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A Simulation Study of Industry 4.0 Factories Based on the Ontology on

Flexibility with Using FlexSim Software

Article in Management and Production Engineering Review · September 2020

DOI: 10.24425/mper.2020.134934

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Management and Production Engineering Review
Volume 11 • Number 3 • September 2020 • pp. 74–83
DOI: 10.24425/mper.2020.134934

A SIMULATION STUDY OF INDUSTRY 4.0 FACTORIES BASED

ON THE ONTOLOGY ON FLEXIBILITY
WITH USING FLEXSIMr SOFTWARE
Sławomir Luściński1 , Vitalii Ivanov2
1
Kielce University of Technology, Poland
2
Sumy State University, Ukraine

Corresponding author:
Sławomir Luściński
Kielce University of Technology
Faculty of Management and Computer Modelling
al. Tysiąclecia Państwa Polskiego 7, 25-314 Kielce, Poland
phone: +48 41 3424378
e-mail: [email protected]

Received: 6 April 2020 Abstract

Accepted: 9 August 2020 The main aim of the article is to develop a simulation model of flexible manufacturing
system with applying the ontology on flexibility. Designing manufacturing systems matching
both production and market requirements becomes more and more challenging due to the
variability of demand for a large number of products made in many variants and short
lead times. Manufacturing flexibility is widely recognised as a proven solution to achieve
and maintain both the strategical and operational goals of the companies exposed to global
competition. Generic simulation model of flexible manufacturing system was developed using
FlexSimr 3D software, then the example data were used to demonstrate the developed model
applicability. “The Ontology on Flexibility” was applied for evaluation of achieved flexibility
of manufacturing system.
Keywords
Industry 4.0, Simulation Modelling, Flexible Manufacturing System, FlexSimr .

Introduction mental process of innovation and transformation in

industrial production (...) driven by new forms of
Digital transformation of the production compa- economic activity and work in global, digital ecosys-
ny under the influence of the development of flexi- tems” [3].
ble manufacturing systems with applying advanced Industry 4.0 (I4.0) is a collective term for the
information and communication technologies (ICT) technology and concept of value chain organisation,
in production automation creates a new paradigm which includes four key elements [4]: Smart Fac-
of production systems, which is defined through an tories, Cyber-Physical Systems (CPS), Internet of
umbrella framework heading as the Industry 4.0 (ger, Things (IoT), and Internet of Services (IoS). Pro-
Industrie 4.0). The term was coined in the German duction in I4.0 can be considered as the intelligent
High-Tech-Strategy 2020 presented during Hannover- flow of the workpieces machine-by-machine in a fac-
Messe Fairs 2011 [1]. Accordingly, to the original tory, supported by real-time communication between
definition [2], Industrie 4.0 refers to the intelligent machines [5]. Collaborative manufacturing, along
networking of machines and processes for the indus- with computer-based distributed management, oper-
try with the help of information and communication ationalizes Industry 4.0 concept [6]. Cyber-Physical
technologies. German Federal Ministry for Economic System is a mechanism controlled or monitored by
Affairs and Energy (BMWi) published new agenda computer algorithms; CPS integrates computation-
for economy digitisation in which expands Industry al (cyber) world and physical world. Physical pro-
4.0 definition to express that it “describes a funda- cesses are a source of data for computational pro-

