Industrializzazione di una famiglia di componenti meccanici secondo i principi dell'industria 4.0

Il progetto di tesi tratta l'industrializzazione di una famiglia di componenti meccanici con gli obiettivi di riduzione del lead time e dei costi di produzione ed un miglioramento della qualità costruttiva. Per fare ciò è stato definito un nuovo ciclo di fabbricazione che riunisse tutte le operazioni di asportazione di truciolo in un unico centro di lavoro di fresatura. Sono state definite, progettate e messe in atto tutte le fasi del processo produttivo utilizzando i moderni software CAD-CAM-CNC. Al termine sono stati elaborati i risultati ottenuti svolgendo anche una analisi economica per valutare il risparmio percentuale annuo sul costo di produzione. Infine è stato fatto un confronto fra il vecchio ed il nuovo processo produttivo realizzato secondo i principi dell'Industria 4.0 ed i relativi vantaggi che esso permette di ottenere.

Edge and Big Data technologies for Industry 4.0 to create an integrated pre-sale and after-sale environment

The fourth industrial revolution, also known as Industry 4.0, has rapidly gained traction in businesses across Europe and the world, becoming a central theme in small, medium, and large enterprises alike. This new paradigm shifts the focus from locally-based and barely automated firms to a globally interconnected industrial sector, stimulating economic growth and productivity, and supporting the upskilling and reskilling of employees. However, despite the maturity and scalability of information and cloud technologies, the support systems already present in the machine field are often outdated and lack the necessary security, access control, and advanced communication capabilities. This dissertation proposes architectures and technologies designed to bridge the gap between Operational and Information Technology, in a manner that is non-disruptive, efficient, and scalable. The proposal presents cloud-enabled data-gathering architectures that make use of the newest IT and networking technologies to achieve the desired quality of service and non-functional properties. By harnessing industrial and business data, processes can be optimized even before product sale, while the integrated environment enhances data exchange for post-sale support. The architectures have been tested and have shown encouraging performance results, providing a promising solution for companies looking to embrace Industry 4.0, enhance their operational capabilities, and prepare themselves for the upcoming fifth human-centric revolution.

Progettazione ed Implementazione Front-End di un Sistema Integrato di Customer Assistance in ambito Industry 4.0

Al giorno d'oggi, l'industry 4.0 è un movimento sempre più prominente che induce ad equipaggiare gli impianti industriali con avanzate infrastrutture tecnologiche digitali, le quali operano sinergicamente con l'impianto, al fine di controllare ed aumentare la produttività, monitorare e prevenire i futuri guasti, ed altro ancora. In questo ambito, gli utenti sono parte integrante della struttura produttiva, in cui ricoprono ruoli strategici e flessibili, collaborano fra loro e con le macchine, con l’obiettivo di affrontare e risolvere proattivamente una vasta gamma di problemi complessi. In particolare, la customer assistance nel settore industriale può certamente variare in relazione a molteplici elementi: il tipo di produzione e le caratteristiche del prodotto; l'organizzazione ed infrastruttura aziendale interna; la quantità di risorse disponibili che possono essere impiegate; il grado di importanza ricoperto dalla customer assistance nel settore industriale di riferimento; altri eventuali fattori appartenenti ad un dominio specifico. Per queste ragioni, si è cercato di individuare e categorizzare nel modo più accurato possibile, il lavoro svolto in questo elaborato ed il contesto nel quale è stato sviluppato. In questa tesi, viene descritta un'applicazione web per erogare assistenza al cliente in ambito di industria 4.0, attraverso il paradigma di ticketing o ticket di supporto/assistenza. Questa applicazione è integrata nel sistema Mentor, il quale è attivo già da anni nel settore industriale 4.0. Il progetto Mentor è una suite di applicazioni cloud-based creata dal gruppo Bucci Industries, una multinazionale attiva nell'industria e nell'automazione con sede a Faenza. In questo caso di studio, si presenta la progettazione ed implementazione della parte front-end del suddetto sistema di assistenza, il quale è integrato ed interconnesso con un paio di applicazioni tipiche di industria 4.0, presenti nella stessa suite di applicazioni.

Progettazione e sviluppo di un supporto Industry 4.0 per la manutenzione predittiva di macchine in ambito farmaceutico

La mia tesi riguarda il progetto che ho sviluppato all'interno di IMA Active. Inizia con un'introduzione ai concetti e tecnologie presenti nell'Industry 4.0, ho illustrato i vantaggi dell'utilizzo di piattaforme per il monitoraggio e supporto alla manutenzione predittiva degli asset in ambito aziendale per poi addentrarmi nella demo che ho sviluppato in Python per simulare le funzionalità che dovranno essere implementate in un sistema terzo (di tipo OSISoft Pi). In questo percorso ho introdotto il concetto di DTW e Golden batch che sono stati indispensabili nello sviluppo del progetto.

