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Method for Performance Analysis of Production Lines Based on Digital Models

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Transdisciplinary Engineering for Resilience: Responding to System Disruptions 365
L. Newnes et al. (Eds.)
© 2021 The authors and IOS Press.
This article is published online with Open Access by IOS Press and distributed under the terms
of the Creative Commons Attribution Non-Commercial License 4.0 (CC BY-NC 4.0).
doi:10.3233/ATDE210116

Method for Performance Analysis of

Production Lines Based on Digital Models
Powered by Real-Time Data
Suewellyn KRÜGER1, Samuel Henrique WERLICH and Milton BORSATO
Federal University of Technology – Paraná (UTFPR), Curitiba-PR, Brazil

Abstract. The intention to improve the performance of the processes involved is

considered one of the main guidelines for companies' competitive advantage.
Technological advances help to improve yields, operations, decision making and
cost reduction when adopted in their daily processes, and assembly lines are
constantly monitored, but the detection of adversities is still considered complex.
Because of this difficulty, the proposal for a virtual model with greater fidelity to
reality, such as the digital twin model, is promising. A virtual model of the shop
floor system composed of physical characteristics present in the industrial
environment, being fed with data that occurs in real-time, offers the simulation
possible predictions of setbacks with greater fidelity. This monitoring provides the
user with an improvement in the process control, assisting in the planning of
operations, enabling changes in the virtual model of compliance verification,
improving performance and productivity, reducing related times and costs for later
application in the physical model. In this way, the objective of this work proposes
the elaboration of an application method where it is possible to analyze the
performance of productive lines through digital models integrated with the data feed
system in real-time.

Keywords. Digital Twin, Industry 4.0, Simulation, Real-time data, Manufacturing

System, Transdisciplinary.

Introduction

The highlight of many companies in relation to their competitors is linked to the use of
competitive intelligence, helping in the process of innovating manufactured products as
well as improving quality and reducing the costs involved in the procedures performed.
Among the various technological advances present in the current market, the
involvement of information, equipment and the communication of the entire system in
real-time provide an agile and independent data analysis of both the process and the
product, advising decision-making in the stages of product development.
In a transdisciplinary way, Industry 4.0 is related by its involvement in several areas
such as information technologies, data exchange, the use of integrated systems, the use
of the internet of things, cloud computing, modeling and information security. A smart
factory based on Industry 4.0 involves a connection between mobility, structures,
logistics and networks. Getting decision-making efficiently and in real-time through the

1
Corresponding Author, Mail: [email protected].
366 S. Krüger et al. / Method for Performance Analysis of Production Lines

joining of various technologies with the latest innovations serves as an incentive to

practice Industry 4.0 [1].
The automotive industries use the concepts of Industry 4.0 because they consider
productivity as central feasibility for the organization, featuring lean manufacturing
characteristics, emphasizing the identification and elimination of waste constantly,
aiming to reduce delivery times in the processes, improving the management of stocks
through faster responses to market changes [2].
In line with Industry 4.0, the use of tools and techniques for monitoring and
supervising industrial performance is associated with a competitive advantage. The use
of predictive production techniques helps in the search for control of productivity loss
points, enabling the anticipation of possible failures and even malfunctions of machines,
which can be applied in several areas such as maintenance, planning, programming and
even production [3 ].
A technology that can be considered when talking about monitoring is the digital
twin, as it is a virtual representation of all the resources in the system. Ranging from the
machine and shop floor layout, to the products, processes and tasks performed, entering
the real times of the system, thus obtaining a continuous view of the functioning of the
entire process.
The use of technologies based on simulations draws even more attention from
companies as they allow the demonstration of possible solutions in the virtual
environment before applying them to the physical itself. The great related value is in the
fact that the user can experiment and evaluate in the virtual certain changes and
combinations of factors present in the physical environment system [4].
Always present wishes in the automotive industry involve intelligent manufacturing
and a way to assist this is through the virtual modeling of the system. Thus it provides
companies with certain preventions, improvement and control of the processes carried
out and the simultaneous monitoring of the activities carried out, assisting in the decision
making of problems that may occur related to productivity [5].
Through a bibliographic survey, some points were related to support this research.
When the search for the term system monitoring in real-time was carried out, little
research was found involving the application of digital twin with industrial
environments. If the search directs to the association between devices, with sensors and
actuators, with the monitoring of the states of the connected devices through the Internet
of Things (IoT) in a short period, what is found are only simulations, desiring its
application in a real environment for a better evaluation of the method as well as the
creation of a human-machine interface for its proper follow-up and monitoring [6].
Having some aspects observed in this bibliographic survey, this research is directed
to the difficulties that many companies face in managing to improve performance issues
of their systems and to adapt quickly to the production of a new item. The development
of a method presented in this article will help to improve the company's flexibility and
the difficulty in adapting to the exceptional.
Through the bibliographic survey carried out, it was observed the lack of
applications in the practice of a digital model with the feeding of real data in real-time
and with the monitoring in real-time, a gap that will be directed to this research. The rest
of this work will be structured as follows: section 1 presents the main concepts on the
relevant topics involved such as manufacturing systems, digital twin and assembly line.
Section 2 describes the entire methodology for proposing the application of the digital
model and finally, in section 3, the next steps for the physical application of the model
 S. Krüger et al. / Method for Performance Analysis of Production Lines 367

