=Paper=
{{Paper
|id=Vol-2248/paper3
|storemode=property
|title=Synopsis of the MBSE, Lean and Smart Manufacturing in the Product and Process Design for an Assessment of the Strategy "Industry 4.0"
|pdfUrl=https://ceur-ws.org/Vol-2248/paper3.pdf
|volume=Vol-2248
|authors=Eugenio Brusa
|dblpUrl=https://dblp.org/rec/conf/ciise/Brusa18
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==Synopsis of the MBSE, Lean and Smart Manufacturing in the Product and Process Design for an Assessment of the Strategy "Industry 4.0"==
https://ceur-ws.org/Vol-2248/paper3.pdf
Synopsis of the MBSE, Lean and Smart
Manufacturing in the product and process design for
an assessment of the strategy “Industry 4.0”
Eugenio Brusa
Dept. Mechanical and Aerospace Engineering
Politecnico di Torino
Torino, Italy
eugenio.brusa@polito.it
Copyright © held by the author
Abstract—The industrial product development is currently supplier, as some implementation, like the Word Class
managed by resorting to the Model Based Systems Engineering Manufacturing (WCM), already defines and supports [9]. A
(MBSE), aimed to decompose the systems complexity, to the comprehensive discussion about the mutual coupling
Lean Manufacturing, allowing to achieve the targets of between Systems Engineering, even in its implementation as
Quality, Cost and Delivery (QCD), and to the enabling Model Based (MBSE), Lean (LM) and Smart Manufacturing
technologies of the Smart Manufacturing. Those three (SM) is herein proposed, by analysing methods, processes,
approaches are still assumed completely uncoupled, against the tools applied by each approach. As a result, they look like the
evidence of the disruptive power of their mutual and full
edges of an ideal triangle, which defines the perfection of
integration, as is herein discussed. This integration looks the
their full integration for a unified approach to design, to
goal to be achieved for a definitive assessment of the so-called
strategic initiative “Industry 4.0”, as is currently promoted
produce and to deliver.
worldwide to improve the industrial productivity.
II. CHARACTERIZING THE MBSE, LM AND SM
Keywords—Industry 4.0, Model Based Systems Engineering,
Lean Manufacturing, Smart Manufacturing, Product lifecycle A. The MBSE and SE
development, System Design.
To synthetize herein briefly, the MBSE primarily looks at
the product as a complex system and helps the designer and
I. INTRODUCTION the manufacturer to manage the whole Product Lifecycle
The most recent transformation of the worldwide Development. The MBSE allows decomposing the system
industrial organization aims to improve the system quality, to complexity, and assuring a complete traceability of the
reduce cost, and to finalize the product delivery to the system requirements to functions, of functions to subsystems
customer needs [1]. A review of the product and process and components, of subsystems to the built parts, classified
design activity, respectively, is currently promoted. To by a part number. This action is effectively performed, by
achieve those targets, a straight application of the Systems resorting to some pillars, like the method, the process, the
Engineering (SE) to the product development [2], of the tools and the data management [2].
Gemba Kaizen to the process management [3], and of the The methodology includes a preliminary selection of a
enabling technologies promoted by the strategic initiative suitable model of the Product Life Cycle, as the well-known
“Industry 4.0” to the industry digitalization [4], automation “V–diagram” depicted in Fig.1, and even other ones [10].
[5] and “autonomation” [6], is proposed. The last two
approaches are even known as “lean” (LM) [7] and “smart”
(SM) [8] manufacturing, respectively. Many companies
currently resort to those approaches, although a complete
awareness of their powerfulness seems not yet achieved.
Particularly, those approaches are wrongly assumed to be
completely uncoupled. The SE is often associated only to the
product development, although it is intrinsically linked to the
process management. The LM is often perceived as a
rationalization of the material processing, by neglecting its
connection to the product development. Finally, the
disruptive technologies supported by the SM are just
considered as a progress of tools, more than a mean to
Fig. 1. The ‘V–diagram’ used as a model for the Product Life Cycle in the
implement the LM and, very seldom, they are considered as MBSE.
a relevant part of the SE implementation. Despite that wrong
perception, those three innovation levers are tightly This model clearly states the relevant role of the
cooperating to face the product complexity, by assuring customer in defining the system requirements and the
quality, cost reduction, effective delivery as well as the importance of the stakeholders. The design activity
product reliability, availability, maintainability and safety (Application Lifecycle Management, ALM) is somehow
(RAMS). Moreover, they allow a suitable interaction mirrored, by level, with the corresponding actions of
between customer, designer, manufacturer, maintainer and manufacturing (Product Lifecycle Management, PLM), and
XXX-X-XXXX-XXXX-X/XX/$XX.00 ©20XX IEEE
links the system conception to its production, through the homologation, when is foreseen, or to product liability and
“V” look of the diagram. A key issue of this method is that it RAMS.
