Digital Twins-Based Production Line Design and Simulation Optimization of Large-Scale Mobile Phone Assembly Workshop

Zhao, Ran; Zou, Guangxin; Su, Qianyi; Zou, Shangwen; Deng, Wenshun; Yu, Ao; Zhang, Hao

doi:10.3390/machines10050367

Cited by 13 publications

(11 citation statements)

References 39 publications

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“…Especially when different system configurations or processes need to be validated [8], simulation is a significant tool for modelling and analyzing the true performance of manufacturing systems. It has functions such as identifying and dealing with bottlenecks in manufacturing plants, predicting plant capacity, observing machine operating efficiency and so on [9][10][11][12].…”

Section: Simulation-based Methods For Resource Configuration Of Manuf...mentioning

confidence: 99%

Order-Driven Dynamic Resource Configuration Based on a Metamodel for an Unbalanced Assembly Line

2022

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Resource-constrained product general assembly lines with complex processes face significant challenges in delivering orders on time. Accurate and efficient resources allocation of assembly lines remain a critical factor for punctual order delivery, full use of resources and associated customer satisfaction in complex production systems. In order to quickly solve the order-based dynamic resource allocation problem, in this paper a metamodel-based, multi-response optimization method is proposed for a complex product assembly line, which has the characteristics of order-based production, long working time of processes, multiple work area re-entry and restricted operator quantity. Considering the complexity of the assembly line and the uncertainty of orders, the correlation between system performance indicators and resource parameters is investigated. Multiple metamodels are constructed by the Response Surface Methodology to predict and optimize the system performance. The adequacy of the constructed metamodels is verified and validated based on the bootstrap resampling method. Under the condition of ensuring the throughput demand of the assembly line, the desirability function is applied to simultaneously optimize the multi-response, and the resource allocation solution is generated. The method in this paper can be used to rapidly adjust the resource configuration of the assembly line when considering the order changes.

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Section: Simulation-based Methods For Resource Configuration Of Manuf...mentioning

confidence: 99%

Order-Driven Dynamic Resource Configuration Based on a Metamodel for an Unbalanced Assembly Line

2022

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“…Arena simulations software was used to perform a discrete event simulation of the trouser assembly (Bongomin et al, 2020). Some studies revised the production line architectures by mixing and integrating two different lines and improved production efficiency, reducing production costs (Zhao et al, 2022). A review study for assembling line balance problems advised using decision support software and experienced planners to reduce planning time and effort (Boysen et al, 2022).…”

Section: Literature Surveymentioning

confidence: 99%

Bi̇r Teksti̇l Şi̇rketi̇ İçi̇n Üreti̇m Hatti Atama Problemi̇

ABDELSALAM>¹,

MOHAMMOUD>²,

EDER>³

et al. 2023

Mühendislik Bilimleri Ve Tasarım Dergisi

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In this study, the production process of Karaman Textiles, for which production planning is done manually, was observed and analyzed. This study aims to minimize the unused machine capacity and idle time of the existing system by developing a mixed integer programming (MIP) model, developing scenarios, and obtaining the results with GAMS software. In addition, the results of the scenarios are compared and evaluated to reach the optimal result that meets and maximizes the efficiency of the production process. The company's usual production planning is done manually and determined according to annual demand. The study aims to minimize the machine working times and that complete planning of the production in the most optimal way. In this study, the company's production time and machine usage times were optimized, and under normal conditions, 15,000 fabric pants were produced for 8 hours a day, 5 days a week, and 4 weeks a month. The scenario analysis aimed to produce by adding 4,000 pieces of velvet pants in addition to 15,000 fabric pants in the first scenario. The second scenario aims to minimize the production time of 15,000 fabric pants by limiting the working times of the machines owned by the company.

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“…In order to solve this problem, the least square method is used to fit the bottom edge contour of the terminal head. The rotation angle a of the terminal head can be calculated by fitting the slope k of the straight line, which is in equation (1).…”

Section: Terminal Head Angle Adjustmentmentioning

confidence: 99%

“…These products include many terminal buckling operations in the assembly process, such as power terminals, antenna terminals, flexible printed circuit terminals, and so on. 1 With the development of electronic products toward light and thin, the scale of terminals is becoming smaller, which puts forward a more serious difficulty for automatic assembly. One terminal typically includes a terminal head with a flexible line and a terminal base mounted on the printed circuit board.…”

Section: Introductionmentioning

confidence: 99%

Automatic buckling system of micro terminals combined vision and force signals

Jiang

Zhang

et al. 2023

Measurement and Control

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Micro terminals are often used in every laptop, mobile, and other electrical product. It is challenging to automatically buckle the terminal head to its terminal base during manufacturing because of trouble in accurate positioning and gripping. A double-robots collaborative assembly system is developed to buckle millimeter-scale terminals in three-dimensional space. Robot 1 takes the terminal head horizontally by grasping its flexible line with a customized clamp, including two fingers. Robot 2 presses the aligned terminal head through a force control strategy to ensure that the terminal head and the terminal base can complete buckling accurately, even if there is a certain deviation in the vertical direction. There are two cameras to be used in the system. A horizontally placed camera is used to detect and calculate the angle between the terminal head and the horizontal plane. The angle data will drive robot 1 to make the terminal end face parallel to the horizontal plane to complete the pose correction of the terminal head. Another camera is vertically fixed at the end of industrial robot 1 and used to detect and calculate the position deviation between the terminal head and the terminal base. The position deviation will drive robot 1 to align the terminal head with the terminal base to complete the position correction. The YOLOv3, least square, and feature extraction algorithms are used in image processing. The accuracy of the YOLOv3 target detection model trained by self-made data set can reach more than 95% under different conditions. The detection period is within 65 ms. The experimental results show that the terminal assembly system designed in this paper has excellent reliability and assembly success rate. It also has a significant reference value for other terminals’ automatic buckling assemblies.

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Digital Twins-Based Production Line Design and Simulation Optimization of Large-Scale Mobile Phone Assembly Workshop

Cited by 13 publications

References 39 publications

Order-Driven Dynamic Resource Configuration Based on a Metamodel for an Unbalanced Assembly Line

Order-Driven Dynamic Resource Configuration Based on a Metamodel for an Unbalanced Assembly Line

Bi̇r Teksti̇l Şi̇rketi̇ İçi̇n Üreti̇m Hatti Atama Problemi̇

Automatic buckling system of micro terminals combined vision and force signals

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