SMART FACTORY SYSTEM USING IIOT
TECHNICAL SEMINAR REPORT
Submitted by
S.A.KANNAPPERUMAL
DEPARTMENT OF MECHATRONICS
BANNARI AMMAN INSTITUTE OF TECHNOLOGY
(An Autonomous Institution Affiliated to Anna University, Chennai)
SATHYAMANGALAM-638401
OCTOBER 2019
BONAFIDE CERTIFICATE
Certified that this Technical Seminar report of “SMART FACTORY SYSTEM
USING IIOT” is the bonafide work of “……………….” who carried out the technical
seminar report work under my supervision.
SIGNATURE SIGNATURE
Head of the Department, Supervisor, Assistant Professor,
Department of electronics and instrumentation, Department of electronics and instrumentation,
Bannari Amman Institute of Technology, Bannari Amman Institute of Technology,
Sathyamangalam 638401. Sathyamangalam 638401.
Submitted for Technical Seminar - I Viva-Voce examination held on ………………
INTERNAL EXAMINER EXTERNAL EXAMINER
TABLE OF CONTENTS
CHAPTER NO TITLE PAGE NO
ABSTRACT i
LIST OF FIGURES ii
INTRODUCTION 1
1 MANUFATURING 2
1.1 TYPES OF OPERATION 2
1.2 MANUFACTURING PROCESS 3
2 INSPECTION 4
2.1 TYPES OF INSPECTION 5
2.2 INSPECTION REPRESENTATION 6
3 AUTOMATED GUIDED VEHICLE 7
4 AUTOMATED STORAGE AND RETRIEVAL SYSTEM 8
4.1 AS/RS TYPES 9
5 CASE STUDY 10
6 MOBILE APP
6.1 DEVELOPMENT OF MOBILE APP 11
7 SYSTEM STRUCTURE ON MANUFACTURING 12 Commented [A1]:
7.1 CONCLUSION 13
7.2 REFERENCE 13
ABSTRACT
In this modern world every day a new technology arises to reduce human work and
improve the products quality and reliability in manufacturing methods. This seminar deals
with the technology used in manufacturing process involving automation. Invention of smart
manufacturing system, monitoring, and alerting system for safety involves research and
development. The evolution of process like fixed manufacturing, flexible manufacturing,
programmable manufacturing. In order to hold a sale, share in market the enterprise must
bring update in products and the way they manufacture their product because to ensure that
the they satisfy the quality terms and conditions set up by the government. Also, to reduce
their production cost to have a hike in their profit. Some advance mechanism like vision-
based inspection system and rapid response system along with data analysis takes the
manufacturing environment to the next new level. Not only manufacturing but post customer
satisfaction program also plays a vital role in increasing the enterprises profit. Today the
main tool in any sector is marketing involving customer to producer communication. If this
is not working, then no company with a big capital could sustain in a playground of
Technology and Development. So, a great example is by looking at European countries
because their inventions are great because they use modern and smart technologies for
production, developing countries like India is getting into smart gigs in faster to cope up with
the western quality in production methods and all the whole producing best product.
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LIST OF FIGURES
FIG NO TOPIC PAGE NO
1 MANUFACTURING LAYOUT 3
2.1 INSPECTION SYSTEM 3
2.2 INSPECTION TYPES 4
3 AUTOMATED GUIDED SYTEM 5
4 AUTOMATED RETRIVAL AND 6
STORAGE SYSTEM
5 INDUSTRIAL DEFINED 6
PROBLEMS
6 PROPOSED MOBILE 7
APPLICATION
7 SYSTEM STRUCTURE 7
ii
INTRODUCTION
Today manufacturing process involves difficulties like facility location, scale of
operation, and cost of production. Facility location problem involves site availability near
to customer and suppliers keeping transportation cost in consideration. Then comes the
problem involving scale of operation which involves how much production to be made
and how could the stock be cleared. So, there is new type of manufacturing called flexible
manufacturing system, which includes computer integrated process, group technology
and computer aided manufacturing. After manufacturing the process includes inspection
based on machine vision as off line and on line inspection system. From this process the
products quality could never be compromised, for transportation within the production
line and the warehouse station Automated Guided vehicle could be used. It is already
preprogrammed so the process occurs flawless, the AGV id of 3 types depending on the
payload. Finally comes the storage section it is of Automated storage and Retrieval
System, in this method after receiving the final product they are loaded into AGV then it
stored automatically in the aisle racks and inventory storage areas itself. So the process
occurs smoothly without any error, it completely monitored by using online monitoring
system. The customer monitors the making of their product in real time using the mobile
application. The factory itself is totally interconnected by means of Industrial Internet of
Things Technology.