74
 Management and Production Engineering Review

cesses that generate control signals appropriate to solution to achieve and maintain both the strategi-
the results of calculations [7]. Cyber-physical system- cal and operational goals of the companies exposed
based automation means the integration of homoge- to global competition. Modern manufacturing sys-
neous sources of information from PLC controllers, tems achieve adaptation to volume and product va-
supervisory control and data acquisition (SCADA), riety in three ways [13]: (1) pre-planned generalised
manufacturing execution system (MES), enterprise flexibility of flexible manufacturing systems (FMS),
resource planning (ERP) systems, and streaming (2) limited/focused flexibility to suit a narrower
data from networked sensors placed among and in scope of products variants, or (3) customised flexi-
manufacturing resources. Integrated through time- bility on-demand by physically reconfiguring a man-
stamping, cleaned, and structured data are supplied ufacturing system. In general, the above concepts are
to the enterprise data repository (Data Lake) for covered by an umbrella framework named Change-
Business Intelligence, Big Data, cognitive processing able manufacturing systems (CMS). FMS is a high-
with using artificial intelligence (AI) technologies, or ly automated manufacturing system designed and
traditional data processing purposes. Mass product built-in a priory for pre-defined anticipated prod-
personalisation, flexibility in adapting production ca- uct variants over a certain period without physical-
pacity to demand volume, ability to cost-effective ly changing the manufacturing system itself [1, 14].
unit production on an industrial scale. “Batch size 1” FMSs consist of a set of flexible machines (robot,
production require continuous monitoring and plan- multi-purpose machines or workstations), an auto-
ning to improve production efficiency from an op- matic transport system and a decision-making sys-
erational management perspective. Real-time data tem (scheduler) to decide at each instant (When)
from CPS production systems can be used to drive what has to be done (What) and on which machine
mirrored-in-software physical objects called digital (Where) [15]. FMS implementation in the industry
twins to analyse and simulate real-world environ- is based on the use of a fully computer integrat-
ment and events [8, 9]. A holistic theory of produc- ed manufacturing system consists of a set of com-
tion combines deterministic and cybernetic models puter numerically controlled (CNC) machines, inter-
to enable an integrative comprehension and learning connected by an automated material handling sys-
process in order to predict and control the behaviour tem. The manufacturing flexibility forms present-
of complex production systems [10]. Industrial plants ed in the industry are as follows [16, 17]: Routing
(assets, inventories, production and assembly lines) flexibility; Mix flexibility; Product flexibility; Vol-
need to be designed, monitored and maintained with ume flexibility; Focused flexibility; Assembly flexi-
applying integrated and scalable digital factory mod- bility etc. Terkay et al. [16] introduced The Ontol-
els with multi-level semantic access to all the factory ogy on Flexibility to analyse real production sys-
resources (i.e. assets, machines, workers and objects) tems. According to this approach, we can consider
[11, 12]. each form of flexibility observed in the real-world as
The main aim of the article is to develop a simu- a Compound Flexibility Form obtained by combining
lation model of flexible manufacturing system using some Basic Flexibility Forms defined as the aggre-
FlexSimr 3D software. The flexibility of manufactur- gation of two key concepts: Dimensions and Levels.
ing system was evaluated with applying the ontology There are four basic flexibility dimensions defined
on flexibility. as [16]:
• Capacity – The system can do the same products
The ontology on flexibility at a different scale;
for manufacturing systems • Functionality – The system can do different things
due to different features;
• Process – The system can obtain the same thing
Variety oriented manufacturing driven by mass
in different ways;
customisation manufacturing paradigm in the 90’
• Production planning – The system can change the
of the XX century and the extreme variety of per-
order of execution or the resource assignment to
sonalised production in XXI century results with
do a given set of things.
the co-evolution of products and manufacturing sys-
tems [13]. Designing manufacturing systems match- Each basic flexibility dimension is specified by
ing both production and market requirements be- four attributes: Range, Uniformity, Mobility, and
comes more and more challenging due to the vari- Resolution, which are defined as follows:
ability of demand for a large number of products • Range represents an extension of differences
made in many variants and short lead times. Manu- among the various ways of behaving under a given
facturing flexibility is widely recognised as a proven dimension;

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Management and Production Engineering Review

