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47th SME North American Manufacturing Research Conference, NAMRC 47, Pennsylvania, USA
47th
47th SME
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American Manufacturing
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47th SME North American Manufacturing Research Conference, NAMRC 47, Pennsylvania, USA
Innovative Digital Manufacturing
Innovative
Pennsylvania,Curriculum
Digital Manufacturing
2019
Curriculum for for Industry 4.0
Industry 4.0
Innovative
Innovative Digital
Digital Manufacturing
Manufacturing Curriculum
Curriculum for
for Industry
Industry 4.0
4.0
Manufacturing Rapeepan Promyoo a,b,,International
Shashank Alai a,b,, Hazim El-Mounayri
a,b a,b a,b,*
Engineering
Rapeepan Society Conference 2017, MESIC 2017, 28-30 June
Rapeepan Promyoo a,b, Shashank Alai , Hazim El-Mounayria,b,*
Promyoo 2017, Shashank
Vigo Alaia,b
(Pontevedra), Hazim
Spain El-Mounayria,b,*
RapeepanInitiative
Promyoo a,b , Shashank
for Product
a AlaiIndianapolis,
Lifecycle Innovation,
a,b , Hazim El-Mounayri
IN, 46202, USA
a,b,*
aInitiative for Product Lifecycle Innovation, Indianapolis, IN, 46202, USA
bDepartment of Mechanical and Energy Engineering, Indiana University
bDepartment of Mechanical and
aInitiative for Product Lifecycle Innovation,Purdue University
Indianapolis, IN, Indianapolis,
46202, USA Indianapolis, IN 46202, USA
a Energy Engineering, Indiana University
Innovation,Purdue University
IN, Indianapolis, Indianapolis, IN 46202, USA
bDepartment of Mechanical andInitiative for Product Lifecycle Indianapolis, 46202, USA
Costing models for capacity optimization in Industry 4.0: Trade-off
Energy Engineering, Indiana University Purdue University Indianapolis, Indianapolis, IN 46202, USA
* Corresponding author. Tel.:
bDepartment +1-317-278-3320;
of Mechanical fax: +1-317-274-9744.
and Energy E-mail
Engineering, Indiana address:
University helmouna@iupui.edu
Purdue University Indianapolis, Indianapolis, IN 46202, USA
* Corresponding author. Tel.: +1-317-278-3320; fax: +1-317-274-9744. E-mail address: helmouna@iupui.edu
* Corresponding author. Tel.: +1-317-278-3320; fax: +1-317-274-9744. E-mail address: helmouna@iupui.edu

between used capacity and operational efficiency

* Corresponding author. Tel.: +1-317-278-3320; fax: +1-317-274-9744. E-mail address: helmouna@iupui.edu

