=Paper=
{{Paper
|id=Vol-2063/lidari-paper1
|storemode=property
|title=Internet of Things (IoT) for Dynamic Change Management in Mass Customization
|pdfUrl=https://ceur-ws.org/Vol-2063/lidari-paper1.pdf
|volume=Vol-2063
|authors=Chin Yin Leong,Ichiro Koshijima
|dblpUrl=https://dblp.org/rec/conf/i-semantics/LeongK17
}}
==Internet of Things (IoT) for Dynamic Change Management in Mass Customization==
https://ceur-ws.org/Vol-2063/lidari-paper1.pdf
Internet of Things (IoT) for Dynamic Change Management in
Mass Customization
Chin Yin Leong Ichiro Koshijima
Nagoya Institute of Technology Nagoya Institute of Technology
Aichi-ken, 466-8555 Aichi-ken, 466-8555
Nagoya, Japan Nagoya, Japan
cyleong1984@yahoo.com koshijima.ichiro@nitech.ac.jp
ABSTRACT 1 INTRODUCTION
Mass customization manufacturers always find it challenging to Mass customization refers to the process to deliver wide-market
produce high quality products at the lowest possible cost with min- goods and services, which are tailored to satisfy the specific needs
imal lead-time. The challenge is even more severe for these man- of the customers. The implementation of this concept, initially in-
ufacturers when it comes to their survival in today’s dynamically troduced by Davis [2], has been supported fundamentally through
changing market where customers drive the process by searching theoretical and empirical studies [3–9] . Although many companies
for the information they need in order to create their own products have operated based on this business model, only few managed
and services [1]. As customer-centric mass customization manu- to achieve success [4]. This is because mass customization manu-
facturers, organizations should increase their change-adaptability facturers face difficulties to effectively execute change process to
to maintain their competitive edge in the ever-growing and ever- optimize their market and to meet the diverse product demands
changing market. A successful mass customization strategy should by their customers. The change process for mass customization
involve developing production lines that are highly agile to recon- should be very sophisticated to be implemented mainly due to the
figuration, leading towards reduced setup time in order to cope complexity of equipment and labor used along with production
with the expected or unexpected changes to the production process. lines [10], limiting the potential for mass customization. There is
Besides this, the importance of ‘zero mistakes’ in all activities along much literature published related to mass customization. However,
the value-creation process should also be prioritized. Therefore, the literature related to change management for mass customiza-
the research aims to investigate the feasibility of IoT application tion is scarce. On top of this, Construction Industry Institute (CII)
towards effective change implementation for mass customization research team also found out that there are no formal processes
in a dynamic manufacturing environment. This paper presents an to assure that change in a mass customization setup can be prop-
architecture for dynamic change management that could provide a erly implemented [11]. Thus, the potential of mass customization
new competitive strategy for mass customization manufacturers. A implementation cannot be fulfilled.
set of IoT devices is used as illustrative examples for the dynamic In this modern dynamic changing market, customer orders can
change management implementation in mass customization manu- often vary in any moment of time even after the components/parts
facturing. The architecture of such dynamic change management have already been delivered to the production line. Therefore, mass
is to turn operation data in dynamic form and link all together, customization manufacturers must always be able to bring essential
permitting them to integrate rapidly in the most optimized com- change ability of manufacturing processes to a higher level to assure
bination or sequence required to perform change instantly. This effective mass customization environment. They should be able to
architecture allows for well-informed real-time decision-making provide quick response and to swiftly adapt to product/process
and more importantly, provides the manufacturers with the ability change to create a competitive edge over their competitors. Not
to predict problems before they occur. capable of doing so would result in them drowning in the ever-
growing changes of their market.
KEYWORDS Change requirements from customers are forcing mass cus-
Mass Customization, Internet of Things, Change Management tomization manufacturers to redesign and to modify product fre-
quently. Typically, such change data is expected to be sufficient in
supporting certain personnel in handling various mass customized
products/process. However, traditional change process procedures
commonly used in production lines interfere with the factory’s
dynamic environment, as the information associated with the mass
customization process is enormous and complex. Therefore, an
Permission to make digital or hard copies of part or all of this work for personal or
classroom use is granted without fee provided that copies are not made or distributed
effective operating system in factory floor is required to ease the
for profit or commercial advantage and that copies bear this notice and the full citation implementation of the efficient change process in a mass customiza-
on the first page. Copyrights for third-party components of this work must be honored. tion environment. An adequate management system should be
For all other uses, contact the owner/author(s).
