Enhancing Inventory Accuracy through Stock-Taking in Production Monitoring Systems for Workstations
Abstract
Industry 4.0 promotes the use of Cyber-Physical Systems (CPS) to improve production efficiency through seamless data exchange between virtual and physical components. However, in manual labor-driven environments, discrepancies between virtual stock data and actual material usage can create challenges for accurate production monitoring. This study focuses on addressing these discrepancies by integrating a stock-taking method into a production monitoring system. The system was implemented in an air conditioning train car assembly workshop, where differences of 2–3% between the predicted virtual stock and real-world quantities were identified. By applying the stock-taking method, virtual data were recalibrated to reflect real-time stock levels more accurately. The system's ability to track material usage and losses allowed for significant improvements in inventory accuracy, with immediate updates provided to the CPS. This approach minimizes human error in manual operations, ensuring that material predictions are more aligned with actual consumption. The results show that the implementation of the stock-taking method reduced the margin of error in stock predictions, improving overall production decision-making. These findings suggest that this method can enhance stock accuracy in manufacturing sectors, particularly in developing countries where manual labor is predominant. This study provides practical implications for optimizing material management and reducing production costs by leveraging CPS integration with stock-taking methods.
Keywords
Full Text:
PDFReferences
A. Raj, G. Dwivedi, A. Sharma, A. B. Lopes de Sousa Jabbour, and S. Rajak, “Barriers to the adoption of industry 4.0 technologies in the manufacturing sector: An inter-country comparative perspective,” Int J Prod Econ, vol. 224, p. 107546, Jun. 2020, doi: 10.1016/j.ijpe.2019.107546.
G. N. Schroeder, C. Steinmetz, R. N. Rodrigues, R. V. B. Henriques, A. Rettberg, and C. E. Pereira, “A Methodology for Digital Twin Modeling and Deployment for Industry 4.0,” Proceedings of the IEEE, vol. 109, no. 4, pp. 556–567, Apr. 2021, doi: 10.1109/JPROC.2020.3032444.
S. S. Kamble, A. Gunasekaran, and S. A. Gawankar, “Sustainable Industry 4.0 framework: A systematic literature review identifying the current trends and future perspectives,” Process Safety and Environmental Protection, vol. 117, pp. 408–425, Jul. 2018, doi: 10.1016/j.psep.2018.05.009.
E. A. Lee, “Cyber Physical Systems: Design Challenges,” in 2008 11th IEEE International Symposium on Object and Component-Oriented Real-Time Distributed Computing (ISORC), IEEE, May 2008, pp. 363–369. doi: 10.1109/ISORC.2008.25.
Y. Wang and Z. Wu, “Model construction of planning and scheduling system based on digital twin,” The International Journal of Advanced Manufacturing Technology, vol. 109, no. 7–8, pp. 2189–2203, Aug. 2020, doi: 10.1007/s00170-020-05779-9.
V. Krueger et al., “Testing the vertical and cyber-physical integration of cognitive robots in manufacturing,” Robot Comput Integr Manuf, vol. 57, pp. 213–229, Jun. 2019, doi: 10.1016/j.rcim.2018.11.011.
H. Kivrak, M. Z. Karakusak, S. Watson, and B. Lennox, “Cyber–physical system architecture of autonomous robot ecosystem for industrial asset monitoring,” Comput Commun, vol. 218, pp. 72–84, Mar. 2024, doi: 10.1016/j.comcom.2024.02.013.
Z. Wang, J. Zhou, and H. Wang, “Cyber-Physical System Enabled Path Planning Simulation for Collaborative Industrial Robots,” in 2022 IEEE 25th International Conference on Computer Supported Cooperative Work in Design (CSCWD), IEEE, May 2022, pp. 711–716. doi: 10.1109/CSCWD54268.2022.9776046.
S. Raharno and V. S. Yosephine, “Intelligent flexible assembly system for labor-intensive factory using the configurable virtual workstation concept,” International Journal on Interactive Design and Manufacturing, vol. 18, no. 1, pp. 465–478, Jan. 2024, doi: 10.1007/S12008-023-01567-3.
S. Raharno and G. Cooper, “Jumping to industry 4.0 through process design and managing information for smart manufacturing: Configurable virtual workstation,” Industry 4.0 - Shaping the Future of the Digital World - Proceedings of the 2nd International Conference on Sustainable Smart Manufacturing, S2M 2019, pp. 47–51, Oct. 2019, doi: 10.1201/9780367823085-9.
S. Raharno, M. Z. Febriansyah, and Y. Y. Martawirya, “Development of operation scheduling systems at workstations with the autonomous distributed manufacturing systems (ADiMS) concept,” 2023, p. 110002. doi: 10.1063/5.0105181.
J. Qin, Y. Liu, and R. Grosvenor, “A Categorical Framework of Manufacturing for Industry 4.0 and Beyond,” Procedia CIRP, vol. 52, pp. 173–178, 2016, doi: 10.1016/j.procir.2016.08.005.
T. Lins and R. A. R. Oliveira, “Cyber-physical production systems retrofitting in context of industry 4.0,” Comput Ind Eng, vol. 139, p. 106193, Jan. 2020, doi: 10.1016/j.cie.2019.106193.
J. Barbosa, P. Leitão, E. Adam, and D. Trentesaux, “Dynamic self-organization in holonic multi-agent manufacturing systems: The ADACOR evolution,” Comput Ind, vol. 66, pp. 99–111, Jan. 2015, doi: 10.1016/J.COMPIND.2014.10.011.
M. Moufaddal, A. Benghabrit, and I. Bouhaddou, “A Cyber-Physical Warehouse Management System Architecture in an Industry 4.0 Context,” 2021, pp. 125–148. doi: 10.1007/978-3-030-51186-9_9.
F. Basile, P. Chiacchio, J. Coppola, and D. Gerbasio, “Automated warehouse systems: A cyber-physical system perspective,” in 2015 IEEE 20th Conference on Emerging Technologies & Factory Automation (ETFA), IEEE, Sep. 2015, pp. 1–4. doi: 10.1109/ETFA.2015.7301597.
L. Piardi, P. Costa, A. Oliveira, and P. Leitão, “MAS-based Distributed Cyber-physical System in Smart Warehouse,” IFAC-PapersOnLine, vol. 56, no. 2, pp. 6376–6381, 2023, doi: 10.1016/j.ifacol.2023.10.826.
DOI: http://dx.doi.org/10.22441/ijimeam.v6i3.29151
Refbacks
- There are currently no refbacks.
Copyright (c) 2024 Muhammad Zulfahmi Febriansyah, Sri Raharno, Harry Prayoga Setyawan
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
INDEXED IN
Publisher Address:
Universitas Mercu Buana
Program Studi S2 Teknik Mesin
Jl. Meruya Selatan No. 1, Jakarta 11650, Indonesia
Phone/Fax. (+6221) 5871335
Email [email protected]
Homepage http://teknikmesin.ft.mercubuana.ac.id/
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.