Abstract
Abstract
Abstract
Abstract A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb
Manufacturing companies across all major industries are facing serious challenges trying to competitively design and manage modern products,
Manufacturing companies across all major industries are facing serious challenges trying to competitively design and manage modern products,
Manufacturing
which are becoming companies across complex
increasingly all majormulti-domain
industries are systems
facing serious challenges
or “systems trying to
of systems”. competitively
Model-based designdriven
systems and manage
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Manufacturing increasingly
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a
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as a solution basedModel-based thedesign
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requirements and tracing
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and tracing integrates system
back performance behavioral modeling
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traceability
process.
support the Theverification/validation
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all phasesdesign
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of
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integrates systems
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to
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systems behavior digital
as twin and progress
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global all
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phasesoptimization
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Abstract
trade-offs
support
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decisions
decisions
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verification/validation
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digital twin
curriculum
and progress
products
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globalthedecision
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optimization
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thatinisanas wellon
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asthe
the effective way.
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of
We have developed
trade-offs decisions an innovative
by maintaining digital manufacturing
the cross-product curriculum
digital twin (designed around thedecision
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We have(Systems
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Under
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interconnected,
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integration ofAt the core of
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and
and
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andofmore
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andofsystems
efficient.
this curriculum isIn
engineering,
engineering,
this
thatofcontext,
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by theory
by theory
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implementation
a state-of-the-art
a state-of-the-art
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digital
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innovation through
platform Product
foranproduct
applied (or lifecycle
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system) management
of engineering
development At of
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consisting theintegrated
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engineering,
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tools is driven fromby complete
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The
goes
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innovation
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platform
throughtraditional
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system)
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development
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engineering consisting
fundamentals of contributing
integrated
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software for organization’s
(digital)
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that spanning
is driven profitability
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by complete
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state-of-the-art The
digital
curriculum platform
innovation consists for
of three key(or
product components, namely, modelling
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of integrated continuum, traceability,
(digital) and digital
tools spanning thread. The
the complete curriculum
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innovation
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offor
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of the Manufacturing Engineering Society International Conference
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Keywords: Digital responsibilityDigital
of thethread;
Scientific Committee
Industry 4.0; SDPDof NAMRI/SME.
2017.
Keywords: Digital manufacturing; Digital thread; Industry 4.0; SDPD
Keywords: Digital manufacturing; Digital thread; Industry 4.0; SDPD
Keywords: Digital manufacturing; Digital thread; Industry 4.0; SDPD
Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency
1. Introduction modern products has been greatly influenced by a dramatic
1.
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1044 Rapeepan Promyoo et al. / Procedia Manufacturing 34 (2019) 1043–1050
2 Author name / Procedia Manufacturing 00 (2019) 000–000
Fig. 1. Digitalization of SE process
change of perspective in developing products that are actually
cyber-physical systems and demand a fundamental shift in the
way we design and manufacture products, augmenting
traditional engineering approaches with significant
technologies that will enable Industry 4.0.
Digital manufacturing in its broader sense (i.e. digital
product development or lifecycle) has been proposed to address
the challenges faced when developing modern products. This
is at the heart of Industry 4.0 which is enabled by extensive
digitalization as well as the fusion of technologies to build
cyber physical systems and the smart factory/product. In a way,
it marries advanced manufacturing techniques with the Internet
of Things (IoT) to create a digital manufacturing enterprise that
is not only interconnected, but also communicates, analyzes,
and uses information to drive further intelligent actions back in
the physical world. One of the key enablers of digital
manufacturing is the concept of product lifecycle management
(PLM), a business strategy that supports the development of
products including the information needed to support them
throughout their lifecycle [1]. PLM can be implemented using
a software tool as a backbone for data management by
including supporting tools from several disciplines that are
integrated with it throughout the system’s lifecycle. These tools
span various domains and are usually referred to as end-to-end
lifecycle data management tools.
Although PLM deals with the nitty-gritties of lifecycle
management, it can be considered method-agnostic and hence
systems engineering discipline is used to define the design and
