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Implications of Cyber-Physical Production Systems

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on Integrated
Process Planning and Scheduling

PRESENTED TO: PRESENTED BY:

PROF. DR. ADNAN TARIQ MUHAMMAD ANEES UR
REHMAN
UW-22-ME-MS-005
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Abstract

Cyber-physical Production Systems (CPPS) have become popular in the context of Industry 4.0. CPPS
are related to interlink the entities of the production system (e.g. machines) as well as to decentralized
production control. Decentralized production control means that the work pieces schedule themselves
and determine their own production process in the production system. Thus different production
processes can even process two identical parts.

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Objective

 The objective of this paper is to analyze the impact of Industry 4.0 and cyber-physical production systems
on integrated process planning and scheduling. To this end, the fundamentals of process planning,
scheduling, and their integration are briefly described. Subsequently, the terms Industry 4.0 and CPPS are
analyzed with a particular focus on their core elements. Based on that, it is investigated how these core
elements affect process planning. These results are used to extend an approach on integrated process
planning and scheduling for CPPS.

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Introduction

 The progress of digitization in production systems is one of the most relevant topics in production
research. The transition to cyber-physical production systems (CPPS) currently takes place under the
development of Industry 4.0.In generalized terms, Industry 4.0 can be described as the interconnection
of the production system by cyber-physical systems .

 The decentralized production control also affects process planning, which is conducted before
scheduling to determine the technological way to manufacture a work piece. Although the scenario of
decentralized production control is common for CPPS, its implications for the prior planning steps have
not been fully considered.

 Due to the interaction of process planning and scheduling, an integrated view is necessary.
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Fundamentals of Process Planning and Scheduling

Process planning and scheduling link two crucial functions in a company:

1. Design
2. Manufacturing

 The design is important as it defines the products, while manufacturing determines how fast the
product can be produced and delivered.
 Moreover, it is the place where a significant part of the costs is induced. That is why these two
functions have to be considered thoroughly.

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Process Planning

 Process planning deals with preparing how to produce parts, i.e. develop the process plan.The process
plan contains information about the used raw material, the sequence to produce a part and the working
station, the machine and the respective standard time.

 To determine a process plan, several steps are necessary. Based on the part’s
drawing, the manufacturing processes are derived to operate the work piece.

 Afterwards, machines and the respective tools and fixtures are chosen based on the initial and the
designated shape, and finally the process parameters are determined. With this, all technological tasks and
parameters are defined.

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Process Planning

 The subsequent task is scheduling. The job of scheduling is to assign a task or job to a certain machine.

Process planning describes the technical requirements to produce a part while scheduling plans the timing of

their production.

 While process planning does not consider any information about the capacity of the machines at shop floor

level, scheduling assigns the jobs considering the availability of machines.

 Thereby, several objectives and constraints must be fulfilled, e.g. minimizing throughput time. By assigning

jobs to certain machines, scheduling follows the operation sequence determined during process planning.

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Industry 4.0 and Cyber-Physical Production 10
System

 One core element of Industry 4.0 are cyber-physical systems which can be described as embedded
systems using sensors to capture data and act on physical processes by actuators over digital
networks.

 If cyber-physical systems are applied in production systems, cyber-physical production systems

arise. They consist of autonomous elements and subsystems which are connected with each other
and throughout the entire production system and are described by its three main characteristics:
intelligence, connectedness, and responsiveness towards changes.

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System

 The term “Industry 4.0” has already been present for several years, yet there is still no clear and
common understanding of its actual content. Moreover, different classifications, enabling
technologies and related features and properties are available. Based on this literature review,
the most relevant core elements are summarized as follows:
1. Connectedness
2. Smart Machines and Products
3. Decentralization
4. Big Data
5. Cyber security

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Connectedness

 Industry 4.0 refers to the digital connection of the production system including smart
products and machines. The integration enables building of co-operations, including
entities, smart devices, and people to reach a specific target. This enables the exchange
of information which can either take place within a single company or interlink
different companies leading to networks.

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Smart Machines and Products

 One important component to realize a decentralized cyber-physical production system is the ability
of the machines to communicate with each other, with other devices, and with human beings .For
this, smart machines need to have certain features. First, they must be equipped with sensors and
actuators. With this, they can take data from the environment and interact with it, e.g. they can
continuously check if the process parameters are correct and if not, they can immediately correct
them.

Due to the decentralized production control, machines and products need to communicate to determine
which process step is operated at which machine. To do so, they must know which process step can be
conducted next to reach the designated product.

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Decentralization

 Decentralization refers to the control of the scheduling in how work pieces find their operations and
process sequences themselves at shop floor level. It means that autonomous and cooperative work
pieces determine their way of production, i.e. operations and machines, themselves and negotiate with
the machines for the capacity for their operations. It is possible because decision making is done by each
entity itself on shop floor level and not by a superior control element.

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Big Data

 Besides connectedness through the internet, information processing and big data are other core
elements in this new concept of a connected environment. The basis of Big Data is information. Due
to the ability of smart machines and smart products to collect lots of data. The huge amount of data
enables data analytics to gain further and more specific information about the machine, e.g. the
performance or even its future behavior . Therefore, data information can be processed, which before
were only stored. They can be used to further optimize the production.

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Cyber security

 The connection of the production system with the internet and the increased exchange of information
also imply security issues and lead to disappearing borders between internet and communication
technology of the production system and the other IT systems. Additionally, this condition is prone to
data being accessed by unauthorized people, leading to the loss of expertise. To diminish this risk,
cyber-security must be considered carefully in the context of Industry 4.0 and CPPS .

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Impact of Industry 4.0 on Integrated Process
Planning and Scheduling

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Implications for an Integrated Process Planning
and Scheduling Methodology

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Summary

 Currently the interconnection of the production systems takes place which is called Industry 4.0. One of its
main characteristics is a decentralized production control.
 Decentralized production control also affects process planning since the process plan is a prerequisite for
scheduling.
 To investigate the effects of Industry 4.0 on process planning and scheduling, an analysis was conducted.
Hereto, the core elements of interconnectedness, decentralization, smart machines and products, big data
and cyber-security were identified and afterwards their impact on integrated process planning and
scheduling analyzed.
 The analysis could further distinguish technically driven impacts like connectedness of machines or smart
machines which are prerequisites.
 The major impact, especially from a methodical point of view is based on those core elements which enable
an improvement of the production..
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Summary

 Decentralization requires the existence of process plans. Moreover, the availability of a huge amount of data
enables the possibility to improve the information flow in process planning, e.g. analyzing the performance
of alternative process plans.
 Based on these impacts on process planning, a methodology for integrated process planning and scheduling
for cyber physical production systems was extended. The methodology consists of alternative process plans
and an ad-hoc adaption in case to misleading results of the process plans

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