Smart Factory Project

Faculty of Engineering, University of Porto Smart Factories
Master in Mechanical Engineering
Final Project
SUPERVISOR: ANTÓNIO HENRIQUE MENDES DE ALMEIDA
GROUP MPT_05
19/01/2022 ANA TEIXEIRA - UP202003041 | HELENA FERREIRA - UP201706264 | NUNO FERREIRA - UP202003095 | RUI GOMES - UP201705528 1
Table of Contents
• Product Development
❑ Chosen Product
❑ Materials
❑ Production Process
❑ Market analysis
• Factory Projection
❑ Layouts
❑ FlexSim
• IoT Network
❑ OEE
❑ Node-RED
❑ Dashboards
Product Development
Chosen Product
Materials
Production Process
Market analysis
19/01/2022
• Cheap
• Ductile
• Durable
• Lightweight
Aluminium
Value Property
13
Atomic Number
Atomic Weight
26.98
(g/mol)
Crystal Structure
FCC
Melting Point
660.2
(°C)
Boiling Point
2480
(°C)
Product Development
Mean Specific
Heat (0-100°C)
0.219
(cal/g.°C)
Thermal
Conductivity
0.57
(0-100°C)
(cal/cms. °C)
Co-Efficient of
Linear Expansion
23.5
(0-100°C)
ANA TEIXEIRA - UP202003041 | HELENA FERREIRA - UP201706264 | NUNO FERREIRA - UP202003095 | RUI GOMES - UP201705528
Electrical
Resistivity at
2.69
20°C (Ω.cm)
Density (g/cm3)
2.6898
Modulus of
Elasticity
68.3
(GPa)
Production Process
Market analysis
Chosen Product
Materials
Poisson’s Ratio
4
0.34
Product Development
Chosen Product
Materials
Production Process
Deep Drawing Market analysis
• Fast
• Productive
• Optimal Solution
• Effective
Product Development
• The global cookware market size was valued at USD 11.84 billion in Chosen Product
2020 and is expected to expand at a compound annual growth rate Materials
(CAGR) of 6.9% from 2021 to 2028. Production Process
Market analysis
• The COVID-19 pandemic has also brought a seismic shift in people’s
attitudes toward wellness and the kitchen environment.
• Aluminium cookware is expected to register the fastest CAGR of
7.4% from 2021 to 2028.
• Some key players in the cake pans market are the following: Bundy
Baking Solutions, Nordic Ware, Trudeau Corporation.
Factory Projection
Layouts
Initial Layout FlexSim
Finishing Layout
Factory Projection
Layouts
• Since the production line creates a significant amount of
FlexSim
cake pans to sell, to have the production capacity to
comply with reasonable demands, we decided to add Decision Point: To consider that
2% of the receiving product has
more cake pan geometries in the factory. defects.
Capacity 20
Forklifts
Velocity [m/s] 1.1
Alignment time [s] 4
Press Compress time [s] 4
Extraction time [s] 4
Conveyor Velocity [m/s] 0.33
Coating and Cook. Time [s] 1816
IoT Network
Key Performance Indicators OEE
Node-RED
• The key performance indicators are the OEE (Overall Performance Dashboards
Efficiency), Availability, Performance and Quality.
IoT Network
How do we obtain and display the KPI values? OEE
Node-RED
Dashboards
Node-RED
dashboard
Display and analyse
KPI values
IoT Network
OEE
Node-RED Flow – Machine Logs and OEE calculation Node-RED
Dashboards
IoT Network
OEE
Node-RED Flow – Temperature data and machine Node-RED
status Dashboards
IoT Network
OEE
Node-RED Dashboard Node-RED
Although Node-RED has the capabilities of having a real time Dashboards
dashboard, Power BI is a
more intuitive software
that has the capabilities
make a richer dashboard
with real time data
insertion. The different
graphics are much easier
to do on Power BI than on
Node-RED.
IoT Network
OEE
Node-RED Flow – SQLite database Node-RED
Dashboards
IoT Network
OEE
Power BI Dashboard Node-RED
Dashboards
• More intuitive dashboard.
• Can load databases or other
types of files easily like
Microsoft Access, SQL server,
Azure databases, etc.
• The SQLite database had to be
linked to Power BI by an OBDC
data connection.
IoT Network
Analysis of the Dashboard Data OEE
Node-RED
Dashboards
IoT Network
OEE
Node-RED
Steps to reduce SETUP Time Dashboards
• Observation
• Eliminate Waste
• Identify Internal and External Steps
• After that, reducing the internal steps to a minimum
• Monitor all the setups
IoT Network
OEE
Actions that could reduce Downtime and Node-RED
unplanned stops Dashboards
• Risk Audits
• Sensors
• Data collection automation
• Train Employees
• Preventive maintenance and machine documentation
• Backup
Conclusions
• Aluminium is a cheap and ductile material.
• Deep Drawing is a fast and productive process,
being an optimal solution.
• The pandemic led to a bigger interesse in cooking.
• With Flexsim we could optimize the layout design
and simulate the process. With this, we conclude
that the productivity was too high, leading to the
decision of increase the diversity of products.
• Node-RED was a very useful tool to process the
information and create a database and a IoT
platform.
Thank you
for your
attention!

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Faculty of Engineering, University of Porto Smart Factories

Master in Mechanical Engineering

Alignment time [s] 4

Press Compress time [s] 4

Extraction time [s] 4

Conveyor Velocity [m/s] 0.33

Coating and Cook. Time [s] 1816

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