development activities. Systems Engineering (SE) process has
been proposed and actually adopted by a number of
organizations and companies to handle the complexity of
developing complex modern products or systems [2 - 5]. It was
very quickly realized that a switch from document-based
implementation of SE to Model-based Systems Engineering
(MBSE) is necessary to support the digital transformation and
industry 4.0, including enabling the digital enterprise.
According to International Council of Systems Engineering
(INCOSE), MBSE can be defined as the formalized application
of modeling to support system requirements, design, analysis,
verification and validation activities beginning in the
conceptual design phase and continuing throughout
development and later life cycle phases [7]. There are several
tools and techniques that support SE/MBSE but are not part of
the whole PLM process even though the concept of lifecycle
collaboration is shared among both and the convergence of
these two technologies is an industry trending topic.
The ability to design modern products (which are typically
multi-domain systems) using an integrated digital platform
(PLM + MBSE) that spans the lifecycle is at the heart of the
digitalization revolution which drives the digital enterprise and
Industry 4.0. A typical design course in a Mechanical
Engineering program applies the basic design process to
develop a product with a focus on the mechanical aspect;
typically, without using, an integrated digital platform for the
design, that spans and supports the lifecycle of the product.
This work addresses for the current limitations, and provides
an education that is more aligned with industry 4.0: 1) The need
for a digital manufacturing framework and simulator for the
digital enterprise that can be used to demonstrate best practice
in developing modern products; 2) The need to educate the next
generation of engineers for industry 4.0.
The above achieved by developing a unique curriculum that
demonstrates the digitalization of the Systems Engineering
process through the integration of modeling and simulation
continuum (in the form of MBSE) with Product lifecycle
management (PLM), which is referred to as Model-based
System Driven Product Development (SDPD), Figure 1. SDPD
is a form of Model-based Engineering (MBE) that is extended
to include digital manufacturing. It can also be defined as the
integration of the digital twin with the digital thread [8].1. This
course expands the scope from product design to Systems
lifecycle. In addition, it applies the SE process (vs. Design
process), and employs an integrated digital platform that spans
the lifecycle of multi-domain products (or systems),
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Author name / Procedia Manufacturing 00 (2019) 000–000
characterized by an integrated modeling and simulation
continuum, traceability to the stakeholders needs and
requirements, and PLM capabilities for enabling the digital
thread.
The proposed curriculum is implemented in the form of a
SE Capstone course in a three-level engineering education (as
shown in Figure 2) that prepare students for Industry 4.0,
namely Engineering Education 4.0. In the first level, students
learn the fundamentals including the enabling technologies of
Industry 4.0 (AI, Predictive analytics, IoT, System modeling
and simulation, Cybersecurity, VR, etc.). The second level
consists of the specialized courses in the area of Systems
Engineering, which is the process that has been adopted by
major organizations and companies. The third level is the
synthesis of all the knowledge in levels 1 and 2, and its
implementation in real-life product (typically a multi-domain
system), as part of SE capstone course. The implementation at
level three uses an integrated digital platform and uses the SE
methodology covered as part of specialized courses taken as
part of level 2. In the innovative course digital manufacturing,
the SDPD framework is introduced as an open and modular
solution to cross-domain collaborative product development,
manufacturing and in-service support which fully integrates
modeling and simulation to predict product and process
performance across a wide range of disciplines and domains,
including mechanical, electrical, software and controls.
Fig. 2. SDPD curriculum as part of engineering education
The SE Capstone course is a special version of the typical
Capstone (design) course. There are mainly three differences in
term of process (methodology), product (application) and
digitalization between this SE capstone (or SDPD) course and
other typical capstone courses, as described in Table 1.
Table 1. Differences between SE Capstone and typical Capstone courses
SE Capstone course Typical Capstone
(SDPD) courses
Process SE process Design process
(methodology)
Product Multi-domain system Mechanical product
(application)
Digitalization Integrated digital platform Limited digital
(to enable both digital capabilities
twin and digital thread)
that spans the lifecycle
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In this course, the underlying fundamentals and theories of
system modelling is covered. On the other hand, the SE
methodology is presented as the backbone process for SDPD.
Also, other topics pertaining to the design, manufacturing, and
optimization of a multi-domain systems are covered/reviewed
to the extent that is needed to realize the effective and
intelligent use of the tools and their implementation in the case
studies and final project. The projects are defined and
implemented by teams. The application is required to consist
of a multi-domain system. Teams are expected to conduct the
complete product development process using SDPD
framework and methodology.
2. Framework
The SDPD course consists of three key components: 1)
Modeling and simulation continuum; 2) Traceability; 3) Digital
thread. Students will learn how to use different engineering
models of different fidelity levels at different point in the
system development process in order to make the development
process more efficient and practical. Full integration or co-
simulation of different models are also implemented. The
digital thread is implemented using PLM as the backbone to
support the integration of the different models used throughout
the development cycle. For example, the engineering bill of
materials (EBOM) that is automatically extracted from the
CAD model is used to generate the manufacturing bill of
materials (MBOM) and bill of process. Figure 3 shows a
process flow used in the SDPD course. The PLM platform is
also used to create a workflow and manage all system, product,
and process data. The process flow starts with the creation of
high level “0-D” system model using MBSE. Then, a 1-D
system simulation is developed. 3-D computer-aided-design
(CAD) models of the product are created and simulated using
several computer-aided-engineering (CAE) techniques to
optimize the design of different components. The
manufacturing process is then created and simulated using
computer-aided-manufacturing (CAM) tools. This framework
integrates a “digital twin” (0D to 3D integrated modeling
continuum) with the digital thread enabled by PLM backbone.
Fig. 3. SDPD process flow used for the case study implementation
