The ability to predict and control the outcome of the sheet metal forming process demands holistic knowledge of the product/process parameter influences and their contribution in shaping the output product quality. Recent improvements in the ability to harvest in-line production data and the increased capability to understand complex process behaviour through computer simulations open up the possibility for new approaches to monitor and control production process performance and output product quality. This research presents an overview of the common process monitoring and control approaches while highlighting their limitations in handling the dynamics of the sheet metal forming process. The current paper envisions the need for a collaborative monitoring and control system for enhancing production process performance. Such a system must incorporate comprehensive knowledge regarding process behaviour and parameter influences in addition to the current-system-state derived using in-line production data to function effectively. Accordingly, a framework for monitoring and control within automotive sheet metal forming is proposed. The framework addresses the current limitations through the use of real-time production data and reduced process models. Lastly, the significance of the presented framework in transitioning to the digital manufacturing paradigm is reflected upon.
Since its introduction in 2011, industry 4.0 has been coined the "4th industrial revolution" following mechanization, industrialization and IT/automation as the first three, and represents the current trend of automation technologies (cyber-physical systems, internet of things, cloud computing, etc.,) in the manufacturing industry, with their potential for disruption of the manufacturing paradigm as we know it. However, the effect and role of industry 4.0 on the design and development of the new products to be manufactured in industry 4.0 facilities is not clear. This research presents a literature review to; 1) understand the concept of industry 4.0 from an implementation (state of practice) viewpoint, 2) learn about approaches and considerations currently deployed for developing products to be produced in manufacturing plants progressively transforming into industry 4.0 environments. Results reveal that the potential of industry 4.0 is underexploited within product design and development, especially in the conceptual stages lacking methods, tools, and approaches. While later stages of the product development (production planning, ramp-up) have received some attention in regards with optimizing production operations, several publications acknowledge its potential to benefit earlier process stages.
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