© 2017 Copyright held by the author/owners. prepared for the relationships and the interactions among tasks,
SEMANTiCS 2017 workshops proceedings: LIDARI, September 11-14, 2017, functions, departments, and organizations, which promotes the flow
Amsterdam, Netherlands of information, ideas and integration of dynamic change process.
LIDARI2017, September 11, 2017, Amsterdam, Holland Chin Yin Leong and Ichiro Koshijima
1.1 Conventional Change Process in a Mass plans and facility allocations to avoid significant impact on the
Customization Environment productivity time line.
The overview of the conventional change process in mass cus-
1.2 Enabler for Efficient Change Process in
tomization organization is showed in Figure 1. This shows that
conventional change process practice is associated with certain Mass Customization
difficulties and constraints. The formal use of conventional change Changes will not only affect production planning but will also influ-
process is a centralized structure with extra layers in the hierarchy. ence cost and scheduling, directly or indirectly. When the impact of
When a change is triggered by customer, the actual change process change can be predicted, then only time, cost and resource can be
in production floor will only be started when the approval docu- allocated to affect the change. Well-managed change is important
ments have been released. The impact of change will be severe if to avoid unwanted problems. Therefore, mass customization manu-
it occurs when the production has already started. In order to get facturers must have the ability to respond to change effectively to
the documents released from the engineering team, local operating minimize any form of negative impact on the production. Imple-
team could have missed the golden hours to prepare for the required menting effective change process is a challenge in mass customiza-
change, possibly causing late delivery of the product. Another issue tion manufacturing mainly due to the complexity of equipment and
that arises in the change process is the lack of operational data that labor used along the production line [10].
is connected to enterprise applications. Neither the R&D team nor With the unveiling of the fourth industrial revolution or Industry
the operation team has the actual manufacturing data when the 4.0 in recent years, Internet of Things (IoT), as one of the key ele-
change is taking place. ments for industry 4.0, has become a hot topic among industrialist.
IoT refers to physical devices that are inter-networked with elec-
tronics, software, sensors, actuators and network connectivity. The
internetwork created enables these physical devices to receive and
exchange essential information in real-time. Internet technologies
could be the key enabler for efficient dynamic change management
in mass customization manufacturing. Internet technologies could
prove to be essential in setting up a dynamic network that is more
than capable of handling high-intensity information for efficient
manufacturing planning and control system in real-time for mass
customization manufacturers. This will provide visibility and con-
trol of the factory floor by connecting human operators, sensors
and operations data across multiple machines and lines, allowing
Figure 1: Centralized change process structure for cus- for the ability to monitor performance and to identify inefficien-
tomized product cies along the production line. The potential of IoT application in
Industry 4.0 has lightened up once again the feasibility of mass
customization. Therefore, this research aims to investigate the fea-
Besides this, human operators, who are disconnected from rele- sibility of IoT application towards effective change implementation
vant and essential production related electronic data (product data for mass customization in a dynamic manufacturing environment.
management), will be confused by the delivery of new components This paper introduces the primary/fundamental concepts and
before any paper-based operating manuals are provided to them. technologies of IoT that could benefit dynamic change management
The human operators are constraint from interacting with avail- in mass customization manufacturing. This paper also proposes an
able documents that is pre-formatted. Besides, the process to get architecture of dynamic change management, showing all operating
the documents released is often associated with long lead times, modules that are connected for well-informed real-time decision-
which is caused by extensive document management. This is time making to provide the ability to predict problems before they occur
consuming to check-out the old documents and to prepare new in factory floor. The development of IoT for industrial application
documents to send for approval. Centralized structure for change can be extended to a higher skill base for information technology
process can be efficient if the manufacturing environment is very and computer-integrated manufacturing in order to implement
stable and the parts changes very little. The bureaucracies of this dynamic change process in mass customization factory floor. This
kind of change process are static and unresponsive to changes in will help to achieve sustainable competitive advantage for mass
the environment that have limited the flexibility and speed of local customization manufacturers in the ever-growing changes market.
decision-making.