applies some reusable and digital models. They include a
qualitative description of the system behaviour, architecture It is worth noticing that nowadays the MBSE approach
and operation (functional modelling) and a quantitative one includes a combined functional and non-functional or
(physical or better numerical modelling), based on a dysfunctional analysis to anticipate the prediction of system
numerical and mathematical structure. The numerical reliability, since the preliminary design activity [11]. This
modelling is exploited to describe the system geometry, to action is made easy by a straight correspondence between the
predict its performance, to make a trade-off of its main steps of the product development and those required by
configurations, typically by resorting to an heterogeneous the RAMS analysis, as is described in Fig.3.
simulation, in which the functional and the physical models
CONTENTS, TOOLS AND PRODUCTS
are both included. The verification of requirements and the Customer needs and Mission, Scenarios
business modeled Contexts
product validation even resort to those models to check the COMMON ACTIVITIES
ANALYSES
TRADE-OFF: Requirement diagram
correspondence between product and model, and between Define alternative
Requirements
REQUIREMENTS
solutions and Activity, Sequence, State, Use case ANALYSIS
product and customer needs, respectively. optimise
Functions and/or
Dysfunctions
diagrams (Behaviour); Block, Internal
NUMERICAL MODELING block, Package (Architecture)
FUNCTIONAL
The process brings the user to perform the requirement INTEROPERATED
MODELS
Functional architecture FUNCTIONAL BREAKDOWN STRUCTURE
(FBS)
ANALYSIS
analysis, then the operational, functional, logical and HETEROGENEOUS
SIMULATIONS Logical architecture
LOGICAL BREAKDOWN STRUCTURE
(LBS) PHYSICAL
physical analyses, in sequence, to reach a design synthesis. Product architecture PRODUCT BREAKDOWN STRUCTURE ANALYSIS
V&V: (PBS)
The tools exploited include some typical diagrams, defined VIRTUAL AND REAL
Product integration
TESTING
within a standard language, as the SysML, but even some and design synthesis
architecture frameworks, as they are defined, for instance, by HOMOLOGATION RAMS TARGETS
several Departments of Defence (DODAF, MODAF, NAF) / LIABILITY
or some Space Agency (ESAAF). Particularly, some typical
system capabilities, which are exploited in operation, are Fig. 2. A synopsis of the main features of the MBSE approach applied to
identified within the architecture framework, through several product development.
views of the system, and this helps the designer to define the
Functions
best solution among those proposed. Functional
Functional
Hazard
Analysis Failure
Finally, several tool software are interoperated through a Logical Conditions
Analysis
platform, which defines a tool chain, including several data Architecture
bases, which need an effective data management to share the Logical Reliability
Analysis Allocation
information, through a careful control of changes introduced Reliability
Target
by the operators, classified by a hierarchic level. It is worth Physical
Architecture
noticing that nowadays aside a functional analysis a Physical Reliability
dysfunctional is already accomplished in the preliminary Analysis
Reliability
Prediction
technology trade–off [11]. This includes a preliminary Prediction
investigation about the system behaviour in presence of Fig. 3. Comparison between activities and results of the functional and
classified failure modes in its architecture, thus allowing a dysfuctional analyses.
prediction of the system effectiveness and reliability, before
that a final configuration could be defined. The analogy between functional and dysfunctional
The MBSE offers some typical features to help the behaviors is defined. As the functional analysis focuses on
product developer in reaching the goals above mentioned. As the functions, the functional hazard analysis identifies the
Fig.2 shows, the two common activities of the trade-off system failures. Similarly, a logical component performs a
analysis and of the requirements verification and system logical operation, while in the other analysis it is required to
validation (V&V) are deployed by resorting to the three assure a target of reliability, which becomes a real
typical analyses of requirements, functions (and operations) reliability performance in the final product, as a commercial
or dysfunctions, and physics of the system. More recently, component is identified to physically provide that logical
the application to the industrial product and no longer only to operation.
the software, suggested of decomposing the functional When the MBSE approach is implemented, a digital
analysis into a preliminary identification of functions and model of the whole product is preliminarily synthesized and
operations and then of the logical activities performed by the used to predict the product performance in operation.
system architecture, thus adding the logical analysis as an Particularly, the FBS, as is depicted in Fig.4, representing
intermediate step of the design activity [2]. The language (as the example of a flywheel on magnetic suspension, is used
the SysML) provides some diagrams, made standard to be to generate an IBD, for instance, which allows the trade-off
shared between customer, manufacturer and supplier. Three analysis [12]. The latter is sometimes converted into a LBS,
main graphical products as the functional, logical and
or directly into a numerical model, having the same layout,
product breakdown structures are created. They allow
distinguishing the functions of system, from the logical but including, in addition and within the blocks, some
components, describing their operation, but never the mathematical equations, describing quantitatively the
commercial products associated, from the product system performance. Numerical simulation is used to define
components, which are then selected, among those actually the label data of the commercial components most suitable
available on the market. The design synthesis brings to a to be selected for composing the PBS.
