Manufacturers of custom mass production face the need to individualize the product with high productions while maintaining high productivity and quality standards.
Products share a common basis but are customizable to some degree. Sections with large repetitive batches coexist with others where the product is individualized based on predetermined options in modular architectures.
Typical companies of mass personalized production with this casuistry are found in sectors such as automotive, trucks, industrial machinery, agricultural machinery.
In these cases, Industry 4.0 solutions tend to do this.
Flexible planning, load balancing, scheduling and layouts:
From the use of planning tools and load distribution dynamically and on the basis of real-time data on the state of production. The use of autonomous AGVs (3) capable of supplying materials to the lines in a flexible way and without predetermined routes is also considered.
Online and automated quality control:
Through the use of artificial vision systems or from sensors capable of detecting changes in process parameters. In the most advanced cases, we work with adaptive systems capable of self-correcting when detected deviations.
Automation also in offline operations:
Based on the use of collaborative robots, AGVs and automated flexible cells.
Large-scale Production Model
In this case the main objective in large-scale production is maximum automation with high levels of operational efficiency (OEE – availability, quality, performance) with certain levels of flexibility to adapt to the production mix. The batches are large and there is hardly any customization.
Industry 4.0 solutions in these cases must be addressed to:
Through the use of robots in all stages of manufacturing, from the preparation of machines, tools or molds, to sub-assemblies, finishing operations or movements of materials using AGVs.
Online quality control and automatic parameter adjustment:
From sensorized lines and through programmable machines capable of optimizing its operating parameters based on quality indications. Fully automated final quality controls are also proposed, especially for electronic systems.
Traceability systems throughout the supply chain :
They are systems that allow automatic tracking and identification of products individually and in real time using RFID systems and throughout the supply chain using technologies, for example, blockchain.