Dijital İkizler Gömülü Gerçek Zamanlı Üretim Yürütme Sistemi Tasarımı: Kitlesel Özelleştirme ile Üretim Yapan Bir Firmada Uygulama

Abstract

Many companies use information management systems to ensure their efficiency and internal communication. From medium-sized companies to large-scale companies, enterprise resource planning systems are used for reasons such as ensuring accurate workflows, controlling stocks and regulating their productions. These enterprise resource planning systems lack to show current status of production flow, workloads, status of warehouses and many other similar instant situations. Disruptions and lack of communications occur between enterprise resource planning systems and production lines.

For this reason, in the event of sudden changes in customer demand, critical personnel using enterprise resource planning cannot determine the state of production lines, what their change will affect, which parts will be delayed or which workstations will change. Decision making mechanisms may not work properly.

In this study, a manufacturing execution system is designed, in which product design processes, material conditions in warehouses, workloads in production lines and instant status of all work steps from the delivery of the final product to the warehouse can be monitored. This manufacturing execution system is also represented by using unified modeling language.

The study is based on the operations of a defense industry company that uses enterprise resource planning. The structure eliminates the differences between the realization of the production line of the company and the enterprise resource planning systems. This structure is designed to:

• Determine the work steps in product design stage and follow up the workforce, • Follow the status of product prototype production and testing stages, • Create the production plan, • Monitor the material flows of the warehouse, • Determine workload in the production line, • Prioritize workstations and materials waiting for processing, • Monitor in-production stocks, • Control quality of devices and kits, • Deliver finished products to warehouse.

The production line can be easily monitored by decision makers against situations that causes changes in the system and ability to instantly see the workload and workflow can be gained. Workstations which will be affected by the system changes and alternative solutions can be found by the use of manufacturing execution system.

A digital twin has been created to show how the system works. This twin is used for two different purposes. In the first use, five different products were sampled from the production line. Production of the products for one year, depending on the production plans, was used. Work densities, bottlenecks, waiting and total processing times are obtained by using the model. With the second use, digital twin is integrated in to the manufacturing execution system by using its online system status data. When an unplanned order for a product enters the system, the time of the order to leave the production line, queues in the operations and number of queues with bottlenecks are determined by the use of the digital twin.

With the designed manufacturing execution system, a live connection is provided between the enterprise resource planning systems and the production line and engineering works.