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CHAPTER 1
MANUFACTURING
This section explores the various factors that distinguish different types of manufacturing
systems. The factors are (1) types of operations performed, (2) number of workstations
and system layout, (3) level of automation, and (4) system flexibility. From these factors,
a general classification of manufacturing systems is derived.
Types of Operations
Type of material processed - Different engineering materials require different types of
processes. Processing operations used for metals are usually different from those used for
plastics or ceramics. These differences affect the type of equipment and handling method in
the manufacturing system. Size and weight of the part or product. Larger and heavier work
units require bigger equipment with greater power capacity. Safety hazards increase with the
size and weight of parts and products, Part geometry. Machined parts can be classified as
rotational or non-rotational, Rotational parts are cylindrical or disk-shaped and require
turning and related rotational operations. Non-rotational parts are rectangular or cube-like
and require milling and related machining operations to shape them. Manufacturing systems
that perform machining operations must be distinguished according to whether they make
rotational or non-rotational parts. The distinction is important not only because of differences
in the machining processes and machine.
2
MANUFACTURING PROCESS:
Fig 1 Manufacturing layout
3
CHAPTER 2
INSPECTION
In quality control, inspection is the means by which poor quality is detected and good
quality is assured. Inspection is traditionally accomplished using labor intensive methods that
are time consuming and costly. Consequently, manufacturing time and product cost are
increased without adding any real value to the products. Also, the manual inspection is
performed only after final manufacturing so a large amount of material is wasted and the
capital is completely drowned. The new type of inspection includes complete automation
inspection rather than sampling inspection by manual methods. Software tools to track and
analyze the sensor measurements over time for process control. Uses feedback vision thus
the values are defined accurately rather thus the overview, so product quality is at its par as a
good product. Advance inspection is combined with sensor technology to automate the
operation of sensor system.
Fig 2.1 Inspection system
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2.1 TYPES OF INSPECTION SYSTEM
OFF Line Inspection: Off-line inspection is performed away from the manufacturing
process, and there is generally a time delay between processing and inspection. Off-line
inspection is often accomplished using statistical sampling methods. Manual inspection is
common. Factors that tend to promote the use of off-line inspection are (1) variability of the
process is well within the design tolerance, (2) processing conditions are stable and the risk
of significant deviations in the process is small, and (3) cost of inspection is high relative to
the cost of a few defective parts. The disadvantage of off-line inspection is that the parts
have already been made by the time poor quality is detected. When sampling is used, an
additional disadvantage is that defective parts can pass around the sampling procedure.
On-Line Inspection. The alternative to off-line inspection is on-line inspection performed
when the parts are made, either as an integral step in the processing or assembly operation, or
immediately afterward. Two on-line inspection procedures can be distinguished as on-
line/in-process and on-line/post-process. On-line/in-process inspection is achieved by
performing the inspection procedure during the manufacturing operation. As the parts are
being made, the inspection procedure simultaneously measures or gages their dimensions.
The benefit of in-process inspection is that it may be possible to influence the operation that
is making the current part, thereby correcting a potential quality problem before the part is
completed. When on-line/in-process for automated manufacturing systems, this on-line
inspection method is typically done on a 100% basis using automated sensor methods.
Technologically, automated on-line/in-process inspection of the product is usually difficult
and expensive to implement. With on-line/post-process inspection, the measurement or
gaging procedure is accomplished immediately following the production process. Even
though it follows the process, it is still considered an on-line method because it is integrated
with the manufacturing workstation, and the results of the inspection can immediately
influence the production operation. The limitation of on-line/post-process inspection is that
the part has already been made, and it is therefore impossible to make corrections that will
influence its processing. The best that can be done is to influence the production of the next
part.
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2.2 INSPECTION REPRESENTATION:
Fig 2.2 Inspection Types
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CHAPTER 3
AUTOMATED GUIDED VEHICLES
In industry, the transportation way is done only by manual movement as a help of human aid
in a traditional manufacturing industry, which requires more time and a separate person for
the operation so it is replaced by a smart vehicle named as a automated guided vehicle, which
already programed to act, it moves to the completed area for picking the material and placing
it in the next station for further manufacturing. It reduces time and saves a human work by
transporting a material in a safe manner. The AGVs move by following the wire which is laid
under the working area, the other way is to follow a sensor and finally by using robotic
operating system (computer programmed method of tracking path). The automated guided
vehicle is divided into three types based on the payload it is carrying and the environment it
is working, they are Driverless automated guided system, AGV pallet truck, and unit load
carrier.
Fig 3 Automated guided system
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CHAPTER 4
AUTOMATED STORAGE AND RETRIEVAL SYSTEM
Mechanized and automated storage systems are available that reduce or eliminate the amount
of human intervention required to operate the system. The level of automation varies. In less
automated systems, a human operator is required to handle each storage/retrieval transaction.