On top of that, human operators, in a mass customization sys-
tem, tend not to question the basic design of the product that they
are assigned to assemble. They would assume that it is what the
customers want. This will lead to a high tendency of errors in as-
sembly of the changed components, which might result in costly
reworks and delays. As a consequences, OEM manufacturers could
face difficulties in order to identify possible disturbances or changes
in the need for the changed component and to readjust production
Internet of Things (IoT) for Dynamic Change Management LIDARI2017, September 11, 2017, Amsterdam, Holland
2 PARADIGMS FOR DYNAMIC CHANGE
MANAGEMENT
A dynamic change management approach is adopted alongside
with the integration of internet technologies in order to implement
an effective mass customization environment. A dynamic change
management architecture composes of three components, namely:
i Dynamic linkage in operating field
ii Real-time environment
iii Monitoring and early error detection
2.1 Dynamic linkage in operating field
One of the issues limiting the success of mass customization in
(a)
change processes is the lack of an integrated network to avoid man-
ufacturing data loss along the production line. There is some useful
computer-aided engineering software for engineering change man-
agement. However, the electronic data is often disconnected from
the human operators, who are working on the front line of pro-
duction. On the other hand, automated systems cannot effectively
and efficiently distribute planning and control tasks to human op-
erators on the factory floor, who have the first-hand experience
of the production process and could influence the process by their
actions [6]. Hence, a participation of human operator in dynamic
change management cannot be neglected. To complete the change
activities, the human operator needs information or collection of
data and requirements. However, communication methods between
equipment and human operators are still cumbersome. This is be- (b)
cause human operators’ hands will most probably be occupied with
product assembling task.
Internet of Things (IoT) presents an interesting approach to effec-
tively integrate numerous connected devices that rely on sensory,
communication, networking, and information processing technolo-
gies with interface processors to form a global dynamic network
infrastructure [20]. Myo armband has been used here to study
human-computer interaction in the factory floor. Myo armband is
a wearable technology that reads electrical activity of user’s mus-
cles to control a robot with gestures and motion under hands-free
environment. The interaction of controlling Parrot Bebop 2 by the
gestures from Myo armband is presented in Figure 2. Gestural inter-
action devices like Myo armband could be beneficial for the factory
floor as it can be used without an external static sensor. Thus, the (c)
human operator will have the freedom to still move around while
performing their routine work properly. This kind of gestural in-
teraction device provides an advantage where the human operator
is not required to carry any mechanical devices to remote control
equipment from a certain distance. Gestures are instinctive, human
beings are skilled, and little thought is needed [21], and will allow
for the human operator to focus on the production task itself.
Such gestural interaction device will enable human operators to
remotely control computers and machines in the factory plant for
information support during occurrences of an unexpected change
task. Application of gestural interactions via Myo armband will sig-
nificantly improve the efficiency of dynamic change management
implementation. With the assistance of such advanced wearable
technologies, human operators can now fulfill their potential by (d)
taking on the role as strategic decision-makers and flexible problem-
solvers on the factory floor [22]. Figure 2: Remote control of drone using gestural commands
based on Myo armband
LIDARI2017, September 11, 2017, Amsterdam, Holland Chin Yin Leong and Ichiro Koshijima
Another challenge as discussed above with relation to dynamic a multitude of data sources that need to be monitored and con-
change management for mass customization manufacturers in- trolled in the manufacturing system. Connecting human operators,
volves handling of higher-intensity information of the production machines and smart devices in the factory will generate big data.
processes. The higher-intensity information refers to the raw data The big data needs smart infrastructure to capture, to manage and
input, originating from a multitude of data sources that need to to process them within an acceptable time frame [20]. The emerg-
be monitored and controlled in the manufacturing system. With ing and developing technology of cloud computing is considered
growing number of smart devices used in the factory floor, it is as a promising computing paradigm for this big data.
essential to establish high efficiency ways to tie into already ex- Mass customization can utilize numerous cloud platforms for big
isting manufacturing information technologies through the use data management such as ThingWorx, Google Cloud, and Bosch IoT
of standardized, platform-independent interfaces such as OPC-UA suite. Capitalizing on IoT for dynamic change management requires
[22]. In addition, most of the smart devices, such as drones, Myo network infrastructure as IoT will generate an unprecedented vol-
and Leap Motion, do not have sufficient computational power to ume and variety of data in the factory floor. Internet-based comput-
process the sensor signal carrying the raw input data. Thus, an ing is required to provides shared computer processing resources
interface processing device, such as laptop, tablet or raspberry PI, and data to multiple computers and other devices on demand. Cloud
will have to be employed in the production floor to process the computing is not enough for real-time data processing due to its
raw input from the aforementioned smart devices. The processed inherent problems, such as unreliable latency, lack of mobility sup-
raw input data will then only be possible to be integrated into the port and location-awareness [? ]. Fog computing is a new kind of
manufacturing system. network infrastructure that provides resources for services at the
edge of the network. The fog computing extends the cloud com-
puting to be closer to IoT devices through provisioning, trimming
2.2 Real-time environment
and pre-processing the data before sending to the cloud. With the
In a modern dynamic changing market, customer orders can often right tools, mass customization manufacturers will be capable of
vary in any moment of time even after the components parts have managing the manufacturing data for greater agility in the change
already been delivered to the production line. Therefore, mass cus- process.