definition of the whole product integration, tailored to The software tools used to build up the digital model
need to be interoperated, i.e. connections must allow a
straight transition of information between the tools [13]. Kaizen [3]. It promotes a continuous improvement (kaizen)
This is sometimes a bottleneck for the development of this of the process and of the frame within which is actually
approach although several solutions are currently available. performed (gemba), through some small and effective
They are based either on a tool chain provided by a unique changes, overcoming specific problems or inefficiencies
vendor, who assures the products interoperability by design, (muda), identified step by step, by the people involved in the
or on some connectors, compliant with some standards like production activity. This leads to a simplification of the
the OSLC [14]. process itself, to improve the customer satisfaction, and to
rationalize the whole production line (lean production). The
Functional Breakdown Structure (FBS) five principles of the Lean Thinking and Manufacturing [15],
are applied, since, the main issues of this approach are the
value, the value flow, the process flow, the pull production
and the perfection of results. Particularly, a specific goal in
the material transformation process is making the theoretical
time to produce a given element (averaged on the production
baseline), known as the “takt time”, as much as possible
close to the real time to produce it, or the “cycle time”, to
increase productivity and effectiveness [3,15].
The three pillars of the LM are the so–called house-
keeping (HK), the identification and elimination of
inefficiencies or muda (ME), and the assessment of suitable
standards to be repeatedly applied, by the operator, to the
Internal Block Diagram (IBD) process (STD).
As for the SE, a method can be identified in the practice
of Gemba Kaizen. The process management is meant to
perform simultaneously two actions, as the maintenance of
the existing practices and their continuous improvement. The
first rule applied is “Plan–Do–Check–Act” (PDCA), then a
coherent standardization follows, and applies the rule
Standardize–Do–Check–Act (SDCA). The goals driving
those activities concern the priority of quality over all; the
Numerical model for dynamic simulation use of data, collected and retrieved by the process, to
evaluate its effectiveness, but even to create a base for a
statistical analysis; the target of customer needs and
satisfaction as a unique and real target of the whole process.
Several tools are exploited. A policy is first stated, to
define the object of improvement (policy deployment), then
people are involved through the Quality Circles, being
groups of operators asked to express their useful suggestions
about any process inefficiency (QC). Particularly, they must
Product Breakdown Structure (PBS) monitor the effectiveness of operations, to reduce the fatigue
of operators, by increasing the ergonomics, safety,
productivity, quality, and security, and decreasing the
production time and cost.
The operators express their suggestions, through different
means, but all concern the quality improvement, the cost
reduction and the delivery enhancement (QCD). Upon the
suggestions received, the management defines some
standards, and then the operators, who drive their continuous
refinement, test them and allow a definitive assessment.
When the Gemba Kaizen is applied, several paths are
followed, constituting a sort of checklist of activities. They
are organized like into a matrix form. The rows of that ideal
Fig. 4. Example of the evolution of the MBSE digital model of a flywheel
on magnetic suspesion.
matrix are the three activities of HK, ME, and STD
previously described. They define the items of the process
management, somehow like the use cases of the SE. The
B. The Gemba Kaizen and the Lean Manufacturing matrix columns are the three main goals defined by the QCD
Many approaches currently applied to the process system. They define also the metrics to be applied, to
management, more than to the product development, as the evaluate the effectiveness of the running process.
SE does, including the Total Quality Control (TQC), or Particularly, when the manufacturer plains the activity, he
Management (TQM), the Just In Time (JIT), the Total defines the Quality Function Deployment (QFD, related to
Predictive Maintenance (TPM), the WCM already cited, ISO 9000 series and 14000 and others), the Cost metrics
basically resort to the Japanese philosophy of the Gemba (about product quality, productivity, stocks, production line
flexibility, machinery stops, use of space, lead-time), and The performance of process is easily evaluated, by
Delivery targets (efficiency, promptness, completeness, time, filling, along the production line, the so–called Value Stream
related to the implementation of the JIT). Map (VSM), in several data boxes, where all the indexes
describing the effectiveness of the running process are
The maintenance is performed by implementing the certified.
