A Study of Implementing Integrated Manufacturing System and Project Management System in a Manufacturing Industry

Tan, Thin Xuan (2022) A Study of Implementing Integrated Manufacturing System and Project Management System in a Manufacturing Industry. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

The term"Industry 4.0" is becoming frequently used. The I4.0 principle is being attempted to be used in a variety of domains, including home appliances or smart homes, smart manufacturing, and many more. This is a collaborative with a manufacturing company. It is a case study of a corporation’s I4.0 implementation, namely the digital manufacturing of the production operation, in which automation and machine-to-machine integration are key activities in their implementation programme. Powerwell is a company that specialises in the design, manufacture, and sale of power distribution systems. The purpose of this project is to concentrate on the following primary areas: the implementation of a product lifecycle management (PLM) system, the automation system, and the research of its impact. This project offered a framework that provides an overview of the technique to be used when carrying out project activities in order to achieve the specified objectives. It involved determining the company’s needs, creating a technique for retrofitting punching and shearing machines, putting the project life cycle management operational processes in place, and gathering data. Powerwell has used this project to put the shearing machine retrofitting solution into practise. Hardware-wise, a limit switch has been configured as a counter to automatically count the number of outputs. In order to alert the engineer and operator to any process or quality issues, an additional andon light is installed. The results of the retrofitting of the shearing machine show that, after adopting the I4.0 system, the analysis showed that the % of average OEE has increased from 43.23% to 46.74% for small parts, an increase from 37.76% to 38.42% for medium parts. The large part has shown a significant increase of OEE average, the values has increased from 31.90% to 44.03%. Lastly, Powerwell has incorporated the 3DEXPERIENCE PLM system. The results of implementing 3DX in Powerwell show that production efficiency has increased by decreasing the overall number of errors that occurred, the number of change requests that were made, and the amount of time needed for drawing approval, design review, and manufacturing. These improvements were made after using 3DX, and they are 42.7%, 11.5%, 13.9%, and 25.0%, respectively. In short, all Powerwell personnel will be completely aware of the benefits and features of the product, allowing them to take full advantage of all of its potential. Production engineers may predict and solve problems with the punching and shearing procedure using real-time data, which improves the organization’s productivity and efficiency. Additionally, there are less instances of human error when collecting data. The shortening of the product lifecycle is thus achieved by enabling faster output, improved data integrity, and greater scalability through the integration of many digital platforms to manage engineering projects