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Aerospace manufacturing is improving its productivity and growth by expanding its capacity for production by investing in new tools and more equipment to provide additional capacity and flexibility in the face of widespread supply disruptions and unpredictable demand. However, the cost of such measures can result in increased unit costs. Alternatively, productivity and quality can be improved by utilizing available resources better to reach optimal performance and react to emerging disruptions and changes. Elastic Manufacturing is a new paradigm that aims to change the response behavior of firms to meet sudden market demands based on automated analysis of the utilization of the available resources, and autonomous allocation of capacity to use resources in the most efficient manner. Through digitalization of the shopfloor, streaming data from equipment enables companies to identify areas for improvement and boost the efficiency without large capital expenditure. Additionally, the impact of supply chain disruptions can be reduced through demand forecasting, inventory optimization, early warning systems, and flexible reallocation of resources; all of which could be managed elastically through integrated data collection in the supply chain. This paper describes how smart factories with more flexibility and resilience can be achieved with semantically-enhanced quality analytics, maintenance solutions, and automated key performance indicator monitoring. An example of measuring the capacity utilization rate, by following the measurement of multiple KPIs from a shopfloor level using data from a real aerospace project is demonstrated showing the significance of monitored process performance.

Modern manufacturing has to cope with dynamic and changing circumstances. Market fluctuations, the effects caused by unpredictable material shortages, highly variable product demand, and worker availability all require system robustness, flexibility, and resilience. To adapt to these new requirements, manufacturers should consider investigating, investing in, and implementing system autonomy. Autonomy is being adopted in multiple industrial contexts, but divergences arise when formalizing the concept of autonomous systems. To develop an implementation of autonomous manufacturing systems, it is essential to specify what autonomy means, how autonomous manufacturing systems are different from other autonomous systems, and how autonomous manufacturing systems are identified and achieved through the main features and enabling technologies. With a comprehensive literature review, this paper provides a definition of autonomy in the manufacturing context, infers the features of autonomy from different engineering domains, and presents a five-level model of autonomy — associated with maturity levels for the features — to ensure the complete identification and evaluation of autonomous manufacturing systems. The paper also presents the evaluation of a real autonomous system that serves as a use-case and a validation of the model. QC 20230529 DiManD Innovative Training Network (ITN)

Modern manufacturing has to cope with dynamic and changing circumstances. Market fluctuations, the effects caused by unpredictable material shortages, highly variable product demand, and worker availability all require system robustness, flexibility, and resilience. To adapt to these new requirements, manufacturers should consider investigating, investing in, and implementing system autonomy. Autonomy is being adopted in multiple industrial contexts, but divergences arise when formalising the concept of autonomous systems. To develop an implementation of autonomous manufacturing systems it is essential to specify what autonomy means, how autonomous manufacturing systems are different from other autonomous systems, and how autonomous manufacturing systems are identified and achieved through the main features and enabling technologies. With a comprehensive literature review, this paper provides a definition of autonomy in the manufacturing context, infers the features of autonomy from different engineering domains, and presents a five-level model of autonomy -- associated with maturity levels for the features -- to ensure the complete identification and evaluation of autonomous manufacturing systems. The paper also presents the evaluation of a real autonomous system that serves as a use-case and a validation of the model.

The application of digital twins and artificial intelligence to manufacturing has shown potential in improving system resilience, responsiveness, and productivity. Traditional digital twin approaches are generally applied to single, static systems to enhance a specific process. This paper proposes a framework that applies digital twins and artificial intelligence to manufacturing system reconfiguration, i.e., the layout, process parameters, and operation time of multiple assets, to enable system decision making based on varying demands from the customer or market. A digital twin environment has been developed to simulate the manufacturing process with multiple industrial robots performing various tasks. A data pipeline is built in the digital twin with an API (application programming interface) to enable the integration of artificial intelligence. Artificial intelligence methods are used to optimise the digital twin environment and improve system decision-making. Finally, a multi-agent program approach shows the communication and negotiation status between different agents to determine the optimal configuration for a manufacturing system to solve varying problems. Compared with previous research, this framework combines distributed intelligence, artificial intelligence for decision making, and production line optimisation that can be widely applied in modern reactive manufacturing applications. QC 20221123Part of proceedings: ISBN 978-3-031-18325-6

The manufacturing industries in a number of high-labour-cost economies are undergoing a shift towards increased automation and intelligence typified by the ‘Industry 4.0’ paradigm. Advances from computer science research including digital informatics enables the addition of intelligence and autonomy to the flexible and reconfigurable manufacturing systems developed by manufacturing systems research. One such advance is the development of Data Distribution Services (DDSs) that enable the robust and timely distribution of high-quality data in a scalable manner. This paper describes how a DDS can be used to integrate systems across a production enterprise, including directly on a shop floor rather than using additional specialised shop floor integration components often required by other communications protocols.