housekeeping, and five activities are performed. They
compose the so–called set of “5 S” (seizi = clean out the
production line; seiton = configure properly what you kept in C. The Industry of the Future and the Smart
line; seiso = clean the machinery and check; seiketsu = Manufacturing
applied the three above steps to the operators; shitsuke = Proposing in few sentences a complete description of the
assure the self-discipline of the operators, write the standards strategic initiative “Industry 4.0”, resorting to the Smart
and make some practices). According to that scheme, the Manufacturing aimed to enhance the industrial productivity,
rules of housekeeping are defined, and the related standards is rather difficult. Nevertheless, it is known that the Fourth
are written. Industrial revolution [4], coming after the introduction of
machines, production lines, robotics and automation in the
The standardization is even deployed by considering the factories, is based on the smart cyber-physical systems and
targets of quality, by resorting to a list of five issues, known the Big Data technologies, which deeply exploit the internet
as the “5 M” items (men, machinery, materials, methods, (now Internet of Things, IoT), the cloud, and remote sensing
metrics). and monitoring systems. Those enabling technologies are
The improvement is based on the elimination of bringing the Industry to the future.
inefficiencies or muda, and is performed by identifying the They support the creation of suitable infra- and intra-
root cause by answering to a sequence of the so–called five structures to implement the SE and the LM. Smart and
“why?” or “5 W”. A classification of muda into mura intelligent systems are widely interconnected, to perform a
(changes, variations, irregularities) and muri (excesses), true collaborative and somehow autonomous work, to be
respectively, helps in sorting the problems to be solved. They adaptable to the working environment changes, to allow a
consider seven typical categories (7 muda), as the excess of continuous and effective monitoring, prognosis, diagnosis
production, the excess of stocks, inefficiencies related to and control of systems in operation.
product defects, operator motion, process performance, late
incoming of goods in production, and transportation systems. To investigate the interaction between SM, MBSE and
LM, a short synthesis of the enabling technologies
The architecture of the Gemba is even well defined. The characterizing the fourth revolution is proposed in Fig.6,
Gemba House, like in a framework, describes it completely according to [16].
[3]. The production line layout is configured upon the
principles of the Total Productive Maintenance (TPM) and 1 Advanced Manufacturing Solutions (Collaborative Robotics)
the Total Flow Management (retrieving the information back 2 Additive Manufacturing
from the customer, as an input to retail units, distribution, 3 Augmented reality
manufacturing, and supplier), respectively. Very often, a
4 Simulation (performance, process, machine)
structure organized by cells is proposed, to define different
steps of the manufacturing activity [15] (Fig.5). MBSE and SE 5 Horizontal and Vertical Integration (Units,
Sections, Departments)
MATERIAL MATERIAL
CELL A DISTRIBUTION CELL B DISTRIBUTION 6 Industrial internet
7 Cloud
PROCESS 1 PROCESS 1 PROCESS 1 PROCESS 1
8 Cyber-security
9 Big Data and analytics
SEPARATOR SEPARATOR SEPARATOR SEPARATOR
Fig. 6. Selection of enabling technologies introduced and enhanced by the
PROCESS 2 PROCESS 2 Industry of the Future [16].
SEPARATOR DELIVERY SEPARATOR DELIVERY
One of the main goals of those technologies is allowing a
WASTE WASTE
cyclic use of products, i.e. monitoring and maintenance of
the manufactured systems should increase the possibility of
re-use or longer use. A crucial issue is the integration of
Fig. 5. Example of generic structure by cells of the industrial process as manufacturing units spread on the different locations
proposed by the Lean Thinking [15]. (horizontal), with customers and suppliers, as well as that
between the design, the management and the workshop,
The Gemba includes also a hierarchy of managers and inside the same factory (vertical).
operators, all playing a specific and delimited role (to be
interpreted as cells of people). The model of Learning All the enabling technologies introduced support an
Enterprise, where everybody sees, observes and suggests, is effective enhancement of the manufacturing performance,
implemented, through an operational chain starting from the quality and safety, because they are based on the extensive
CEO (Chief Executive Officer) and going to the workshop use of both the mechatronics and the digitalized information.
operator, through the chiefs of unit, department, and section. The system smartness is often related to different levels of
Therefore, the LM exploits a real Training Within Industry artificial intelligence, corresponding to some functions of
(TWI) [15]. sensing, controlling and actuating, under a defined strategy
[17]. The advanced manufacturing solutions basically
include the automated systems and the collaborative
robotics, expression of mechatronics, and the additive It might be used as a sentry node of a network to warn the
manufacturing technologies, fully based on the industrial operators about any abnormal behavior of either the bearing
digitalization of product [18]. components or the hosting system. If it is used remotely, it
allows applying the IoT technology, to monitor the life of
The collaborative robotics helps humans in making components and warn the manufacturer about any need of
faster, controlled and more precise the manufacturing action, maintenance. In case of the active magnetic bearing, the
improving the performance, decreasing the pain of operators system simultaneously performs the monitoring action and
and assuring high levels of quality and safety. The design of the active vibration control. To install the smart bearing it is
collaborative robotic devices surely faces some issues related required a deep description of its calibration and properties,
to complexity and to the actual needs to be satisfied, as in the which is digitally provided, since its production, through the
exoskeletons. The intensive use of automation in ISO Data Matrix method [22]. Therefore, the smart bearing
manufacturing and material processes increases the looks simultaneously as a smart device in operation and a
complexity related to multi-physics involved in the coupled smart product in terms of the information contained in its
phenomena exploited [19]. Moreover, sensors in automated assembly and shared with the manufacturer, in service.