tomization manufacturers have to be highly agile in responding to
the requested changes in order to avoid any potential slowdowns
or bottlenecks across the production line. Implementation of a dy-
2.3 Monitoring and early error detection
namic network linking equipments and human operators provides
the means to take appropriate actions during a dynamic change Mass customization capability of a firm is determined by its ability
process. Forewarned is forearmed, and the critical factor that deter- to produce customized products with cost effectiveness, volume
mines the effectiveness of project change control is how fast the effectiveness, and responsiveness [8]. Errors in producing custom-
right people is aware of the change and takes necessary actions made products will be extremely costly as compared to errors in pro-
accordingly. ducing mass products. This is because the custom-made product is
Changes in manufacturing conditions could be executed quickly unlikely to be sold to others aside from the customer who requested
by relying on latest production related information. Thus, the adop- for it. Apart from cost, mistakes and errors during production could
tion of real-time capability will provide manufacturers with real- cause late delivery of product to customers. Not to mention, these
time information to make key manufacturing decisions. To execute could cause the customers to lose confidence towards the mass
a successful change strategy, production line needs to be proac- customization manufacturers. Thus, a closed monitoring and early
tive in reconfiguring and reducing setup time needed to cope with error detection method is critical to ensure the customized product
changes in production. Greater planning capability is one of the is correctly built and delivered on time. Deployment of a system
important criterion for mass customization manufacturers to foster that stresses the importance of ‘zero-mistakes’ in production is
dynamic changes. Real-time information platforms provide greater indispensable for a dynamic change in mass customization manu-
planning capability by allowing manufacturers to view up-to-the- facturing [15]. Therefore, the last component for effective dynamic
minute production progress in factory-floor. change management requires monitoring and early error detection
Planners and managers can use the production progress data along the production line of a mass customization manufacturer.
to create better production plans whenever unpredicted changes In recent years, researchers used RFID technology to identify,
are triggered. They can also identify disturbances or changes in trace and monitor objects locally or globally [12, 24]. However,
the need for parts and readjust production plans or facility alloca- there is a drawback to RFID systems where they require human op-
tions before these changes significantly impact productivity. Real- erators to tag and to read the tag manually. These will pose certain
time operation data executed in the factory can then be imme- difficulties to implement this technology in large scale involving
diately recorded in electronic documents for reporting, eliminat- complex products, such as vehicle or heavy-duty equipment produc-
ing/reducing errors associated with human factors. This will save tion [24]. On top of this, the cost of RFID tags is another challenge
the time to digitize the data collected in paper forms [12]. for manufacturers who produce large-scale products that make up
Another challenge with relation to dynamic change manage- thousands of parts. The work in progress visibility and traceability
ment for mass customization manufacturers involves handling of could be further improved through integration of more advanced
high-intensity information of the production processes. The high- IoT technologies to form an autonomous surveillance system for
intensity information refers to the raw data input, originating from early warning.
Internet of Things (IoT) for Dynamic Change Management LIDARI2017, September 11, 2017, Amsterdam, Holland
Using modern smart surveillance systems that can be integrated Each component is associated with a set of unified requirements.
into computer vision and artificial intelligence community, these For dynamic linkage in operating field, the dynamic operating data
will allow for real-time monitoring and detection, which is essential plays an important role as information support for the change pro-
for dynamic change management in mass customization manufac- cess. The efficiency of information support to human operator is
turing. With computer vision technology, video captured through improved by the use of human-computer interaction devices that en-
the factory’s surveillance system can be transformed into digitized able human operator to remote control electronic devices or robots
data for object detection and recognition [25]. The method will under hand free environment. This has to be supported by data
allow for object detection and will capture manufacturing data for interface process devices to complete the data integration activities.
seamless real-time synchronization with material and associated Communication technology, fog computing and cloud computing
information flow on the factory floor. Using object recognition tech- are fundamental elements to provide real-time platform in dynamic
nology, it will improve work in progress visibility and traceability change management. Efficient change implementation need mon-
by enabling real-time adaptive decision mode to optimize opera- itoring, thus autonomous surveillance and visual computing are
tional logistics [12]. The data generated from this visual computing must have elements for this paradigm.
system can be integrated into existing manufacturing system based The approach for IoT deployment in dynamic change manage-
on the provided data interface platform. ment for a mass customization manufacturer is illustrated in figure
For automated cameras to be effective in error detection during 4. The combined platform to gather and consolidate changes of data
manufacturing processes, the viewing range of the camera has to be across lines and locations are summarized in the given diagram.
able to cover the whole factory floor. Implementing closed-circuit
television (CCTV), which has limited camera viewing, could be
costly. This is because during product assembly, the camera views
could be impeded by different product orientations. Therefore, mass
customization manufacturer could adopt unmanned aerial vehi-
cle (UAV) equipped with a camera be used to provide substantial
flexibility as compared to CCTV. The video stream from UAV is
connected to the computer in real-time. UAV does not require a
mounting platform and can fly to any location, thereby able to take
photographs or real-time videos from a range of areas inside the
factory. The UAV can also fly autonomously without colliding with
obstacles and has faster speed as compared to ground robots [26].