Modulare Logistiksysteme in der Prozessindustrie unter Einbeziehung von Industrie 4.0

Zur Gewährleistung einer kundenindividuellen, flexiblen Produktion, welche auch kleine Losegrößen kostengünstig produzieren kann, werden zukünftig Fabriken der Prozessindustrie nicht nur modular sondern darüber hinaus mobil sein. Zur Erreichung dieses Zieles werden neben Produktionselemente, auch sämtliche Logistikkomponenten in Containern zu Modulen zusammengefasst. Hierfür ist es notwendig Lager, aber auch komplexe Verpackungsmaschinen, zu konzipieren welche sich zusammen mit Produktionsmodulen, nach dem Plug-and-Produce-Prinzip, zu kompletten Produktionslinien verknüpfen lassen. Die Steuerung und Organisation erfolgt nach den Gedanken von Industrie 4.0.

Zielgerechte Logistikkonzepte in Betrachtung von LNG- Umschlageplätzen unter Berücksichtigung von Industrie 4.0

Logistikkonzepte in der Spedition und Transportgewerbe spielen heutzutage eine immer wichtigere Rolle, um Lohnnebenkosten so niedrig wie möglich zu halten. Gerade in der Spedition entsteht ein Zusammenspiel aus zeitnaher Lieferung von Konsumgütern und Optimierung der Lagerhaltungskosten bei dem die modulare Integration von Logistik, Informationstechnischen Systemen und vernetzter Kommunikation eine ganz spezifische Rolle hat. Anbindung von der Industrie zum Kunden wird dadurch immer mehr verstärkt, wobei sich somit dies zusehends zu einem Technologietransfer der Industrie 4.0 entwickelt. Die deutsche Wirtschaft steht augenblicklich am Übergabepunkt zur virtuellen Revolution im Industriezeitalter.

Industrie 4.0 Framework, Challenges and Perspectives

The world is increasingly in a global community. The rapid technological development of communication and information technologies allows the transmission of knowledge in real-time. In this context, it is imperative that the most developed countries are able to develop their own strategies to stimulate the industrial sector to keep up-to-date and being competitive in a dynamic and volatile global market so as to maintain its competitive capacities and by consequence, permits the maintenance of a pacific social state to meet the human and social needs of the nation. The path traced of competitiveness through technological differentiation in industrialization allows a wider and innovative field of research. Already we are facing a new phase of organization and industrial technology that begins to change the way we relate with the industry, society and the human interaction in the world of work in current standards. This Thesis, develop an analysis of Industrie 4.0 Framework, Challenges and Perspectives. Also, an analysis of German reality in facing to approach the future challenge in this theme, the competition expected to win in future global markets, points of domestic concerns felt in its industrial fabric household face this challenge and proposes recommendations for a more effective implementation of its own strategy. The methods of research consisted of a comprehensive review and strategically analysis of existing global literature on the topic, either directly or indirectly, in parallel with the analysis of questionnaires and data analysis performed by entities representing the industry at national and world global placement. The results found by this multilevel analysis, allowed concluding that this is a theme that is only in the beginning for construction the platform to engage the future Internet of Things in the industrial environment Industrie 4.0. This dissertation allows stimulate the need of achievements of more strategically and operational approach within the society itself as a whole to clarify the existing weaknesses in this area, so that the National Strategy can be implemented with effective approaches and planned actions for a direct training plan in a more efficiently path in education for the theme.

Digitalisierung und Industrie 4.0 – Herausforderungen für eine Ethik der Arbeit

Die im Auftrag der Ev. Kirche im Rheinland erarbeitete Studie ist vor allem auf die Frage der sozialethischen Herausforderung der Strategie 'Industrie 4.0' fokussiert. Da diese nicht sinnvoll ohne die Wahrnehmung der normativen Perspektive und der sozialpolitischen Rahmenbedingungen erörtert werden kann, wird zunächst die sozialethische normative Ausgangsposition einer protestantischen Arbeitsethik kurz in Erinnerung gerufen, um dann die sozialpolitischen Rahmenbedingungen knapp zu thematisieren. In einem nächsten Schritt wird die Landschaft der mit dem Konzept der Digitalisierung bezeichneten Entwicklungen skizziert, um dann auf den Charakter, die Instrumente und die Umsetzung des Konzepts der 'Industrie 4.0' einzugehen. Darauf aufbauend werden dann die arbeitsbezogenen Optionen und Alternativen thematisiert, um schliesslich diejenigen Optionen auszuzeichnen, denen in sozialethischer Perspektive bevorzugte Aufmerksamkeit zukommen sollte.

