Üretim sistemleri için endüstri 4.0 uygulamalarında simülasyon yaklaşımı ve bir uygulama

Abstract

Endüstri 4.0 son yıllarda en çok konuşulan ve hakkında pek çok kaynak bulunan yeni paradigmalardan biridir ve dördüncü endüstri devrimi olarak tanımlanmaktadır. Son yıllardaki gelişmeler ve bazı kilit teknolojilerin yükselişi (sensörler, aktuatörler, bulut bilişim, veri madenciliği gibi) Endüstri 4.0'ı ve beraberinde getirdiği yeni imkânları mümkün kılmıştır. Endüstri 4.0 geniş bir konu olmakla birlikte; siber fiziksel sistemler, akıllı fabrikalar, nesnelerin interneti gibi birçok kavramı da beraberinde getirmiştir. Endüstri 4.0'ın sağladığı birçok faydanın yanı sıra uygulaması ve tasarımı gibi alanlarda birçok zorluk da bulunmaktadır. Bu zorlukları ortadan kaldırmak ve Endüstri 4.0 uygulamasının faydalarını arttırmak için, bir sistemin simülasyonla modellemesi, karar vermede literatürde kullanılan kilit yaklaşımlardan biridir ve birçok başka olanak sağlar. Bu çalışma üretim sistemlerinde Endüstri 4.0 uygulamaları için simülasyon yaklaşımının sağladığı imkan, fayda ve olanakları mevcut literatür taraması ve bir elektronik imalat sektöründe bir uygulama ile ortaya koymayı amaçlamaktadır. Simülasyon yaklaşımı üçüncü sanayi devriminden bu yana kullanılmaktadır. Ancak dördüncü sanayi devriminden sonra ürünlerden, işletmelerden, makinelerden ve cihazlardan toplanan büyük miktarda veri nedeniyle sadece tasarım aşamasında değil sonrasında da etkili ve dinamik olmak zorundadır. Çalışmada ilk olarak anahtar kelimelerle araştırmanın alanı belirlenmiş ve bir temel araştırma sorusu ve ona hizmet edecek altı alt araştırma sorularıyla birlikte detaya ve yukarıda belirtilen amaca ulaşılmaya çalışılmıştır. Çalışma boyunca bu sorular ve akabinde temel araştırma sorusu cevaplanmaya gayret gösterilmiş ve örnek olması ve pekişmesi açısından elektronik imalat sektöründe faaliyet gösteren bir işletmede simülasyon modellemesi yapılmıştır.

Industry 4.0 is one of the novel paradigms and the most talking topics in the recent years, there are many resources about it in literature for almost all the industry sector. Industry 4.0 is defined as the fourth industrial revolution, because it provides a wide and new range of possibilities to the Industry. Recent advances and trends of some key technologies such as actuators, sensors, cloud computing and big data analytics make Industry 4.0 possible. Industry 4.0 is a broad subject and there are many concepts related to it for example, cyber physical systems, smart factory and Internet of Things, etc. Industry 4.0 brings many benefits and challenges, together. In order to eliminate these challenges and increase the benefits of Industry 4.0 implementation, simulation modeling of a system is a one of key approaches using in literature for decision making and provides many other possibilities. This study aims to state possibilities of using simulation approach for implementing Industry 4.0 in production systems by reviewing literature. Simulation have used in industry since the third industry revolution but it has to be effective and dynamic after the forth industrial revolution due to the huge amount of data collected from products, processes, machines and devices. The current study started with the investigation of Industry 4.0 paradigm, its technologies and challenges. Then, simulation approach and its types are defined. Literature was also reviewed according to defined literature review methodology, Finally, An application was made on production area by using simulation approach. The results showed that the simulation approach is very useful to eliminate the challenges of the Industry 4.0 implementation. Furthermore, simulation and new technologies (e.g. Virtual Reality), together, can be used to meet visualization requirements of Industry 4.0. Simulation also provides validation of proposed algorithms for Industry 4.0 implementation. First and foremost, the main purpose of this study was to explore and understand possibilities of simulation approach for implementing Industry 4.0 technologies in production system. In order to address the research gap and objective, in Section 1.2, the overall research question was formulated and it was divided into six smaller research questions that will serve as guidance during the whole research process. In previous section 5.1, these six research questions have been answered by discussing the previous sections of this report. Finally, thanks to these six research question, it is possible to answer to the overall research question: What kind of possibilities do the different simulations provide for implementing Industry 4.0 technologies in case of internal production systems/processes? The thesis starts with a literature review about Industry 4.0 paradigm and simulation approach in order to get to know existing literature related to the topic of the research. Industry 4.0 is still a young research area, even though there is more and more research about it. It was found lots of literature related to Industry 4.0 background, challenges and technologies, and also simulation types and usage area. In the main part of this study, the literature review and analysis, we obtained the papers related to possibilities provided by simulation for implementing Industry 4.0 technologies from three databases according to the screening criteria. As a result, simulation enables to meet the different challenges of Industry 4.0 technologies. Simulation is the one of the key approach to solve problems related to Industry 4.0 implementation and improve the production system implemented Industry 4.0 technologies. Simulation can be used for adoption of employees and new technologies to the new system in Industry 4.0 era. The simulation helps to safely train workers to correctly use and implement new technologies in real system. Furthermore, simulation provides an opportunity to evaluate and analyse proposed algorithms/programs/methods that are developed to solve many problems related to implementation of Industry 4.0 technologies, such as Big Data analytics, scheduling, production planning and control, evaluating manufacturing effectiveness, etc. without changing the real system. Also, simulation can be used to improve human-machine coproduction for implementation of Industry 4.0 in order to meet the challenge related to organizational and production fit. It can be said this study has successfully answered the overall research question, although this study is limited to certain amount of articles. The next section will explain what kind of limitations this study has and the future research which can be done about the topic. In order to know more about simulation for implementing Industry 4.0 technologies, it could be interesting do this research for a certain industry such as automotive industry. This study helps company to be aware importance of simulation approach for implementation of Industry 4.0 technologies and possibilities that simulation provides in Industry 4.0 era, and a lot of space have been left by this study for further research.