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2.1. Model-based Systems Engineering
The first step in SDPD process flow is to create a system
model. According to the INCOSE definition, a system is an
integrated set of elements, subsystems, or assemblies that
accomplish a defined objective. The elements of the system
interact with each other and the environment. These elements
include products (hardware, software, and firmware),
processes, people, information, techniques, facilities, services,
and other support elements. Systems engineering is an
interdisciplinary approach and means to enable the realization
of successful systems [7]. System engineering focuses on
designing and managing complex systems over their life cycles
including activities such as specification, design and analysis,
integration, verification and validation of the product to be
developed.
Systems Engineering has become prevalent in various
industries like automotive, defense, aerospace, etc. Until
recently, systems engineering was carried as an engineering
practice, with the help of documents to manage and pass
information across system lifecycle phases. Although the
document-based approach in systems engineering could be
successfully realized with proven benefits, it had some
fundamental limitations. Moreover, increasingly complex
systems demand a more formalized approach to carry out SE
activities. Model-based approach is becoming the industry
standard in systems engineering. Taking its roots from software
engineering, the formalization of SE is called Model-Based
Systems Engineering (MBSE).
The output of systems engineering activities is a coherent
model of the system where emphasis is placed on evolving and
refining the model using model-based methods and tools. The
system model is an integrative representation of the system
structure and behavior, sometimes referred to as system
architecture. In order to develop a complete system model, it is
necessary to have a modeling environment that supports
modeling using graphical/textual language, a well-defined
modeling methodology and an intuitive tool interface. The
system model constitutes a variety of information that is
reflective of the stakeholder requirements in the form of
various architectural viewpoints using a number of modeling
artifacts.
The main purpose of MBSE is to identify the system’s
functional and non-functional requirements based on the needs
of the various stakeholders such that a model can provide an
architectural representation of the system that is compliant of
these requirements. For systems engineering model to be
complete, it must represent the system’s functional and logical
architecture, along with a physical architecture, all at various
levels of abstraction. The system functional requirements help
identify the various system-level functions which are further
decomposed and allocated to various logical subsystems and
components of the system. A physical architecture is the
technical solution of the logical architecture. These
architectures together constitute the structural and behavioral
representation of the system which is further subject to
evaluation. At the moment, there are various commercial and
open source system modeling solutions available for systems
engineers to effectively design their respective systems. Their
choice of the solution is highly influenced by factors such as
the application domain, industry, fidelity of the model required
for SE activities, etc.
SysML (Systems Modeling Language) is a general-purpose
modeling language to support the systems engineering
activities by allowing the use of descriptive models [8]. SysML
is based on the object-oriented concepts in software
engineering, hence supporting high reusability of the artifacts
while modeling. A system can be modeled using SysML with
the help of a modeling tool that supports SysML’s object-
oriented modeling. In this unique curriculum, we use a system
model developed in SysML as a reference to develop a multi-
physics simulation architecture.
2.2. 1D System Simulation
Once we have a system architecture model in place that
defines the structure and behavior of the system, it should be
validated against its functional requirements. In other words,
the system’s logical architecture shall be validated to assess the
system performance based on inputs such as the system
component parameters. Model-based system simulation is a
means to analyze the behavior of the system with help of
continuous/discrete dynamic simulation models.
The diagrams in SysML precisely capture the system
requirements and allow to describe the structure and behavior
of the system. However, analyzing the behavior of the systems
to assess requirements is not provided by SysML. Various
SysML tools provide simulation capabilities which are still
limited. Hence, predictive analysis of system models must be
done by simulation using domain-specific simulation tools. In
an MBSE workflow, a simulation architecture can be defined
based on the logical architecture developed in the modeling
tool. A model-based simulation architecture consists of the
various system components and subsystems linked to each
other through ports and interfaces. These components are
designed using mathematical equations of the system
components. The links or interfaces between these components
facilitate the exchange of information, energy, objects through
the respective ports of the components. A mathematical solver
is used to solve these equations based upon the attributes
defined for system components as inputs and the results can be
interpreted in the form of graphs and values for different system
variables. Some of the most widely used system simulation
software include Simcenter Amesim, GT Power, Mathworks
Simulink and DS Dymola. For our simulation purposes, we
chose Simcenter Amesim because of its easy-to-use concepts
and vast number pre-built component libraries.
2.3. CAD Simulation
After stakeholder needs and requirements are known,
detailed engineering of 2D drawings or 3D models can be
created. Computer-aided design (CAD) is typically used to aid
the designer in the creation and optimization of the models.
Recently, several CAD software can be integrated with MBSE
tools and provide traceability analysis of the CAD geometry
and stakeholder requirements. This integration allows
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Author name / Procedia Manufacturing 00 (2019) 000–000
designers to increase their productivity and also improve the
quality of the design.
2.4. CAE Simulation
The next step in SDPD process is to perform engineering
analysis of the 3D CAD geometry (product simulation and
optimization. Computer-aided engineering (CAE) tools are
used in different types of engineering analysis including finite
element analysis, computational fluid dynamics, and multibody
dynamics. Commonly, engineers need to use several software
tools to simulate a component or product assembly. As
products and materials become increasingly complex, product
development (design cycles) time will dramatically increase.
As such, CAE software tools with integrated solvers providing
powerful solutions for different type of analysis (i.e. linear and
nonlinear structural analysis, dynamic, acoustics, and thermal
analysis) are needed to help make informed decisions. Product
