of Polish companies are not familiar smartphones that trigger the desired function, eg.
with the term Industry 4.0. Those recognizing the idea are checking in at a particular place [32, 33].
usually large companies, benefiting from foreign capital, The potential of these solutions is great and continuously
employing over 500 people, and not representing heavy growing, which makes automation and flexibility a
industry [27]. promising field for research and implementation.
Polish companies however benefit from some of the
solutions within Industry 4.0, even if they are not aware of
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