• Mobility expresses the ease with which it is possi- tions; gives the alternative way for finding problem
ble to modify the behaviour under a given dimen- solution through experiments with a model. A simu-
sion; lation is the imitation of the operation of a real-world
• Uniformity expresses the variability of perfor- process or system over time [18]. Extended defini-
mance of the system due to mobility; tion of computer simulation including four aspects of
• Resolution expresses how close the alternatives are simulation (operations systems, purpose, simplifica-
within the range of given dimensions. tion, and experimentation) is as follows: experimen-
Concept of flexibility levels is related to the real tation with a simplified imitation (on a computer) of
implementation of various form of FMSs [16]: an operations system as it progresses through time,
• Level 1: Flexibility; for (...) better understanding and (or) improving that
• Level 2: Reconfigurability; system [19]. Figure 1 introduces a process diagram of
• Level 3: Changeability. a simulation study presented with Business Process
Due to this model, we can proceed with flexibil- Model Notation (BPMN).
ity analysis for each basic dimension separately and FlexSimr 3D Simulation software package was
establish a level of flexibility for each of them. As used for computer modelling and discrete simulation
a result, we can obtain a detailed characterisation of purposes. FlexSim enables modelling and discrete-
the flexibility of the manufacturing system. time simulation with visualisation in 3D technology,
including virtual reality experience. Realistic graphi-
Research methodology cal 3D animation and extensive performance reports
(customised dashboards) allow through a series of
Computer simulation is intermediate between simulations to track problems and find alternative
theory supplied by analytical means and observa- solutions in a relatively short amount of time. There

Fig. 1. The process of a simulation study.

76 Volume 11 • Number 3 • September 2020

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are three tools available to employ optimisation set of tools to perform several operations. Automated
methods for simulation modelling with FlexSim [20]: guided vehicles (AGVs) are used for internal trans-
1) Simulation Experimenter Control tool with portation and logistics purposes. AGVs use fixed
build-in OptQuest (requires an additional license) routes.
that solves problems with evolutionary algorithms, Let consider an example of a production cycle of
2) Flexiscript (internal script language) to batch 120 products as a mix of three types. The specifica-
processing, exchange of data with third-party soft- tion of product routing due to the type of product is
ware and advanced customisation; 3) external DLLs given in Table 1.
(dynamic-link libraries) to combine FlexSim and Machining unit times for each technological op-
Matlab (or Scilab) to handle linear programming eration performed in a particular cell on a specific
optimisation or simulation analysis. Since the year type of product are given in Table 2.
2017, the emulation tool to control 3D models with
simulated programmable logic controllers (PLC) was Table 1
introduced to FlexSim as well as the interface for ex- Product routing.
change of all sensors and controls PLC data directly Product type Machine used
(through serial communication protocol Modbus) or Type 1 M1, M2, M3
with OPC communication server. It makes FlexSim Type 2 M2, M1, M3
digital-twin ready software [21]. Type 3 M3, M2, M1

Problem statement Table 2

Machining unit times [s].

The reference manufacturing system consists of Machine

Product type
production resources, storage spaces including buffer M1 M2 M3
slots, transport systems to support raw material sup- Type 1 15 10 11
ply, and circulation of work-in-progress parts. Two Type 2 8 13 5
problems are investigated during the modelling pro- Type 3 12 13 11
cess with FlexSim: implementation of flexible rout-
ing, transport system topology and control strategy. Computer model
There are three cells M1, M2, M3 – each equipped
with computer numerical control (CNC) machining The screenshot of the simulation surface captured
center that combining drilling, milling, and boring during simulation with a developed model of the ref-
operations. Each cell is provisioned with a unique erence production system is shown in Fig. 2.

Fig. 2. A view of the model during simulation.

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Management and Production Engineering Review