can be analyzed and simulated to predict system performance
during the early design stages.
CAE modeling and simulation software provides an
excellent way for engineers to cost-effectively evaluate how
their products will perform under expected operating
conditions. However, performance of complex products
depends on a large number of design variables. To find the best
design that satisfies certain criteria and multiple constraints,
engineers need to run the simulation multiple times and would
take several weeks to accomplish manually. Design
optimization software takes modeling and simulation to the
next level by allowing engineers to determine appropriate
design variables that yield product designs with exceptional
performance and dramatically reduces design time.
2.5. CAM Simulation
Once the design is optimized, the next step is planning its
manufacturing. This includes designing the manufacturing
process, simulating the process for validation and optimization,
designing the production line, and simulating the assembly and
optimizing the production. The core of the manufacturing
workflow is the CAD model and EBOM (engineering bill of
material). The latter is used to automatically generate the
MBOM (manufacturing bill of material) from which the bill of
process or BOP is generated. On the other hand, CAM is also
used to simulate the manufacturing of individual components.
The most commonly used process is machining, where tool
path is automatically generated once the operation is defined in
terms of its sequences and their parameters. Current digital
tools support all of these functionalities. The extent to which
all these steps are integrated and/or automated varies from
digital platform to another. Some of the most advanced ones
support the digital thread to connect CAD to CAM in a
seamless way. For example, Siemens digital platform provides
tools to enable the digital thread and support the integration for
design (or CAD) and manufacturing (or CAM).
3. Case Study Implementation
This SDPD course was designed to give an exposure to the
overall product lifecycle from capturing requirements to
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estimating the parameters which would help an industry to
assess the productivity and profits from the product. To
demonstrate the use of SDPD process flow, a case study of an
electric skateboard is presented in this paper. Electric
skateboard is a multi-domain system involving mechanical,
mechatronics, and electrical systems.
As a backbone of digital thread for SDPD implementation
of electric skateboard, Teamcenter suite of PLM software was
used for storing different type of files (including Amesim
output, NX 3D model of the skateboard deck and Star-CCM+
analysis file). This will bring many benefits including having
one source of data, defining different levels of authorizations
for people involved in the process based on their roles and
reflecting changes in any of operations on a single database.
Project workflow describing individual tasks and the task
sequence required to complete SDPD course process flow was
created in Teamcenter. Each task defined a set of actions, rules,
and resources used to accomplish that task. Each student was
assigned a role in a team. The software allows students to keep
track of their team progress and any revision of the shared files.
Each team of students required to do a research on electric
skateboard currently available on the market, interviewed
electric skateboard users, and proposed a new improved design.
3.1. System Design
After researching and interviewing stakeholders, students
had to translate stakeholder’s needs into requirements (as
shown in Figure 4) and used MBSE tool to develop system
model. In this example, the system model of an electric
skateboard was developed using Cameo Systems Modeler. The
system architecture precisely captures the system requirements
and allows to describe the structure and behavior of the system.
This static representation of the system model acts as the single
source of truth for the information of the to-be developed
product. Different types of SysML diagrams including block
definition diagram (BDD), internal block diagram (IBD),
parametric diagram, activity diagram, use case diagram, and
state machine diagram were created.
Figure 5 and 6, respectively, show example of block
definition diagram and activity diagram created in Cameo
Systems Modeler for electric skateboard case study. The block
definition diagram describes the architecture of the electric
skateboard system and represents the system hierarchy in terms
of systems and subsystems. Activity diagram describes control,
input, and output flows among actions/operations.
Fig. 4. List of stakeholder requirements
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Fig. 5. Block definition diagram (BDD) of electric skateboard
Fig. 6. Activity diagram describing electric skateboard operation
3.2. 1D System Simulation and Optimization
Electric skateboard is a multi-domain system consisting of
both mechanical and electrical components. System-level
simulation can be done using a dynamic model developed from
a multi-physics system architecture in a 1D simulation tool. In
this case study, Simcenter Amesim is used for the modeling and
analysis of the multi-domain electric skateboard system. The
system (shown in Figure 7) is modeled using a number of
components that are provided in the component libraries. The
modeling is done by the four modes of operation in Amesim.
These are: 1) Sketch mode; 2) Submodel mode; 3) Parameter
mode; 4) Simulation mode. The system components are created
and linked in the “sketch mode”. Distinct mathematical
expressions for the components are assigned in the “submodel
mode”. The features and parameter of the components are
entered in the “parameter mode”. The simulation run is
initiated, and the results are analyzed in the “simulation mode”.
Amesim was used to perform system simulation of the
Electric Skateboard to validate performance requirements.
Based on different diagrams created in Cameo, including block
definition diagram (used for structural representation of the
system), requirements diagram (used for defining the
requirements of the Skateboard, parametric diagram or par
(defining different equations related to the electric skateboard),
etc., the 1D model of the electric skateboard was created and
the simulation was run in batch mode to show different outputs
caused by different user’s weight and varying wheel radius of
the skateboard wheels. Figure 8 shows variation of
displacements of the skateboard for different wheel radius and
user’s weight.
Fig. 7. 1-D Multi-domain system model
Fig. 8. Amesim output showing displacement of the electric skateboard over
time for different wheel radius and user’s weight
3.3. 3D Design
3D geometry model of electric skateboard was created
using NX software. Figure 9 shows 3-D model of skateboard
deck component. The initial geometry of each electric
skateboard component was obtained from stakeholder
requirements and 1-D system model optimization. In addition,
students can perform design requirements validation within NX
software.
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summary after completed 100 runs. Only 38 designs were