and some preliminary results already obtained in the initial stages of the research and
information for its continuity.

1. Background

In view of the wide possibility of using technologies to virtualize the resources of the
processes present in manufacturing, a bibliometric study was carried out and the most
relevant scientific productions were analyzed, thus obtaining the edge of knowledge for
the themes involved with this research.
A pointed trend [1] is the implementation of digital twin through a structural system
with all the elements connected. Making its modularity, autonomy and connectivity
possible through installations and the use of sensors and actuators distributed by the
system.
The need to use current software is presented [7] as a challenge for the rapid updating
of data, such as the times of individual cycles and the degrees of use of workstations and
robots. In addition, [8] the application of a digital twin model for production control in a
continuous manner and updated in real-time must reflect exactly what is happening in
the physical environment, allowing for optimizations, quick and concise decision
making, intervening in a predictive manner.
A relevant point pointed out in another research [6] indicates that it is essential to
detail the modeling concepts for more complex environments when analyzing the
Internet of Things (IoT) devices, such as the industrial factory floor. Modeling tools often
do not support simulation and analysis due to the high number of representations required
in the virtual model of equipment such as machines, devices, sensors and actuators.
When the digital twin model is directed to the shop floor, it considers its own
research [9] as an initial stage and points to future work the interconnection and
intelligent interaction of the shop floor, a bidirectional connection between the physical
and virtual environments, perfecting the virtual model with the increase of fidelity are
fundamental for future applications of the digital twin shop-floor in intelligent
fabrications.
The involvement of Industry 4.0 in a transdisciplinary way adds value to the client
by presenting the real conditions of the process, with a high number of information
implemented in the simulation, bringing the virtual representation closer to reality,
obtaining more efficiently the indication of possible problems in the project and directing
appropriate improvements in advance.
To demonstrate the main issues related to this research, the following will present
relevant concepts and approaches found in reputable scientific publications. Firstly, it
will be discussed on manufacturing systems, followed by an approach regarding digital
twin and finally on production lines with a focus on performance analysis, flexibility and
adaptability.

1.1. Manufacturing System

The manufacturing systems are constantly improving so that they can respond to the
involvement of new technologies, quickly and efficiently directing their final objective,
providing opportunities for the activities involved and improving the final quality.
In general, manufacturing systems can be seen as a set of complex activities because
they involve people, a high diversity of machines and tools, as well as other equipment
368 S. Krüger et al. / Method for Performance Analysis of Production Lines

in its various levels of automation, such as robots and computers. A manufacturing