This is helped by the technology advancements where latest UAV
is also equipped with indoor navigation systems for autonomous
navigation in an indoor environment. The UAV can also be pro- Figure 4: IoT deployment in dynamic change management
grammed to perform scheduled flight for inspection of product for mass customization manufacturer
assembly progress from time to time. Such autonomous surveil-
lance system will be capable of providing real-time monitoring and
error detection. This will reduce the risk of the wrong custom-made
4 CHALLENGES OF IOT INTEGRATION
product being manufactured. Integration of IoT technology in dynamic change management
for mass customization manufacturers are promising for higher
3 ARCHITECTURE FOR DYNAMIC CHANGE achievement. Despite the positive prospect, there are unsolved
MANAGEMENT issues that could arise from both technological and usage point of
view, such as 1) reliability and availability, 2) interoperability and
From the three most important topics discussed above, it is summa-
3) security of IoT devices/applications.
rized that a dynamic change management architecture composes
of three essential components, namely: 4.1 Reliability and Availability
i Dynamic network linking in operating system
The availability of IoT must be accomplished at hardware and soft-
ii Real-time environment
ware levels in order to effectively implement the dynamic project
iii Monitoring and early error detection
change management as discussed in this paper. Availability of hard-
ware refers to the existence of devices that are compatible with the
functionalities and safety in the factory floor. Software availability
refers to ability of the IoT applications that are compatible with
existence manufacturing systems. Failure of IoT devices in field
might put the human operator in danger and possibly affect the
system operation. This could lead to further financial loss to the
organization.
Aside from the issue of availability, the reliability of the IoT
systems should also be seriously considered. In order to have an ef-
Figure 3: Dynamic change management architecture ficient dynamic change management in the factory floor, reliability
LIDARI2017, September 11, 2017, Amsterdam, Holland Chin Yin Leong and Ichiro Koshijima
check must be implemented in software and hardware throughout A framework is proposed to improve efficiencies of change man-
all the IoT layers. Unreliable data gathering, processing and trans- agement in mass customization manufacturing processes through
ferring could lead to disasters in the operating network, internally implementation of internet technologies. The challenges in having
and externally. Reliability of the system should take into considera- successful dynamic change management in mass customization
tion more critical requirements related to the emergency response manufacturing processes involve the need to create a dynamic
applications [20]. As an example, let’s take the reliability and avail- network linking manufacturing equipment with human operators
ability of the Myo armband. In the application of Myo armband to and also to have sufficient computational power to process so-
remote control a drone, unreliable Myo armband detection of hand phisticated manufacturing data during the production phase. The
gestures has been experienced, which will affect the outcome of the dynamic change management discussed in this paper requires ef-
drone control, and lead to the crash of the drone. Such unreliability fective real-time monitoring and early detection of manufacturing
of the system should be ironed out before full implementation of errors.
the dynamic change management. IoT technologies are essential in the effective implementation of
mass customization. The new concept of dynamic change manage-
4.2 Interoperability ment described in this paper, together with fast growing trends of
the smart factory concept, will have major positive implications to
Most of the IoT devices cannot directly connect with each other improve the competitive edge of mass customization manufacturers.
because it requires a data interface process to manage the devices The importance of smart and dynamic change management to fully
and get data out of one ’language’ and into another. For example, reveal the competitive strategy for mass customization manufactur-
the drone itself cannot directly read the EMG raw data from Myo ing aligns well with the demands of the marketplace of tomorrow
armband. Thus, a data interface processor, like raspberry PI, is em- has been presented in this paper.
ployed to process the EMG raw data input from the Myo armband
into programmable logic (PLC) data that can be sent to the drone
to execute relevant movement commands. This would require a ACKNOWLEDGMENTS
lot of custom code to account for all the different protocols and Author would like to acknowledge all of the community of Parrot
brands of IoT devices used. The tedious setup to get all IoT devices Bebop, Myo Armband and Python users who published the infor-
to effectively talk to each other and connect to the network of mation that author assembled, edited and merged to use in own
existing manufacturing system has been holding back many com- tests.
panies in getting IoT up and running in their factory. End-to-end
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