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Smart Factory 4.0 of the Future

Team members

Loo Wei Sheng Dixon (ASD), Yang Funing (ASD), Lai Jian Ting (EPD), Low Wei Kang (EPD), Loh Yi Jun Nicholas (ESD), Jeremy Ngo Hee Guan (ESD)

Instructors:

Bige Tunçer, Nagarajan Raghavan, Keegan Kang

Writing Instructors:

Nurul Wahidah Binte Mohd Tambee

Teaching Assistant:

Ataman Cem

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Project Description

This project is a framework utilising smart factory capabilities such as an integrated digital delivery (IDD) system and digital twin customised to Seiko Wall’s factory flow needs.

It organises and displays information with clarity using a digital system, forming an integrated one-stop solution that assists factory management in the tracking and management of everyday factory progress and energy utilisation, with the final goal of increasing factory production rate.

current situation slide
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seiko wall s needs slides
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Problem Statement

Seiko Wall is a local Small and Medium Enterprise (SME) based in the Architecture, Engineering and Construction (AEC) industry for 43 years and running. Seiko Wall is a market leader and an established provider of quality Architectural Building Façade components and products locally and internationally.

Seiko Wall is currently setting their sights on expanding the business further overseas, having taken on large scale projects such as 400 West Georgia in Vancouver, Canada and 707 Terry Avenue in Seattle, USA. Their current processes have a high reliance on manual labour, a lack of real-time monitoring system, and suffers from poor communication between the factory floor and planning office. To keep up with the rising demand for building façade components, Seiko Wall has thus embarked to leverage on the technologies of Industry 4.0 to digitalize their factory into a smart factory and upgrade their manufacturing capabilities at their factory to keep up with production needs.

IDD

The IDD has the following capabilities
(1) Monitoring of key production metrics such as workstation summary, production efficiency and revenue earned
(2) Monitoring of energy consumption by factory floor and office
(3) Production scheduling of projects with validations from Bill of Material (BOM) and projected material levels.

The first video describes the use case of how the production manager resolves the issue of a delay in delivery.

The second video illustrates the use case of management comparing their current electricity bill with their consumption in the past.

Digital Twin

The digital twin has the following capabilities:
(1) Real-time monitoring of smart cell’s status such as products processed and operational capabilities
(2) Display of all products Seiko Wall is currently working on
(3) Tracking of material levels and locations within Seiko Wall’s factory

The video describes how the system informs the user on breakdowns of the machines allowing them to intervene timely to ensure that production continues.

Impact

The project improves Seiko Wall’s factory in 3 categories:
Productivity – Improved manufacturing output by 2.5 to 3 times with consistent quality
Sustainability – Holistic evaluation of energy performance for sustainable manufacturing
Connectivity– Integration of data between machines and enterprise resource systems and visualization of such data for management to access and base their decisions upon

 

 

In collaboration with:

seiko
FEEDBACK

TEAM MEMBERS

student Loo Wei Sheng Dixon Architecture and Sustainable Design
student Yang Funing Architecture and Sustainable Design
student Lai Jian Ting Engineering Product Development
student Low Wei Kang Engineering Product Development
student Loh Yi Jun Nicholas Engineering Systems and Design
student Jeremy Ngo Hee Guan Engineering Systems and Design

© 2021 SUTD

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