systems allow simultaneously the application of control
actions, but even to extract a continuous information from The augmented reality is another effective mean to
the operated system, which can be monitored, and analyzed implement the smart manufacturing, as in case of the smart
for an effective prognosis of failure and damage conditions, helmet for operators involved in steelmaking or similar
as well as for a diagnosis, after that failures occurred. This industrial plants. Basically, this tool provides two services.
monitoring action can be connected by the industrial internet The information coming from some sensors embedded and
and shared with the operators interfaced with the operating from the network are plotted through a head-up display, and
system, or even remotely analyzed, by working units, even read in real time by the user. These data might prevent the
far from the location of the monitored system. This use exposure of the worker to some risk or any severe operating
involves the transmission of data, through the internet (IoT), condition. Some recent evolutions of this device include a
the cloud and under a severe requirement of cyber security. smart glass, allowing to look at the working environment
through a glass shield, whose transparency and color can be
The additive manufacturing introduces another kind of regulated by resorting to either thermochromic or
smartness, related to the digital content of information electrochromic material [23], which might be automatically
directly sent by the designer to the production line, activated by a light sensor to protect the user against the risk
extensively adaptable to many needs of shaping and of blinding glare [24]. When the operator is required to
optimizing the product. It allows manufacturing systems and perform a quality assurance activity in production line, by
components previously never built up, because of some monitoring the product, the same device is equipped with
surface inaccessible to the tooling machines. The strength of some augmented vision system for damage detection [25],
additive manufacturing is the lying of production data which supports the vision activity. It allows detecting
directly within the digital product mock-up, made through failures, damages and marks as in gears, rolling elements of
the SE as a result of the trade-off accomplished between bearing, or on the surface of the steel strip.
technologies.
Two examples might simplify the above mentioned
concepts. The so-called smart bearing, for instance, is
embedded into the machinery as a component of the whole
assembly, but is even equipped with some miniaturized
sensors, which allow monitoring the inner environment of
bearing, to prevent failures and damage, but even the outer
and surrounding environment of the hosting frame, as it
measures the loading, thermal, vibration and acoustic
conditions [20,21].
Sensors
Wireless
Roller bearings connection
Rolling mill vibration
monitoring Data Fig. 8. Concept of smart helmet with protection shield based on the
acquisition electrochromic smart materials [24] and augmented vision system for
damage detection.
Data elaboration
All those systems exploit a variety of coupled phenomena
Vibration and kinematic energy harvesting
via piezoelectric / magnetic coupling and include a number of components that their complexity
easily rises up and requires some systematic approach to
Diagnosis / Prognosis / Control / Maintenance design the device, as the MBSE, and to perform the detection
Fig. 7. Concept of smart bearing for large equipment monitoring with
of waste, according to the LM approach.
embedded sensors and autonomous energy supply.
MBSE Model Based Systems Engineering Gemba Kaizen Lean Manufacturing
1 4 PRODUCT Development TARGET PROCESS management 1 5
5 6 Traceability MAIN FEATURES Visual management 5 7
7 8 Reusability Continuous improvement 3 9
3 4 Decompose complexity Apply the Learning Enterprise approach 5 6
1 5 Improve quality GOALS Improve quality 1 5
4 5 Reduce cost Reduce cost 1 3
3 4 Avoid human mistakes in product design Avoid human mistakes in processing 3 6
4 9 Avoid re-engineering Improve delivery process 9 2
4 7 Digital models NEEDS Flexible production line (Gemba) 1 2
6 5 Interoperable tools Self-disciplinated operators 5 7
6 7 Reliable tool chain Reliable machinery 1 9
8 5 Secure Data Base Data retrieving 9 7
5 8 Customer ACTORS Customer 5 7
5 6 Stakeholders Stakeholders 5 6
5 8 Operators Operators 5 8
METHODOLOGY
Product Life Cycle Object Gemba (Process cycle)
Model of product lifecycle (V, spiral …) Base Model of process: Total Flow Management
4 6 Application Lifecycle Management (ALM) Process maintenance 5 6
5 6 Product Lifecycle Management (PLM) Process improvement 9 3
Methods vs targets
Selection of technologies
4 6 Modeling Reliability, Availability, … Housekeeping Quality 9 3
...Maintainability, Safety (RAMS)