Facing the climate change challenges in the mining and mineral industry as providers of a sustainable manufacturing process

A sustainable manufacturing process must rely on an also sustainable raw materials and energy supply. This paper is intended to show the results of the studies developed on sustainable business models for the minerals industry as a fundamental previous part of a sustainable manufacturing process. As it has happened in other economic activities, the mining and minerals industry has come under tremendous pressure to improve its social, developmental, and environmental performance. Mining, refining, and the use and disposal of minerals have in some instances led to significant local environmental and social damage. Nowadays, like in other parts of the corporate world, companies are more routinely expected to perform to ever higher standards of behavior, going well beyond achieving the best rate of return for shareholders. They are also increasingly being asked to be more transparent and subject to third-party audit or review, especially in environmental aspects. In terms of environment, there are three inter-related areas where innovation and new business models can make the biggest difference: carbon, water and biodiversity. The focus in these three areas is for two reasons. First, the industrial and energetic minerals industry has significant footprints in each of these areas. Second, these three areas are where the potential environmental impacts go beyond local stakeholders and communities, and can even have global impacts, like in the case of carbon. So prioritizing efforts in these areas will ultimately be a strategic differentiator as the industry businesses continues to grow. Over the next forty years, world?s population is predicted to rise from 6.300 million to 9.500 million people. This will mean a huge demand of natural resources. Indeed, consumption rates are such that current demand for raw materials will probably soon exceed the planet?s capacity. As awareness of the actual situation grows, the public is demanding goods and services that are even more environmentally sustainable. This means that massive efforts are required to reduce the amount of materials we use, including freshwater, minerals and oil, biodiversity, and marine resources. It?s clear that business as usual is no longer possible. Today, companies face not only the economic fallout of the financial crisis; they face the substantial challenge of transitioning to a low-carbon economy that is constrained by dwindling natural resources easily accessible. Innovative business models offer pioneering companies an early start toward the future. They can signal to consumers how to make sustainable choices and provide reward for both the consumer and the shareholder. Climate change and carbon remain major risk discontinuities that we need to better understand and deal with. In the absence of a global carbon solution, the principal objective of any individual country should be to reduce its global carbon emissions by encouraging conservation. The mineral industry internal response is to continue to focus on reducing the energy intensity of our existing operations through energy efficiency and the progressive introduction of new technology. Planning of the new projects must ensure that their energy footprint is minimal from the start. These actions will increase the long term resilience of the business to uncertain energy and carbon markets. This focus, combined with a strong demand for skills in this strategic area for the future requires an appropriate change in initial and continuing training of engineers and technicians and their awareness of the issue of eco-design. It will also need the development of measurement tools for consistent comparisons between companies and the assessments integration of the carbon footprint of mining equipments and services in a comprehensive impact study on the sustainable development of the Economy.

Development and application of a computer-based methodology for design for additive manufacturing of automotive components

The research project aims to improve the Design for Additive Manufacturing of metal components. Firstly, the scenario of Additive Manufacturing is depicted, describing its role in Industry 4.0 and in particular focusing on Metal Additive Manufacturing technologies and the Automotive sector applications. Secondly, the state of the art in Design for Additive Manufacturing is described, contextualizing the methodologies, and classifying guidelines, rules, and approaches. The key phases of product design and process design to achieve lightweight functional designs and reliable processes are deepened together with the Computer-Aided Technologies to support the approaches implementation. Therefore, a general Design for Additive Manufacturing workflow based on product and process optimization has been systematically defined. From the analysis of the state of the art, the use of a holistic approach has been considered fundamental and thus the use of integrated product-process design platforms has been evaluated as a key element for its development. Indeed, a computer-based methodology exploiting integrated tools and numerical simulations to drive the product and process optimization has been proposed. A validation of CAD platform-based approaches has been performed, as well as potentials offered by integrated tools have been evaluated. Concerning product optimization, systematic approaches to integrate topology optimization in the design have been proposed and validated through product optimization of an automotive case study. Concerning process optimization, the use of process simulation techniques to prevent manufacturing flaws related to the high thermal gradients of metal processes is developed, providing case studies to validate results compared to experimental data, and application to process optimization of an automotive case study. Finally, an example of the product and process design through the proposed simulation-driven integrated approach is provided to prove the method's suitability for effective redesigns of Additive Manufacturing based high-performance metal products. The results are then outlined, and further developments are discussed.