The Cellular manufacturing approach was used controlled using RFID tags and transponders. RFID
for the layout of the reference production system. tags extend physical objects with a digital compo-
Ushape topology was applied with combining CNC nent that is instantly available for computer control
machining centers and storage fields for achieving systems via networked transponders placed in a man-
proximity to reduce wasted motion. It is a suitable ufacturing system. By analogy, user-defined data as-
solution for low volume and high mix job shops. Mod- signed to flowitems or objects are global (like global
els developed in graphically oriented simulation envi- variables or attributes in programming languages)
ronment of FlexSim consist of basic elements, called for the control mechanism of simulation.
objects, that represent equipment, or performs a spe- Modelling and simulation of the variability of the
cific function on the simulation surface. There are al- manufacturing process were achieved by applying
so flow elements, called flowitems [20], that interact customised control to pulling and pushing the logic of
with objects in a simulation. Flowitems may have fixed resources, which represent storage fields, buffer-
user-defined data on them called labels. Fixed re- slots, and CNC machining centers. Fixed resources
sources are the objects that send, receive, and per- have a built-in mechanism for implement topology
form activities/operations on flowitems. A list of of connections to move flowitems within the mod-
fixed resources employed in the model is given in el. There are input and output ports to connect ob-
Table 3. jects. Storage field Raw is connected with buffer-slots
M1 In, M2 In, M3 In to supply CNC cells with raw
Table 3 material. Buffer-slots M1 Out, M2 Out, M3 Out are
Fixed resources.
connected with buffer-slots M1 In, M2 In, M3 In to
Objects names Type Description
move work-in-progress and finally with storage field
Orders Source Represents produc- Finished. It is assumed that flowitems coined to the
tion orders release
model as production orders are instantly (in zero
Raw Queue Represents storage
field for raw mate- time) transferred to the object Raw to represent raw
rials due to released materials in the storage field for production orders.
orders Dynamic routing for the manufacturing process
M1, M2, M3 Processor Represent CNC ma- was implemented as data-driven control with us-
chining centers ing GlobalTable objects of FlexSim software. Object
M1 In, M1 Out, Queue Represent input Routing was created to store product routing given
M2 In, M2 Out, and output buffer-
M3 In, M3 Out slots for each CNC in Table 1 (Fig. 3).
machining centers
Finished Queue Represents storage
field for finished
products

The variability of the product was introduced Fig. 3. A screenshot of object Routing content.
to the model through the appropriate definition of
flow elements. Object Orders creates and releases The current destination for flowitem during sim-
120 flowitems of three types vivid as cuboids with ulation is on the intersection of type of the product
three different colours. Flowitems represent a mix of (row) and the current step in the manufacturing pro-
production orders for three types of products. Each cess (column). The current step is incremented by
flowitem has two user-defined labels: label “Type” one after finishing operation in CNC machines (M1,
with a value assigned with the duniform distribu- M2, M3) thanks to Triggers mechanism available in
tion strategy from the set {1, 2, 3}; label “StepNr” properties of fixed resources in FlexSim (Fig. 4).
with initiation value equals 1. Label “Type” stores
a numerical code of product type. Label “StepNr”
stores the current step of the manufacturing process
for each flowitem.
User-defined information sticking to flowitem ob-
jects can be considered as a functional model of ap-
plying radio-frequency identification (RFID) tech-
nology in manufacturing systems. The primary func-
tion of the RFID is automated identification and da-
ta capture. According to the Industry 4.0 paradigm,
the flow of the work-in-progress can be tracked and Fig. 4. A screenshot of object M1 properties.

78 Volume 11 • Number 3 • September 2020

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Properties of objects Raw, M1 Out, M2 Out, routes: smaller, placed inside of U-shape cell and
M3 Out were customised with code written in Flexis- bigger, outside. The inner AGV is moving on mini-
cript programming language. Developed code imple- mal space and is dedicated to work-in-progress trans-
ments data-driven control for pushing flowitems due portation. The outer AGV serves both for raw ma-
to identified topology of the current object’s output terials and semi-products motion. The proposed so-
ports (Fig. 5) and user-defined data of the current lution aims to increase flexibility and throughput of
flowitem. cellular manufacturing.
Configuration of the AGV transportation system
is supported in FlexSim with a dedicated AGV mod-
ule, including the possibility of implementing adap-
tative decision strategies for pick-up and drop-off
operations. Thanks to that, in terms of flexibility,
the transportation system can match manufactur-
ing workstations. There are two Task Executors ob-
Fig. 5. A screenshot of object M1 Out properties.
jects, named AGV1 and AGV2, used in the devel-
oped model. Both were configured with the same pa-
Code snippet is as follows: rameters (Fig. 7).
/**
Send to Port
Custom Code
*/
Object item = param(1);
Object current = ownerobject(c);
Variant tableID = ”Routing”;
Table table = Table(tableID.as(string));
Variant row = item.Type;
Variant col = item.StepNr;
string NextMachine = table[row][col];

for(int i=1; i <= current.outObjects.length; i++) {

Object ConnectedPort = current.outObjects[i];
if(NextMachine == getname(ConnectedPort)) {
return i;
}
}

Data-driven control with using GlobalTable ob-

ject UnitTime was also used to customise the unit
time of operations performed in CNC machining cen-
ters due to product type (Fig. 6). Fig. 7. A screenshot of object AGV1 properties.