Adaptive production systems are a key trend in modern advanced manufacturing. This stems from the requirement for the system to respond to disruption , either in the form of product changes or changes to other operational parameters. The design and reconfig-uration of these systems is therefore a unique challenge for the community. One approach to systems design is based on functional and behavioural modelling, drawn from the field of design theory. Existing approaches suffer from lack of focus on the adaptive properties of the system. While traditional production systems design focusses on the physical system structure and associated processes, new approaches based on functional and behavioural models are particularly suited to addressing the challenges of disruptive production environments resulting from Industry 4.0 and similar trends. We therefore present a Function-Behaviour-Structure (FBS) methodology for Evolvable Assembly Systems (EAS), a class of self-adaptive reconfigurable production systems, comprising an ontology model and design process. The ontology model provides definitions for Function, Structure, and Behaviour of an adaptive production system. This model is used as the input to a functional modelling design process for EAS-like systems , where the design process must be integrated into the system control behaviour. The framework is illustrated with an example taken from a real EAS instan-tiation using industrial hardware.

Part 4: Assembly Cells and Systems; International audience; Aerospace production systems face increasing requirements for flexibility and reconfiguration, along with considerations of cost, utilisation, and efficiency. This drives a need for systems with a small number of automation platforms (e.g. industrial robots) that can make use of a larger number of end effectors that are potentially flexible or multifunctional. This leads to the challenge of ensuring that the configuration and location of each end effector is tracked by the system at all times, even in the face of manual adjustments, to ensure that the correct processes are applied to the product at the right time. We present a solution based on a Data Distribution Service that provides the system with full awareness of the context of its automation platforms and end effectors. The solution is grounded with an example use case from WingLIFT, a research programme led by a large aerospace manufacturer. The WingLIFT project in which this solution was developed builds on the adaptive systems approach from the Evolvable Assembly Systems project, with focus on extending and increasing the aerospace industrial applicability of plug and produce techniques. The design of this software solution is described from multiple perspectives, and accompanied by details of a physical demonstration cell that is in the process of being commissioned.

The adoption of digital manufacturing in small to medium enterprises (SMEs) in the manufacturing sector in the UK is low, yet these technologies offer significant promise to boost productivity. Two major causes of this lack of uptake is the high upfront cost of digital technologies, and the skill gap preventing understanding and implementation. This paper describes the development of software wrappers to facilitate the simple and robust use of a range of sensors and data sources. These form part of a common architecture for data acquisition in the Digital Manufacturing on a Shoestring project. We explain the existing Shoestring demonstrator architecture, and discuss how a ‘crash-only’ microservices architecture would improve fault tolerance and adaptability of the system.

Current sectoral drivers for the manufacturing of complex products - such as airframe assembly -require new manufacturing system paradigms to meet them. In this paper, we propose a conceptual framework for cyber-physical systems driven by ubiquitous context-awareness by drawing together a unique and coherent vision that merges several extant concepts. This framework leverages recent progress in agent-based systems, exible manufacturing, ubiquitous computing, and metrology-driven robotic assembly in the Evolvable Assembly Systems project. As such, although it is adapted for and grounded in manufacturing facilities for airframe assembly, it is not specifically tailored to that application and is a much more general framework. As well as outlining our conceptual framework, we also provide a vision for assembly grounded in a review of existing research in the area.

When producing complex and highly customisable products in low volumes (or in ‘batch sizes of one’), automation of production systems is critical for competitiveness and profitability in high labour-cost economies. To facilitate batch-size-of-one production, ‘topology generation’, ‘realisability’, and ‘control’ algorithms have been developed as part of the Evolvable Assembly Systems (EAS) project. The topology generation algorithm computes all the possible sequences of parallel activities that assembly resources can perform on parts and is run offline whenever the layout of the production facility changes, whereas realisability checking and controller generation are performed at run-time to check whether a production facility with a given set of assembly resources can assemble a desired product, and how the product should be assembled, e.g., which resources to use, and when. Generated controllers are output in Business to Manufacturing Markup Language (B2MML). Taken together, the algorithms thus represent a step toward a complete path from the formal specification of an assembly system and the products to be assembled, to the automated synthesis of executable process plans. This paper presents each algorithm in sufficient detail to allow their reimplementation by other researchers. Topology generation is the most expensive step in the approach. A preliminary experimental evaluation of the scalability of topology generation is presented, which suggests that, for small to medium sized production facilities, the time required for recomputing the topology is sufficiently small not to preclude frequent factory transformations, e.g., the addition of new resources.