1 9 Trade-off Sustainability Elimination of Muda Cost 3 9
1 5 Deployment Service Standardization Delivery 5 9
4 7 Heterogeneuous simulation
4 3 Verification
3 9 Validation
5 7 Requirement Analysis (System goals, … Process Identification and charcterization of Gemba 5
...requirements) Housekeeping: apply "5S" 5 6
4 6 Operational analysis (System context, … Planning of process … 4 9
… mission, scenarios, stakeholders) ...(Plan-Do-Check-Act PDCA)
4 5 Functional and dysfunctional analysis… Standardization: apply "5M" 4 5
... (Functional Breakdown System)
4 5 Logical analysis … Standardization of process… 5 9
...(Product Breakdown System) ... (Standardize-Do-Check-Act SDCA)
4 5 Physical analysis (Product Integration) Elimination of inefficiencies: apply 3 5
"5 W" (Muda identification)
4 6 Design synthesis Classification of muda - mura - muri… 3 4
...and problem solving
Tools
4 5 Diagrams Driving lists 5 6
Requirements diagrams 5S (Housekeeping); 5M (Quality and standards);…
...5W (Root cause); 7 Muda
Context diagrams VSM - Value Stream Map (of Data)
Behaviour diagrams (Use case, States,…
... Sequence, Activity)
Structure diagrams (Block Definition,… Diagrams 5 6
...Internal Block Definition, Package)
Parametric diagrams Example: Fish Diagram
4 5 Architecture frameworks (views) Procedural frameworks 4 6
(MODAF, AF-EAF, AFIoT, AAF, DoDAF, … TQC - TQM - JIT - TPM - QFD
...ESAAF, MODAF, NAF, TOGAF, UAF) The Gemba House
4 Language Operators team 5 6
UML - SysML - IML - AML - LML Quality Circles (QC) who express visual suggestions
Information
Requirements, Functions, Components, Parts Standards
Numerical contents Value Stream Map
Key Performance Indicators (KPI) Key Performance Indicators (KPI)
1 Product baseline Platform Process driveline 1
6 7 Tool chain of interoperated software Operator hierarchic chain 5
6 7 Data bases Data bases 6 7
INDUSTRY 4.0 - ENABLING TECHNOLOGIES
5 Horizontal / Vertical Integration
1 1 Advanced Manufacturing Solutions and Collaborative Robotics
6 Industrial Internet
2 2 Additive Manufacturing
7 Cloud - IoT
3 3 Augmented Reality
8 Cyber-security
4 4 Simulation and system integration by modelling
9 Big Data and Analytics
Fig. 9. The proposed synopsis of the MBSE, Lean and Smart Manufacturing.
Interfaces (HMI). Actually, both the drivelines exploit all of
III. TOWARDS A UNIFIED APPROACH those elements. Moreover, the attention to stakeholders is
high in both the contexts.
A. A synoptic interpretation
As the method is implemented, it can be realized that
If one compares the two approaches of the MBSE and the
despite the difference of nomenclature and of the context
LM actually realizes that a punctual correspondence exists.
(product vs process) a certain dualism is present. The ALM
That comparison is tentatively proposed in Fig.9.
activity is mirrored in the “V-diagram” by the PLM, as in the
Particularly, following some typical references as
LM maintenance is alternately performed with improvement.
[3,7,10,15], the main contents of the MBSE (left column) are
The targets are analogous; since the aim of product
compared to those of the LM (right column). Each element
development is the RAMS as in the process, the quality must
of comparison is described in the middle column. Moreover,
be assured. The sustainability pursued in the product
after collecting the replies to a preliminary questionnaire of
development corresponds to the efficiency in process, and
26 companies, the major influence of the disruptive
both require keeping cost low. The output of MBSE is the
technologies proposed by the SM were associated to each
service as a phase of the delivery, being the target of the LM.
item, by selecting the two most commonly identified. The
legend of numbers and colours is proposed at the bottom of The different steps of process, in both the contexts,
Fig.9. express a dualism. In the product development, the analyses
are performed in sequence, and in the manufacturing, actions
As is evidenced by Fig.9, the MBSE applies to the
are executed in sequence, by resorting to a number of
industrial product a methodology that is similarly applied to
conventional driving lists (“5 S”, “5 M”, “5 W”, 7 muda), as
the process by the LM. An almost perfect dualism is
well as in the MBSE, the applied language provides several
perceived. In some cases a superposition of contents occurs.
suitable diagrams. Even in the LM, some diagrams are
For instance, the goals are the same, they focus on quality,
plotted and exposed in the production line, to involve the
cost, mistake, and inefficiencies. In the LM the role of
operators in the continuous improvement, as the Ishikawa
humans is very evident and the operators are elements of the
diagram or “Fish” Diagram, where the targets of QCD are
process, like in the MBSE, although they are less
related to the 5M at different levels, and to the environment.
