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Journal Articles INSIGHT - International Council on Systems Engineering (INCOSE) Year : 2019

A monitoring strategy for industry 4.0: Master italy s.r.l case study


Manufacturing enterprises are presently facing with an array of industry 4.0 (I4.0) challenges. "Digital requirements" need to be really assessed by an accurate analysis and deep understanding of the operational and technological criticalities in the manufacturing operations. It is required to structure a monitoring strategy for industry 4.0 that contains: 1. The definition of the measuring parameters. 2. The application of the sensor. 3. The execution of the measurement. The goal in fact is to present and to analyse the monitoring strategy adopted in a design for the digital transformation of a real Italian SME company: Master Italy s.r.l. Master Italy s.r.l. is a SME Italian company producing small accessories for civil window frames, is here considered to implement a monitoring strategy. The monitoring strategy is a hybrid approach between the life cycle analysis (LCA) and the exergetic analysis (EA) based on the evaluation of the mass balance (Fig.1.) and the energy balance (Fig.2.). LCA is an analytical tool used to quantify and to interpret the flows to-and-from the environment through the whole life cycle of a product, process or service. LCA appreciates quantities of elements flowing in the processes (say, energy, materials, etc.) but it depends on standard databases. The exergetic analysis is a thermodynamic method [1] that permits to: • Evaluate the quality of energy usage. • Identify and quantify the energy inefficiency of the process. Life cycle analysis (LCA) enables to identify the critical manufacturing process and the critical product of the company in terms of resource consumption and pollutions (green line). The critical process and the critical product in analysis are respectively the die casting aluminium and the steel corner (Fig.1 and Fig.2). The exergetic analysis allows to: 1. Split the manufacturing process in different subsystems. 2. Identify the critical subsystem evaluating the contribute of the exergy loss (E xloss). 3. Define the critical parameters to control. Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mould cavity. The injection cycle of die casting aluminium process is composed by four different phases: 1. Melting: the aluminium enters at the solid state and exits at the molten state. 2. Injection: the molten aluminium is transferred, thought a plunger, into a chamber where it is injected into the mould. 3. Moulding: the molten aluminium solidifies in the mould cavity. 4. Extraction: an ejection mechanism pushes the casting out of the mould cavity. The optimization criterion of the monitoring strategy is to minimize the term E xloss , since the exergy loss is proportional to the generated entropy and this one is responsible for the less-than-theoretical efficiency of the system. The application of the exergetic analysis shows that the moulding phase (Subsystem 3) is the critical subsystem because the exergy loss is highest than other subsystems (Fig.1 and Fig.2). The first goal of the monitoring strategy, for Industry 4.0 implementations, is to select and to define where, what and why to sensorize (red rectangle).
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hal-02423272 , version 1 (23-12-2019)



Concetta Semeraro, Hervé Panetto, Mario Lezoche, Michele Dassisti, Stefano Cafagna. A monitoring strategy for industry 4.0: Master italy s.r.l case study. INSIGHT - International Council on Systems Engineering (INCOSE), 2019, Systems engineering research at French Universities, 22 (4), pp.20-22. ⟨10.1002/inst.12269⟩. ⟨hal-02423272⟩
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