In highly automated systems, loads are entered or retrieved under computer control, with no
human participation except to input data to the computer. An automated storage system
represents a significant investment, and it often requires a new and different way of doing
business. Companies have a variety of reasons for automating the storage function.
Automated storage systems divide into two general types: (1) fixed-aisle automated
storage/retrieval systems and (2) carousel storage systems. A fixed-aisle AS/RS consists of a
rack structure for storing loads and a storage/retrieval machine whose motions are
linear (x–y–z motions).
Fig 4 Automated Storage and Retrieval System.
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4.1 AS/RS TYPES
• Unit load AS/RS. The unit load AS/RS is typically a large automated system designed to
handle unit loads stored on pallets or in other standard containers. The system is computer
controlled, and the S/R machines are automated and designed to handle the unit load
containers. The AS/RS pictured in is a unit load system. Other systems described below
represent variations of the unit load AS/RS.
• Deep-lane AS/RS. The deep-lane AS/RS is a high-density unit load storage system that is
appropriate when large quantities of stock are stored, but the number of separate stock types
(SKUs) is relatively small. Instead of storing each unit load so that it can be accessed directly
from the aisle (as in a conventional unit load system), the deep-lane system stores ten or
more loads in a single rack, one load behind the next. Each rack is designed for “flow-
through,” with input on one side and output on the other side. Loads are picked up from one
side of the rack by an S/R-type machine designed for retrieval, and another machine input
loads on the entry side of the rack.
• Mini load AS/RS. This storage system is used to handle small loads (individual parts or
supplies) that are contained in bins or drawers in the storage system. The S/R machine is
designed to retrieve the bin and deliver it to a P&D station at the end of the aisle so that
individual items can be withdrawn from the bins. The P&D station is usually operated by a
human worker. The bin or drawer must then be returned to its location in the system. A mini
load AS/RS is generally smaller than a unit load AS/RS and is often enclosed for security of
the items stored.
Man-on-board S/RS. A man-on-board (also called man-aboard) storage/retrieval represents
an alternative approach to the problem of retrieving individual items from storage. In this
system, a human operator rides on the carriage of the S/R machine. Whereas the mini load
system delivers an entire bin to the end-of-aisle pick station and must return it subsequently
to its proper storage compartment, with the man-on-board system the worker picks individual
items directly at them storage locations. This offers an opportunity to increase system
throughput.
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CHAPTER 5
CASE STUDY
The real problem involved in a medical industry due to the traditional way of manufacturing.
The company’s production rate is also decreased and the consumer buying the product and
selling to the next customer sells it at an even extra value. So finally, the consumer would
find a different manufacturer and his stay over the market falls, so smart manufacturing
improves productivity, quality and reduces wastage and follows the new guideline of
industry 5.0 that is grow bigger by means of Sustainable Development.
Fig 5 Industrial defined problem
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CHAPTER 6
MOBILE APP
6.1 DEVEPOLMENT OF MOBILE APP:
The mobile application is developed as an API for android users made from an
algorithm for real-time viewing of the retrieved data from the cloud. The data from the
gas sensor is stored in the cloud. We have used Google fire-base cloud system for data
retrieval, authentication and mainly for privacy. The data acquired is stored in our firm’s
server and they are uploaded to mobile applications and used for monitoring. The mobile
application consists of a login page, then firstly, an introduction panel for real-time data
viewing which is been uploaded every 7 seconds from Controller. The second panel
holds the saved for about 200 acquired value. The third panel views a graphical
representation for the stored data as analytic information.
Fig 6 Proposed mobile application
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CHAPTER 7
SYSTEM STRUCTURE ON MANUFACTURING
Fig 7 System Structure
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7.1 CONCLUSION
From the process the smart factory integrated with IIoT could increase productivity,
reduce human error down to eighty percent. Increase the profit up to ninety percent. By
reducing the production cost to fifty percent compared to the traditional method of
manufacturing like using the general way of welding, using man power for transportation,
inspection and packaging which lead to a huge problem could be drastically pit down using
computerized monitoring for inspection and AGV for transportation and AS/RS method easy
storage and retrieval method as it holds a pack of in line database of stocks which reduces
time and involving six sigma quality checking and 5s management system for keeping the
working environment clean. So a smart factory which lay the road to new era of
manufacturing involving virtual enhancement.
7.2 REFERENCES
[1] Aronson, R. B., “Operation Plug-and-Play is On the Way,” Manufacturing
Engineering,
March 1997, pp. 108–112.
[2] Groover, M. P., Fundamentals of Modern Manufacturing: Materials, Processes,
and Systems,
3rd ed., John Wiley & Sons, Inc., Hoboken, NJ, 2007.
[3] Groover, M. P., and O. Mejabi, “Trends in Manufacturing System Design,”
Proceedings, IIE Fall Conference, Nashville, TN, November 1987.
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