system starts with the development of a product, proceeding to the manufacturing
engineering, composing the development of the production processes, as well as the
planning of the necessary resources for the effective production of the product and its
delivery to the customer [10].
This whole set of activities and operations is associated with the necessary inputs,
the transformation processes and the manufacturing life cycle. Depending on the degree
of complexity of these variables, robust monitoring has great value, allowing the whole
process to occur in the best possible way [11].
More and more [12] companies are inserting digital and intelligent manufacturing
in their procedures, improving the modeling of design data, manufacturing, management
and maintenance of the operations involved.
When all this transdisciplinary involvement is analyzed, there is a need for research
regarding the involvement in data capture in an automated way and the generation of a
database in real-time. Connecting the physical and real systems allowing access,
exchanges and data processing, collaborating in the manufacturing systems and boosting
Industry 4.0, we can mention the cyber-physical systems (CPS) [13].
Following the architecture of CPS with Industry 4.0 [14], the proposal of the five
levels in the systems provides an intelligent analysis for integrity, allowing the modeling
of the digital twin and assists in decision making. Working its connectivity in an
advanced way in the collection of data in real-time of the physical environment with the
management, analysis and computation of the data in a cybernetic environment.
When PHCs are used [13], aspects such as self-organization, security, remote
diagnosis, real-time control, transparency, predictability, efficiency and possible
corrections in the virtual model are expected to be improved. All these aspects add value
to an organization based on Industry 4.0 by presenting autonomous optimization,
promoting the digitization of the entire production, in addition to the involvement of
workers, products and resources with intelligent instances.
Researches consider CPS as promising for its involvement with IoT, through the
transdisciplinary distribution between the resources of computing, communication and
control of physical systems, not to mention its use as a data provider for digital models.
These models represent resources of the process assisting in decision making and
production planning, because through their analysis actions are possible in the physical
environment, such as exchanging information providing an improvement in the quality
of services and suggesting in the proposal in the use of digital twin in a manufacturing
process.

1.2. Digital Twin

A digital twin model can be seen as a set of virtual information to portray a product, a
system or a physical process. From the minimum level of the machines, through the
factory level as the assembly line, to the maximum possible as the organizational level
for example [15]. Having been seen as a new technology inserted in the industrial
environment, the analysis of the effects caused in the most complex scenarios present
and its monitoring in decisions over time is essential.
When related to manufacturing, the digital twin can be defined as a virtual
representation of the production systems to synchronize the virtual and real systems. This
synchronization can be carried out [8] using connected smart devices allowing the
 S. Krüger et al. / Method for Performance Analysis of Production Lines 369

communication of data in real-time, the basis of Industry 4.0 with its involvement of
technological resources for the prevention and optimization of recurrent behaviors in the
system.
Its use in manufacturing also makes it possible to simulate and optimize production
systems as it encompasses several aspects, providing a visualization of the entire process,
whether at the level of just one component or even the entire assembly line [16].
Emphasizing the areas of control, production planning, maintenance and also layout
planning, aiming at increasing competitiveness. The digital twin is seen with great
potential in planning and optimization simulations [9], in increasing efficiency and
precision, obtaining considerable financial gains for production [8], and also because it
is not just a large collection of digital artifacts, but a structured model with all the
elements connected [1].
The digital twin model emphasizes the control and decision-making of processes
due to the identification of deviations from the current operation of the equipment and
its causes, helping to identify possible emergencies and generating alerts for the
monitoring team about abnormal events and situations [17]. Among the advantages of its
implementation, we can mention the use of production equipment with mechanisms and
operations monitored by devices. The collection of the generated data takes place through
sensors, actuators and optimized software.
Different levels of integration between the physical and virtual models are defined
according to the modeling. A level can be a digital model when there is no automated
exchange of data between the models, always taking place manually. It can also be a
digital shadow when the automated data flow is unilateral, and any change in the physical
environment has repercussions in the virtual, but the opposite path does not occur. And
finally, the digital twin, in which the data exchange flow occurs in both directions,
providing control on both sides, allowing interventions in the plant, physical
environment, through the virtual environment, its executions and the responses of the
physical environment being obtained in the virtual [16].
Therefore, the application of the digital twin in an industrial environment includes
the improvement of situational knowledge of the entire process with the insertion of the
real data of the system, enabling the improvement in the responses of the conditions of
possible changes and optimization of future conditions with the permission of analysis
of performing predictive maintenance in the process of production lines, such as
automotive assembly lines.