expressively evidenced. The actors are even the same, and
The smallest arms in this diagram are the so–called key
customer plays a crucial role. The data are extremely
points for the punctual intervention of change (Fig.10). For
important in both the drivelines
all those activities, the use of tools to implement a
heterogeneous simulation is mandatory, as well as the
B. Dualisms and analogies support of an effective cloud and of the internet, to allow a
Analysing deeply the synopsis, one can find some complete interoperability. The data sharing and management
dualisms and analogies. A first evident dualism involves the is crucial, thus requiring a perfect horizontal and vertical
requirements of the product development and the standards integration, and to resort to some software deploying the
of process deployment. They are both used as a reference for Manufacturing Execution System (MES).
the verification and validation, they come out from an
Men Machinery Materials Issues
iterative process of assessment and refinement, which
motivate resorting to all of tools foreseen in the two contexts. Goals
The requirement traceability is a key issue of the SE
methodology, as in the LM the Visual Management is, i.e.
for a continuous improvement the information, the problems QCD
and the corrective actions applied must be clearly accessible
by all of the operators. For both the digitalization is a crucial
target of innovation, as is promoted by the SM, but even the Key point
effective integration among units (horizontal and vertical).
Environment Methods Metrics Deployment
In both the contexts, decomposing the complexity is a
priority, in the MBSE simplifying the system architecture is Fig. 10. The Ishikawa or “Fish” Diagram, used in the Lean Manufacturing.
mandatory as well as making lean the process is the goal of
the LM. The goals even include a difference like the It is worth noticing that in both the contexts, the
reduction of cases of re-engineering in the product design, frameworks play a significant role. The MBSE resorts to the
and the improvement of delivery, in the process design. They architecture frameworks to deploy the system, in terms of
are both focused on the overall process implemented and capabilities and views, as the LM actually implements
they promote a unique execution, to keep the costs as low as several procedural frameworks (the Gemba House or the
possible. The implementation of the two methodologies of TQC, JIT, QFD) to manage process, materials and time.
the MBSE and of Gemba Kaizen look needing a straight use
of augmented reality, simulation and modelling, as well as an By converse, it is relevant that the MBSE totally trusts in
efficient communication and sharing of information, through the language used to create the digital models, while the LM
the internet. directly organizes the operators, both in hierarchy and in
groups, or Quality Circles, to retrieve the information and to
The needs express a complementarity of exigencies, i.e. support the improvement. Similarly, if one looks at the
the MBSE expressively requires suitable tools for modelling, platform applied, the tool chain is dominant in the MBSE
interoperated and reliable, based on secure data; the LM while the LM focuses on the operator chain.
points out the need for machinery and operators, reliable and
very well interfaced, by some suitable Man to Machine Concerning the information, a superposition between the
systems (M2M), and more in general by Human Machine two approaches occurs. The elicitation of traceable
requirements, linked to the customer needs, corresponds to satisfaction of needs. This can be assured, thanks to flexible
the assessment of the process standards, based on customer and lean production lines, as well as by means of smart
needs (where customer might be even the following systems and equipment, easily adaptable. The smartness
manufacturing unit), but refined step by step through the often increases the system complexity, thus motivating the
concurrent contribution of all the operators or the application of the MBSE to decompose and handle it.
stakeholders. The Value Stream Map is somehow overlapped
to the quantitative contents of data shared in the product What kind of benefits a final integration of the MBSE,
development. LM and SM might provide? To this question, some answers
are proposed.
The use of Key Performance Indicators (KPI) is
definitely recommended by both the SE and the LM A. The integration between MBSE and LM shall refine
approaches. They define the metrics used to evaluate the and complete the assessment of the Product lifecycle model
product and the process, respectively, and provide a list of assumed by the SE. Particularly, it is well known that a link
suitable items about which the analysis can be effectively between the ALM and the PLM or PDM (Product
performed. In the LM some KPI are frequently used as the Deployment Management) is established by the SE tools, and
Overall Equipment Efficiency (OEE), or the Single Minute is currently exploited to clearly define the requirements
Exchange of Die (SMED). related to manufacturing. Nevertheless, the SE very seldom
defines in details the activities foreseen by the ascending arm
At higher level, it might be noticed that as in the SE the of the “V-diagram”, visible on the right, in Fig.1. A clear
Product Lifecycle Management is the highest level of the decomposition of the actions after sale, as the delivery, the
organization driving the building up of a tool chain to control service, the maintenance are seldom defined, as in some
the changes, in the Gemba Kaizen, the Total Flow specialized contribution as in [26], where the introduction of
Management drives the strategy of production. It might be a second path looking itself as a “V” is exploited to add the
oriented to a “one piece flow”, with a synchronization based personnel training, the maintenance, the monitoring and the
on the “Just in Time”, to perform a “pull production” more decommission, as useful actions to describe completely the
than to a “push production”, since it is excited by the delivery.
customer demand.
