Intelligent factory layout design framework through collaboration between optimization, simulation, and digital twin

Abstract

In the era of the fourth industrial revolution, various internet and communications technologies (ICTs) are being applied to manufacturing systems. Based on these technologies, many companies utilize smart manufacturing systems to optimize the design and operation of their lines and to diagnose failures. To build and/or improve production lines, various computer-aided engineering (CAE) tools such as optimization solvers and simulation tools for validation are required. In addition, experts depend on their experience or utilize numerous trial and error processes, implying that a large time investment is required obtain the best layout design, without any guarantee that the result is in fact the best. Therefore, the paper proposes an integrated intelligent layout design framework that automatically derives an optimal layout according the requirements of the layout. The proposed framework uses mixed integer linear programming, simulation-based optimization, and digital twin to perform processes such as assembly line balancing, cell/buffer optimization, and layout planning sequentially and repeatedly to derive an optimal layout. By applying this, it is possible to automatically derive the optimal layout design considering limited resources and physical constraints. In addition, it can contribute to improving productivity and work efficiency at manufacturing sites.