1.3. Assembly line

There are several cases of application of digital twin in manufacturing processes, so there
is an opportunity to apply it on an assembly line. The assembly lines can also be called
progressive assembly precisely because there are associations and joints of parts as they
travel through the workstations distributed on the factory floor, being sequentially
incorporated one by one until the final product.
The execution of similar methods in the production of items such as automobiles,
the transportation of equipment and the manufacture of household and electronic devices
are considered important characteristics for an assembly line. As well as the sequential
disposition of those involved in it, as operators and tools, as well as the machines and
parts, used to produce the product.
The layout of an assembly line can be considered a direct influence on productivity,
allowing for several dimensioning configurations for the line [18]. Another important
370 S. Krüger et al. / Method for Performance Analysis of Production Lines

feature is the access to the parts that will be used coming to the work stations, their
displacement occurs by transporters or motor vehicles.
The complexity of the assembly lines is due to the high number of interconnected
variables for their operation. These variables are related to technologies, environmental
factors, ergonomic issues and the methods and times for the production of parts [19].
As soon as an assembly line is drawn up, the first characteristic that must be analyzed
is its balance. For the construction of this line, some points must be considered, such as
the verification of all the essential steps to manufacture each item of the product, the
balance of the procedures along the line must be measured, the number of machines and
their production rates is also important.
In an automotive assembly line, all components must be integrated sequentially as
the product will be formed and transported by a transporter. As the product passes
through the line, each operator performs a specific task for their workstation by placing
supplies such as parts and tools at their point sequentially. The company's flexibility in
adapting and incorporating new activities in the manufacturing process and in adapting
to changes in actions and in the production flow quickly and effectively are important
factors for a good manufacturing process.

2. Methodology

There are promising conditions for companies that are involved with the use of
competitive intelligence. The use of knowledge involving intelligent manufacturing with
the technologies of industry 4.0, as a way of assisting decision-making in production
processes, whether new or existing, promotes the improvement of solutions for
applications in production lines with higher quality.
The direction of this research relies on selected literature for a diagnosis of the
problem in question and through observations on the procedures performed in the
company of the application case. This investigation took place through interviews with
the parties involved as process and project engineers together with the analysis of the
documents and times for the procedures to be carried out.
The observation of the procedures and tasks carried out in the company were
analyzed and resulted in the proposal of an analysis of the performance of the production
line aiming at the reduction of costs involved with the detected problems. These
problems may be related to the lack of a virtual model to enable checks and compliance
with changes in the physical environment of the production line.
Changes to an existing project or the insertion of a new product on an assembly line,
cause the responsible team to spend a lot of time between trips, attempts, errors and
successes so that the job can be left with optimum performance. Because of this issue, a
digital model was chosen. Therefore, this research aims to develop an application method
to analyze the performance of the production lines, through a digital model fed with real
data and in real-time providing simulation of ideas in a production environment.
The simulation provides an advantage for its virtual implementation. The team can
have a vision of the assembly line and create scenarios in advance, because until then
this task would only be possible after the complete definition of the project, resulting in
numerous subsequent changes generating a high rate of rework. The simulation assists
in boosting innovation so that it is possible to virtually carry out definitions, plans,
creations, monitoring and control of all production processes.
 S. Krüger et al. / Method for Performance Analysis of Production Lines 371

The application of digital twin in the simulation of processes provides the company
with greater security in decision making by presenting efficient monitoring and aptitude
to the actions performed physically, increasing mobility, enabling the user to make
changes and monitor remotely, without interfering and/or cause losses in the results
obtained by the production. The balancing of the company's assembly line can be used
to promote an increase in income, a reduction in the costs involved, thus increasing the
profits generated. In addition, activities are sequentially distributed among workplaces
according to their operating times, improving the use of operations as well as the
equipment present.
When implemented in digital manufacturing, the use of digital twin virtually
integrates design information and manufacturing processes. Aiming at reducing the costs
involved in the development, anticipating and non-conformities of the system, providing
innovation in the manufacturing area with higher quality products, allowing the creation
and application of innovative models with their due representations and also with the
simulation of possible scenarios in the search for optimization.
Another reason for the use of the digital twin model in this research is because it
does not deal only with the design and optimization of a production system, but involves
involving real data from the production environment, continuously offering a simulation
of the system and contributing quickly in real-time feedback throughout the
manufacturing process [20]. Some steps must be taken so that the proposed method can
reach its final objective, as shown in Figure 1.

Figure 1. Performance analysis method.