© 2019 SAE International. All Rights Reserved. Evolvable Assembly Systems is a five year UK research council funded project into flexible and reconfigurable manufacturing systems. The principal goal of the research programme has been to define and validate the vision and support architecture, theoretical models, methods and algorithms for Evolvable Assembly Systems as a new platform for open, adaptable, context-aware and cost effective production. The project is now coming to a close; the concepts developed during the project have been implemented on a variety of demonstrators across a number of manufacturing domains including automotive and aerospace assembly. This paper will show the progression of demonstrators and applications as they increase in complexity, specifically focussing on the Future Automated Aerospace Assembly Phase 1 technology demonstrator (FA3D). The FA3D Phase 1 demonstrated automated assembly of aerospace products using precision robotic processes in conjunction with low-cost reconfigurable fixturing supported by large volume metrology. This was underpinned by novel agent-based control for transformable batch-size-of-one production. The paper will conclude by introducing Phase 2 of the Future Automated Aerospace Assembly Demonstrator - currently in development - that will translate the Evolvable Assembly Systems research to a higher technology readiness level and address the challenges of scalable and transformable manufacturing systems.

Modern manufacturing companies are under economic pressure to respond more rapidly to a changing production environment, including short product life cycles, individually customisable products, and the introduction of new disruptive manufacturing processes. This paper details a new manufacturing philosophy and software architecture for Evolvable Assembly Systems, based on the principles of decentralization, context-awareness and intelligent resources, that is implemented using intelligent agent technology and a data distribution service. We also detail the Smart Manufacturing and Reconfigurable Technology demonstrator - an instantiation of the Evolvable Assembly Systems architecture - that implements a proof-of-concept abstract custom pharmaceuticals production line.

The automation and flexibility of production systems is a key step towards improved profitability and competitiveness in high labour cost areas, when producing high-complexity, low-volume products. In the Evolvable Assembly Systems (EAS) project, the 'manufacturability' (or 'realisability') and 'control' algorithms were introduced to accommodate the batch-size-of-one production of highly customisable products. These algorithms enable checking whether a production line can manufacture a given product with its available set of resources, and how the product should be manufactured, e.g. which resources to use, and when. To this end, the authors formally define production recipes, which represent products, and manufacturing resources which make up a manufacturing facility. This paper re-defines these notions in the ISO-standard EBNF (Extended Backus-Naur Form) notation, and adapts the the manufacturability and control algorithms to accommodate the new definitions. The new algorithms and data structures reflect more closely the ones that are used in an implemented software tool. This paper also reports a method by which recipes and resources could be used to generate manufacturing process controllers in the Business to Manufacturing Markup Language (B2MML) standard. In doing so, this paper takes a step toward a complete path from the formal specification of a manufacturing facility and the products to be manufactured, to the automatic generation of executable process plans.

Research into molecular computation offers exciting possibilities for interfacing computation with biological systems. This could be achieved using light to switch photochromic molecules between states. For example, 6-Nitro-BIPS2 can be switched from a Spiropyran (SP) state to a Trans-Merocyanine (MC) state using UV photons while visible light switches from MC to SP. The MC state is also fluorescent. Modified spiropyrans targeted to proteins can improve imaging contrast3, alter enzyme activity4, alter protein interactions5 and switch vesicle permeability6.

In this paper we detail experimental methods to implement registers, logic gates and logic circuits using populations of photochromic molecules exposed to sequences of light pulses. Photochromic molecules are molecules with two or more stable states that can be switched reversibly between states by illuminating with appropriate wavelengths of radiation. Registers are implemented by using the concentration of molecules in each state in a given sample to represent an integer value. The register's value can then be read using the intensity of a fluorescence signal from the sample. Logic gates have been implemented using a register with inputs in the form of light pulses to implement 1-input/1-output and 2-input/1-output logic gates. A proof of concept logic circuit is also demonstrated; coupled with the software workflow describe the transition from a circuit design to the corresponding sequence of light pulses.