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Manufacturing Maps, a Novel Tool for Smart Factory Management Based on Petri Nets and Big Data Mini-Terms

Author

Listed:
  • Javier Llopis

    (Ford Spain, Polígono Industrial Ford S/N, Almussafes, 46440 Valencia, Spain
    These authors contributed equally to this work.)

  • Antonio Lacasa

    (Ford Spain, Polígono Industrial Ford S/N, Almussafes, 46440 Valencia, Spain
    These authors contributed equally to this work.)

  • Eduardo Garcia

    (Ford Spain, Polígono Industrial Ford S/N, Almussafes, 46440 Valencia, Spain
    These authors contributed equally to this work.)

  • Nicolás Montés

    (Department of Mathematics, Physics and Technological Sciences, University CEU Cardenal Herrera, C/San Bartolome 55, Alfara del Patriarca, 46115 Valencia, Spain
    These authors contributed equally to this work.)

  • Lucía Hilario

    (Department of Mathematics, Physics and Technological Sciences, University CEU Cardenal Herrera, C/San Bartolome 55, Alfara del Patriarca, 46115 Valencia, Spain
    These authors contributed equally to this work.)

  • Judith Vizcaíno

    (Faculty of Mathematics, University of Valencia, Blasco Ibáñez Avenue, 13, 46010 Valencia, Spain
    These authors contributed equally to this work.)

  • Cristina Vilar

    (Faculty of Mathematics, University of Valencia, Blasco Ibáñez Avenue, 13, 46010 Valencia, Spain
    These authors contributed equally to this work.)

  • Judit Vilar

    (Faculty of Mathematics, University of Valencia, Blasco Ibáñez Avenue, 13, 46010 Valencia, Spain
    These authors contributed equally to this work.)

  • Laura Sánchez

    (Faculty of Mathematics, University of Valencia, Blasco Ibáñez Avenue, 13, 46010 Valencia, Spain
    These authors contributed equally to this work.)

  • Juan Carlos Latorre

    (Department of Mathematics, Physics and Technological Sciences, University CEU Cardenal Herrera, C/San Bartolome 55, Alfara del Patriarca, 46115 Valencia, Spain
    These authors contributed equally to this work.)

Abstract

This article defines a new concept for real-time factory management—manufacturing maps. Manufacturing maps are generated from two fundamental elements, mini-terms and Petri nets. Mini-terms are sub-times of a technical cycle, the time it takes for any component to perform its task. A mini-term, by definition, is a sub-cycle time and it would only make sense to use the term in connection with production improvement. Previous studies have shown that when the sub-cycle time worsens, this indicates that something unusual is happening, enabling anticipation of line failures. As a result, a mini-term has dual functionality, since, on the one hand, it is a production parameter and, on the other, it is a sensor used for predictive maintenance. This, combined with how easy and cheap it is to extract relevant data from manufacturing lines, has resulted in the mini-term becoming a new paradigm for predictive maintenance, and, indirectly, for production analysis. Applying this parameter using big data for machines and components can enable the complete modeling of a factory using Petri nets. This article presents manufacturing maps as a hierarchical construction of Petri nets in which the lowest level network is a temporary Petri net based on mini-terms, and in which the highest level is a global view of the entire plant. The user of a manufacturing map can select intermediate levels, such as a specific production line, and perform analysis or simulation using real-time data from the mini-term database. As an example, this paper examines the modeling of the 8XY line, a multi-model welding line at the Ford factory in Almussafes (Valencia), where the lower layers are modeled until the mini-term layer is reached. The results, and a discussion of the possible applications of manufacturing maps in industry, are provided at the end of this article.

Suggested Citation

  • Javier Llopis & Antonio Lacasa & Eduardo Garcia & Nicolás Montés & Lucía Hilario & Judith Vizcaíno & Cristina Vilar & Judit Vilar & Laura Sánchez & Juan Carlos Latorre, 2022. "Manufacturing Maps, a Novel Tool for Smart Factory Management Based on Petri Nets and Big Data Mini-Terms," Mathematics, MDPI, vol. 10(14), pages 1-22, July.
  • Handle: RePEc:gam:jmathe:v:10:y:2022:i:14:p:2398-:d:858578
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    References listed on IDEAS

    as
    1. Eduardo Garcia & Nicolás Montés, 2019. "Real-Time Idle Time Cancellation by Means of Miniterm 4.0," Energies, MDPI, vol. 12(7), pages 1-13, March.
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    Cited by:

    1. Bingyin Lei & Yue Ren & Ziyang Wang & Xinquan Ge & Xiaolin Li & Kaiye Gao, 2023. "The Optimization of Working Time for a Consecutively Connected Production Line," Mathematics, MDPI, vol. 11(2), pages 1-12, January.

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