B. The Gemba looks like a system and, in principle, no
The impact on those analogies of the SM looks large, limitation inhibits to apply some of the tools of the SE to the
according to the feedbacks collected. If one looks at the process, once that the production line is identified as the
proposed association between the enabling technologies and system to be analysed. Particularly, the diagrams exploited
the items identified for both the methodologies (Fig.9), by the SysML to decompose the system complexity might be
immediately can realize that a good coverage is assured. freely used to analyse the process. Some specialized
diagrams, as the State Machine, can be even simulated to
Moreover, the contribution of advanced mechatronics, in
check the performance of the system [2].
terms of advanced solutions for manufacturing and robotics
and augmented reality is relevant and affects both the C. The integration between LM and SM looks natural, if
product development and the process deployment. By one assumes that the SM is conceived to enhance the
converse, the Additive Manufacturing, nowadays so productivity. Many enabling technologies are required to
strategic, provides a good contribution in some issues, while make faster, more effective and more precise the action of
the perception of a huge impact on the overall system looks improvement. Nevertheless, all the technologies supporting
lower. the monitoring, prognosis and diagnosis activities will
provide a key contribution. Particularly, if the remote control
The simulation still represents an important element,
currently applied to systems in operation, like motor
particularly in the meaning of extended heterogeneous
vehicles, trains, aircrafts and spacecrafts, will be even
simulation, including functional and numerical modelling.
applied to the elements of manufacturing systems, for
The horizontal and vertical integration seems more a target
instance to the bearings, to retrieve data for an effective
than an input for the application of such unified approach,
maintenance [20], or to the testing facilities, assuring the
although a preliminary organization of the working units and
system quality, the benefit will increase significantly.
of the operators to be effectively integrated is needed, to
apply the disruptive technologies above described. It is known that mechanical components requiring a
continuous maintenance, being designed for a finite life and
All the issues related to the network, the data collection,
somehow consumable, need a clear traceability of their
elaboration, transmission and management are crucial, for
intrinsic and operational data since the testing performed
many activities here mentioned. Particularly, the technology
before the delivery. Therefore, a real horizontal integration
and the infrastructures related to the industrial internet and to
with customer will be complete, when the test, the service
the cloud is perceived as a key element of powerfulness of
and the maintenance will be suitably monitored and coupled.
the whole rationale. The impact of the Big Data and
This action resorts to the SM smart systems and data
analytics is impressive, although the cybersecurity might be,
management ass a key element of the infrastructure to
simultaneously, the element either of strength or of weakness
actuate the remote testing and operation monitoring.
of this system.
D. The integration between MBSE and SM is defined in
C. Towards the integration two levels. If one looks at some smart systems like robots,
As it was demonstrated, a relevant issue of the mechatronic and autonomous systems, the system integration
convergence among MBSE, LM and SM is the customization is suitably driven by the MBSE, through all its tools.
of product. More and more the customers require a Nevertheless, if the activity of remote monitoring is
personalized version of product, or better a complete designed, the MBSE is helpful to define all the system
parameters, considering the mission, operation and
requirements, related to service. Quite often, it happens that For the product development, the main stream of
despite the application of remote monitoring systems innovation concerns the application of the digital twin and
connected through the cloud, the designer is poorly aware functional modelling in addition to numerical modelling, for
about the real specifications required by the application, a comprehensive virtual engineering, prototyping and testing
since a too short investigation about the requirements and the [30]. Nevertheless, the effectiveness of those tools depend on
functions to be exploited is preliminarily performed. a complete development of the interoperability protocols, of
the IoT infrastructures, of the cloud and related services,
E. To clarify the mutual integration of the MBSE, LM,
needing to be more and more service oriented [31].
and SM, the example of the smart bearing looks suitable. It
is first a product to be developed and equipped with a set of Other technologies are strictly involved, as the ICT, with
sensors, then it becomes a node of the monitoring network particular care of the network band and configuration, as the
and can perform the in-monitoring of its own defects and 5G. In addition, even the HMI systems could improve the
failures, as well as the out-monitoring, i.e. it is a sentry of the impact of the proposed approach. A crucial issue concerns
process performance for the machinery, where is embedded. the inclusion into the global deployment environment
Moreover, the bearing as a system to be tested needs a test previously described of optimized business models, supply
bench for a complete homologation. The results of this chains, logistics to configure a balanced ecosystem in the
activity are enclosed into the firm of the bearing, nowadays factory.
traced, by the labels applied, easily detected and read in
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