feasible, 54 designs were infeasible, and 8 designs were error.

Fig. 9. 3-D model of skateboard deck

3.4. Product Simulation

Fig. 11. Design optimization of skateboard deck
After 3D CAD geometry model of electric skateboard was
created, different types of engineering analysis can be
3.6. Manufacturing Process Design
performed. In this paper, structural analysis of the skateboard
deck using Finite element analysis is presented. The analysis
The manufacturing process design can be done concurrently
was carried out in STAR-CCM+ software. According to the
with the product design to ensure that manufacturing
stakeholder requirement that the skateboard shall be withstand
constraints are reconciled during product design process. In this
the maximum user’s weight of 200 lb, the normal force applied
step, students need to create engineering bill of materials
on the top surface of the skateboard was selected to be 900
(BOM), manufacturing BOM, and manufacturing bill of
newton (N). The boundary condition used in the model was the
process (BOP). Teamcenter Manufacturing Process Planner
8 holes connected to the skateboard truck and wheels at the
(MPP) module was used in the case study of electric
bottom side of the skateboard deck. Figure 10 shows the plot
skateboard. MPP enables user to manage manufacturing data,
of Von-Mises stress of the skateboard deck.
process, resource, and plant information in an integrated
product and production lifecycle environment.

3.7. Manufacturing Process Simulation

After engineering BOM, manufacturing BOM and BOP

were created, students are required to develop manufacturing
plan and simulate manufacturing processes. Tecnomatix
process simulate was used in this step. Figure 12 shows the
assembly of skateboard deck and wheels using a robot.
Tecnomatix software allowed students to design, simulate,
offline program the operations of robot to optimize product
efficiency.

