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The Digital Shopfloor: Industrial Automation in the Industry 4.0 Era

The Digital Shopfloor: Industrial Automation in the Industry 4.0 Era
Performance Analysis and Applications

River Publishers Series in Automation, Control and Robotics

The Digital Shopfloor: Industrial Automation in the Industry 4.0 Era
Performance Analysis and Applications

Editors:
John Soldatos, Athens Information Technology, Greece
Oscar Lazaro, Innovalia Association, Spain
Franco Cavadini, Synesis-Consortium, Italy

ISBN: 9788770220415

Available: April 2019

doi: https://doi.org/10.13052/rp-9788770220408


In today's competitive global environment, manufacturers are offered with unprecedented opportunities to build hyper-efficient and highly flexible plants, towards meeting variable market demand, while at the same time supporting new production models such as make-to-order (MTO), configure-to-order (CTO) and engineer-to-order (ETO). During the last couple of years, the digital transformation of industrial processes is propelled by the emergence and rise of the fourth industrial revolution (Industry 4.0). The latter is based on the extensive deployment of Cyber-Physical Production Systems (CPPS) and Industrial Internet of Things (IIoT) technologies in the manufacturing shopfloor, as well as on the seamless and timely exchange of digital information across supply chain participants. The benefits of Industry 4.0 have been already proven in the scope of pilot and production deployments in a number of different use cases including flexibility in automation, predictive maintenance, zero defect manufacturing and more. Despite early implementations and proof-of-concepts, CPPS/IIoT deployments are still in their infancy for a number of reasons, including:
  • Manufacturers' poor awareness about digital manufacturing solutions and their business value potential, as well as the lack of relevant internal CPPS/IIoT knowledge.
  • The high costs that are associated with the deployment, maintenance and operation of CPPS systems in the manufacturing shopfloors, which are particularly challenging in the case of SME (Small Medium Enterprises) manufacturers that lack the equity capital needed to invest in Industry 4.0.
  • The time needed to implement CPPS/IIoT and the lack of a smooth and proven migration path from existing OT solutions.
  • The uncertainty over the business benefits and impacts of IIoT and CPPS technologies, including the lack of proven methods for the techno-economic evaluation of Industry 4.0 systems.
  • Manufacturers' increased reliance on external integrators, consultants and vendors.
  • The absence of a well-developed value chain needed to sustain the acceptance of these new technologies for digital automation.
Automation, Industrial Internet of Things, Industry 4.0, Manufacturing, Simulation, Digital Twins, Automation Platforms, Training, Migration

Chapter 2: Open Automation Framework for Cognitive Manufacturing
by Oscar Lazaro, Martijn Rooker, Begoña Laibarra, Anton Ružić, Bojan Nemec and Aitor Gonzalez


660

Chapter 4: IEC-61499 Distributed Automation for the Next Generation of Manufacturing Systems
by Franco A. Cavadini, Giuseppe Montalbano, Gernot Kollegger, Horst Mayer and Valeriy Vytakin


1341

Chapter 5: Communication and Data Management in Industry 4.0
by Maria del Carmen Lucas-Estañ, Theofanis P. Raptis, Miguel Sepulcre, Andrea Passarella, Javier Gozalvez and Marco Conti


781

Chapter 6: A Framework for Flexible and Programmable Data Analytics in Industrial Environments
by Nikos Kefalakis, Aikaterini Roukounaki, John Soldatos and Mauro Isaja


639

Chapter 7: Model Predictive Control in Discrete Manufacturing Shopfloors
by Alessandro Brusaferri, Giacomo Pallucca, Franco A. Cavadini, Giuseppe Montalbano and Dario Piga


866

618

Chapter 9: Digital Models for Industrial Automation Platforms
by Nikos Kefalakis, Aikaterini Roukounaki and John Soldatos


749

Chapter 10: Open Semantic Meta-model as a Cornerstone for the Design and Simulation of CPS-based Factories
by JanWehrstedt, Diego Rovere, Paolo Pedrazzoli, Giovanni dal Maso, Torben Meyer, Veronika Brandstetter, Michele Ciavotta, Marco Macchi and Elisa Negri


605

Chapter 12: Building an Automation Software Ecosystem on the Top of IEC 61499
by Andrea Barni, Elias Montini, Giuseppe Landolfi, Marzio Sorlini and Silvia Menato


924

Chapter 13: Migration Strategies towards the Digital Manufacturing Automation
by Ambra Calà, Filippo Boschi, Paola Maria Fantini, Arndt Arndt Lüder, Marco Taisch and Jürgen Elger


665

Chapter 14: Tools and Techniques for Digital Automation Solutions Certification
by Batzi Uribarri, Lara González, Begoña Laibarra and Oscar Lazaro


637

Chapter 15: Ecosystems for Digital Automation Solutions an Overview and the Edge4Industry Approach
by John Soldatos, John Kaldis, Tiago Teixeira, Volkan Gezer and Pedro Malo


680

Chapter 16: Epilogue


649