The Triggers mechanism available in properties of

AGV was used to control unloading due to content
in FlexSim (Fig. 8).

Fig. 6. A screenshot of object UnitTime content.

The transport subsystem of flexible manufactur-

ing systems should support the movement of raw ma-
terials, semi-products, finished products, tools, post-
production waste etc. Using two automated guide
vehicles (AGV) in the developed model is proposed.
AGVs are moving on two separate ellipsoids fixed Fig. 8. A screenshot of object M1 properties.

Volume 11 • Number 3 • September 2020 79

Management and Production Engineering Review

If AGV carries multiple flowitems, then a pre-

defined trigger would cause to unload all flowitems
intended for a current destination before moving on.

Model optimisation

The developed model of reference production sys-

tems was used in a series of simulation experiments. Fig. 10. A screenshot of the simulation experiment con-
The basic run of simulation with initial data assumed trol.
during the model development produces relevant da-
ta collected and presented on the simulation dash-
board shown in Fig. 9. It was assumed that maxi-
mum load (capacity) of AVGs is 120 pcs of flowitems.
Overall cycle time for production 120 units of the
mixed product takes 2203.31 [s].
FlexSim’s Experimenter was employed to con-
duct optimisation of the maximum load of AVGs.
The two independent variables were defined:
variable1 – MODEL:/AGV2>variables/maxcontent;
variable2 – MODEL:/AGV2>variables/maxcontent.
Respectively, Finished products vs Time was
pointed out as Performance Measure. Then appro-
priate optimiser experiments were designed and run
for 2203.31 [s] (Fig. 10).
The obtained results of optimisation are shown
in Fig. 11. Fig. 11. A screenshot of FlexSim’s optimiser results.

Fig. 9. A screenshot of the dashboard for a basic simulation run.

80 Volume 11 • Number 3 • September 2020

 Management and Production Engineering Review

Fig. 12. A screenshot of the dashboard for simulation run after optimisation.

Among the best solutions, the Solution 13 was and Production Planning flexibility. The model can
the most appropriate, because of giving the lowest simulate manufacturing of the same products at
capacity for both of AVGs (Table 4). a different scale; it can adjust different production
conditions, particularly batch size, level of produc-
Table 4 tivity, etc. The functionality of CNC machining de-
Optimisation’s best solutions. termines a wide spectrum of features and variety of
Solution ID Variable 1 Variable 2 products according to available tools set pre-defined
1 61 61 for each CNC. The full flexibility in this dimension to
7 118 69 extend the diversity of the products can be achieved
11 85 89 through the implementation of tools supply due to
12 33 84 service requests from particular CNC machine trig-
13 16 31 gered by information carried by particular flow item
15 120 71 in the FMS. The system can obtain the same thing
16 63 62 differently due to functionality, but flexibility in this
19 120 69 dimension is also limited: model dose does not imple-
ment adaptative routing strategy to accommodate to
temporary machine out of service or balance utilisa-
The final run dashboard for simulation with in- tion of the CNC machining centres. It requires both
troducing optimised maximum capacity of AVGs is extended Functionality flexibility and implementa-
shown in Fig. 12. tion of more appropriate algorithms for manufactur-
ing execution control. Production planning flexibility
Flexibility analysis of the model is partially supported by default with FlexSim built-
in simulation control mechanism. Advanced queuing
The presented computer simulation model of strategies requires the implementation of customised
FMS consists of CNC machining centres intercon- algorithms.
nected with AGV transportation system and with The analysis of the flexibility of the reference pro-
data-driven manufacturing execution mechanism im- duction system model due to the flexibility levels is
plemented delivers Capacity, Functionality, Process summarized in Table 5.

Volume 11 • Number 3 • September 2020 81

Management and Production Engineering Review

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