Fig. 10. Von-Mises stress of skateboard deck

3.5. Product Optimization

The next step in SDPD process flow is to perform design

optimization of the product. The optimization process was done
using HEEDS MDO (Multi-disciplinary Design Optimization)
software. HEEDS MDO allows students to automate the search
for better and more robust designs according to multiple
Fig. 12. Assembly process simulation
criteria, while simultaneously satisfying multiple constraints
and using a large number of design variables. For the
In addition to process simulation, students required to create
skateboard case study, the design optimization objective was to
plant design to simulate the overall manufacturing processes
minimize the volume of the skateboard deck with subjected to
and calculate production throughput. Tecnomatix Plant
displacement and von-Mises stress constraints. The design
Simulation software was used in this step. Plant Simulation can
variables considered in this case study were the thickness and
bring different benefits to the manufacturing processes
the length of the skateboard deck. The number of optimization
including: material flow optimization, resource utilization and
run was set 100. Figure 11 shows the screenshot of output
logistics for all levels of plant planning from global production
facilities, through local plants, to specific lines. An assembly
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8 Author name / Procedia Manufacturing 00 (2019) 000–000
line of electric skateboard was simulated in both 2-D and 3-D
simulation as shown in Figures 13 and 14, respectively.
Tecnomatix plant simulation uses discrete event simulation
(DES) techniques which required product arrival time and
processing time for each work station. After running the
Tecnomatix plant simulation, students were able to verify the
feasibility of an assembly process and get an estimate of the
throughput and resource utilization for the electric skateboard
manufacturing process. What-if scenario were also performed
by varying the number of available resources to optimize the
process throughput.
Fig. 13. 2-D simulation of electric skateboard manufacturing process
Fig. 14. 3-D simulation of electric skateboard manufacturing process
4. Conclusion
Model-based systems driven product development (or
SDPD) has been proposed as the framework for developing an
innovative digital manufacturing curriculum that supports the
training of the next generation of engineers for Industry 4.0.
The curriculum provides a foundation for implementing the
digital twin and its integration with the digital thread. Students
learn and practice a new methodology, SDPD, which basically
consists of driving product development digitally using
integrated models and a digital thread across the cycle. The
product here is a multi-domain system. The process is driven
by systems requirements and traceability is established for
verification. This knowledge is core to what companies
nowadays are looking for as its most relevant to the
development modern products, which are becoming
increasingly complex.
The SDPD framework integrates high level system
modeling to capture stakeholder needs and requirements with
system’s simulation. The latter allows for efficient and cost-
effective sizing of the system components from different
domains (electric, mechanical, controls, etc.) and is interfaced
with 3D component design and optimization. This represents
the modeling and simulation continuum. Design is integrated
with manufacturing through a digital thread, including process
design, process simulation and plant simulation. PLM and
Systems model enable the traceability throughout the lifecycle
of development. The proposed digital manufacturing
curriculum was introduced as part of SE capstone and was also
implemented in capstone design. This work has
demonstrated/produced the following:
1. Exemplary MBSE curriculum for Engineering
Education 4.0
2. The development of key, integrated skills for the digital
enterprise
3. The ability to demonstrate the benefits of
digitalization/model-based engineering to industry,
including: Greater innovation in product development,
increased efficiency, faster time-to-market, increased
adaptability/agility/customization, knowledge re-use, and
better ability to comply with standards
4. The ability to synthesis knowledge and skills acquired
over the course of college engineering education and to
apply them effectively to complete a real-life modern
product development within the time line of one semester
The next step consists of extending the curriculum to cover
the digital twins for product, production, and performance.
Also, verification/simulation techniques such as MIL, HIL, and
SIL, will be introduced for a more complete implementation of
the SE V-diagram. Currently, a prototype of the electric
skateboard is being tested and validated against the results from
both the Amesim 1D simulation and Nastran 3D CAE. In
parallel, we are developing the digital twin of the electric
skateboard by embedding different sensors for a more
comprehensive assessment and real time data collection during
actual operation.
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