Using the method developed for the performance analysis, observations were first
made of the points that face problems in the assembly line. These points result in low
yield, high index with failures in quality, low in capacity and gains in production.
Through the analysis of a monitoring system present in the company of the application
case, historical data was extracted from points where there were large numbers of line
stops and directed to points with low performance.
In the next stage, an environment was selected to perform the performance analysis.
A fraction of the assembly line that will be virtualized was selected since it does not have
the full operation of the equipment involved in the procedures, it has considerable levels
of non-quality of the final products and a large volume of rework.
Another fundamental point for choosing this cut was that this line has more
automated factors and characteristics than the others, thus presenting greater conditions
for the implementation of the digital twin model. This fraction of the assembly line can
be considered complex due to the number of functions and actions performed, in addition
to all the sequencing of activities performed by machinery present. This cutout
corresponds to the part of the line where the wheels are mounted for their subsequent
insertion in the vehicle.
372 S. Krüger et al. / Method for Performance Analysis of Production Lines

After choosing the point to be virtualized, the selection of data to feed the digital
model is essential. Data such as the type of wheels produced, the number of wheels
audited, the number of wheels in compliance, as well as in non-compliance are some of
the important data extracted from the devices of the line. Other relevant data for the
virtual model are the factory and line layout, downtime and setup times, operating times
and maintenance schedules. These data directly influence the performance of the line,
and other data may also be collected for the construction of the virtual model.
The software to be chosen for the modeling must be available in the company in the
case of an application for the implementation of the data in real-time, directly with data
from the assembly line. The line data is recorded in a MOP (Marge OPérationnelle),
prepared using the Node-Red tool based on the communication flow from the hardware
devices to an online environment and then sent via the UDC protocol (User Datagram
Protocol) to Spotfire, responsible for carrying out intelligent data analysis. Finally, the
work and structured data will be sent to the GCP cloud (Google Cloud Platform).
The storage and processing of the information will be carried out in the GCP
resulting in a dashboard with the relevant information for the virtual model. Other
important data for the virtual model will be inserted in the simulation through interfaces
present in the simulation software.
After having created the virtual model and the relevant data being fed, a fidelity
analysis must be carried out to verify compliance. Observations of what happens in the
digital model will be made according to what happens in the real environment, resulting
in coherent replicas. Thus, this virtual model can be accepted for the proper continuation
of the research. When changes in the virtual model are applied to the physical
environment, observing its occurrence requires attention by comparing the results
obtained through the virtual simulation in accordance with what occurs at the end of
physical production.

3. Results/ Conclusion

Therefore, through the procedures demonstrated in this research, the method proposed in
an organizational environment will seek an estimate of the realization of the processes,
aiding in the prevention of possible mistakes and aiding in the company's decision-
making in the case of application. The provision of a digital manufacturing process
environment is conducive to the optimization of production systems and processes.
The digital twin is being carried out in several types of research recently and its
targeting for the manufacturing area collaborates with the production planning and
control. The use of real data in the virtual model with real-time feed is considered
promising for the improvement of its application in production systems.
Another important point for the elaboration of this digital twin model is to make
interventions on the assembly line via distance, avoiding that there are comings and
goings to the factory floor to observe, analyze and, mainly, cause a line stop to perform
some attempted change. These unnecessary displacements result in activities that do not
add value to the company and unplanned line stops have an impact on production and
quality losses.
Some data from the wheel production machines, which will be inserted in the virtual
model, have already been pre-determined because they are considered essential for a
simulation, such as the operating times, the line stop times, the average cycle times and
the causes of line stop for predictive analysis. Other data will still be evaluated for
 S. Krüger et al. / Method for Performance Analysis of Production Lines 373

insertion or not in the virtual model, always in the search to increase the degree of
fidelity.
The realization of this research has some risks that must be taken into account, which
may result in its planning. As your application will be carried out in a company in the
automotive industry, you must have full access to information and data related to the
production line. In addition to the data, access to the company's system as well as to the
available software that is compatible with what is wanted.
Among the positive points, it can be considered that this project will bring gains for
the company in the application case, by doing virtual modeling of the production line
and mainly simulating with data inserted in real-time, making it possible to boost
business competitiveness. With the mirroring of the virtual model, with what is
happening in the physical environment, they support production planning and
monitoring, reducing production downtime, impacting the costs involved with
maintenance in addition to the increase in productivity resulting in profits for the
company.

Acknowledgement

Special thanks to the Fundação Araucária for encouraging research.

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