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Procedia CIRP 93 (2020) 32–37
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53rd CIRP Conference on Manufacturing Systems

An Industry 4.0 framework for tooling production using metal additive

manufacturing-based first-time-right smart manufacturing system
Mandaná Moshiria,*, Amal Charlesb, Ahmed Elkaseerb,c, Steffen Scholzb,d, Sankhya Mohantya,
Guido Toselloa
a
Department of Mechanical Engineering, Technical University of Denmark, Building 427, Produktionstorvet, 5 DK-2800 Kgs. Lyngby, Denmark
b
Institute for Automation and Applied Informatics, Karlsruhe Institute of Technology, 76344 Eggenstein-Leopoldshafen, Germany
c
Faculty of Engineering, Port Said University, Port Fuad 42526, Egypt
d
Karlsruhe Nano Micro Facility, Hermann-von-Helmholtz-Platz 1, 76344 Eggenstein-Leopoldshafen, Germany
* Corresponding author. Tel.: +45-52211838. E-mail address: [email protected]

Abstract

This paper presents a concept for an integrated process chain for tooling production based on metal additive manufacturing. The proposed
approach aims at taking advantage of a fully digitized production line, describing the main steps for the synergetic integration of the manufacturing
assets. The production line entails digital infrastructure that collects and elaborate data from various monitoring sensors to execute corrective
actions and continuously optimize the process. This line will bring breakthrough benefits, like flexibility and full traceability. Also challenges,
as change management in the industry, skills gap, the requirement of new business models and product re-design have been addressed.
© 2020 The Authors. Published by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review under responsibility of the scientific committee of the 53rd CIRP Conference on Manufacturing Systems
Keywords: Smart manufacturing, Industry 4.0, Additive Manufacturing, Automation, Tooling

1. Introduction successful implementations of MAM for tooling production. In

particular, MAM enables introduction of conformal cooling
Metal Additive Manufacturing (MAM) is a group of digital channels (curved conduits inside the insert) into the new design
production technologies that involve manufacturing the of mould inserts. These conformal channels promote a more
product layer-by-layer using metallic materials. In one of the efficient cooling of the plastic injected inside the mould,
most industrially-relevant MAM processes, known as laser thereby decrease the manufacturing cycle time, improving the
powder-bed fusion, a thin layer of metallic powder is iteratively thermal management (dissipation) of the process, and
spread over a building platform and processed with a laser (of enhancing the quality of the plastic product [8–10]. Although
appropriate wavelength, power, frequency and pulse duration). there have been some attempts to utilise MAM for tooling,
The laser scans over the layer according to the CAD design of there have been no detailed study on incorporating MAM into
the product being manufactured in order to selectively melt a full production line for first-time-right (FTR) tooling
corresponding areas of the powder bed [1]. Such a process manufacturing. In this context, the scope of this paper is to
allows unparalleled design and material freedom, which opens present an original concept of a smart and holistic production
the possibility for new product-functionality and performances system, incorporating elements of Industry 4.0, for the
[2,3]. The main current applications of MAM involve manufacture of mould tool components by using MAM
biomedical [4], aviation and aerospace [5], automotive [6] technologies. In the proposed production line, every step will
industry and tooling production [7]. The production of mould be fully monitored to collect manufacturing data in order to
components for injection moulding exemplifies one of the most recognise responses, control their performance through

2212-8271 © 2020 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review under responsibility of the scientific committee of the 53rd CIRP Conference on Manufacturing Systems
10.1016/j.procir.2020.04.151

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 Mandaná Moshiri et al. / Procedia CIRP 93 (2020) 32–37 33
00 ( ) 000

Figure 1 Manufacturing process chain for tooling production.

continuous process optimisation, and ensure full traceability of (corresponding to specifications of the product). This would
the products and the equipment used. The integrated create a knowledge feedback-loop whereby the digital
manufacturing process chain is presented in subsequent production system would continuously learn from the previous
sections of this paper with an initial focus on the aspects that process instances to better simulate the successive instances
make it “smart” and digital. Then, the advantages and expected [15,16]. For products with a larger lot size, the response models
challenges of such a production line are explained along with created via the machine learning algorithms can increasingly
other key aspects, while highlighting the research gaps to be substitute simulations in the daily production workflow within
addressed for reaching the final objective. the integrated manufacturing process chain, while simulations
will still play a major role in pre-production stage. However,
2. Integrated manufacturing process chain for small lot size production, simulations will play an active
role during production stage with response models from
2.1. Production flow machine learning algorithms solely being used for feedback
process control. It is worth emphasizing that to achieve this
Figure 1 illustrates the layout and the workflow of the goal, and other objectives later presented in this paper,
proposed production line for tooling manufacturing, wherein a application of machine learning will be essential.
single independent production module/unit is defined for a The manufacturing process proposed for the MAM is Laser
hybrid chain. The layout contains all the required steps to fully Powder Bed Fusion (LPBF). Metal powder from storage, e.g. a
produce a complete tool, making it an independent production silo, is directly fed into the machine´s dispenser through a pipe.
module. Further, the module contains both additive and Then, using optimal processing parameters, the MAM machine
subtractive technologies and is designed for manufacturing produce a component near-net-shape to the final product. Any
companies that can work with products of small lot size, down residual unused powder in contact with the part is removed by
to a one of part production. The integrated process chain starts a robotic arm that also removes the build plate on which the
with the design of the components using CAD software, in part is produced, and put it on a conveyer belt. This will bring
combination with advanced tools like topology optimisation the platform and the part inside a furnace for heat treatment, for
and generative design, to simultaneously take advantage of the the relief of residual stresses resulting from prior MAM process
MAM increased design freedom as well as ensure the optimum and bring the metal alloy to its optimal mechanical properties.
performance of the final product. A topology optimisation tool Since the component has already a geometry close to the
would ensure equal (or even better performance) while final one (near-net-shape) it will not require a great amount of
optimising other design parameters, for example reducing the material removal. However, considering the current limitations
weight [11,12]. Next, the performance of the optimised part of LPBF technologies regarding part´s precision, accuracy and
under “in-service” conditions has to be simulated to ensure that surface quality [17–20], some extra post-processes are
the functional requirements are satisfied. Simulations of the necessary to meet the requirements of the final application. 5-
manufacturing process are also conducted to predict eventual axis CNC operations together with some other finishing
issues during production of the optimised part, and adopt operations, e.g. wire-EDM and polishing, are included
necessary preventive/corrective measures [13,14]. In current depending on the final application of the tool [21]. For
digital production lines, the simulation step has already become simplifying these post-processing operations, the part is printed
important, with the significance set to increase along with the directly on top of a designated fixture. To make this
advancement of faster and more reliable algorithms. The digital manufacturing line fully integrated, behaving as a unique
and Industry 4.0 integrated nature of the process chain will system, compatible fixtures assembled in a frame can be
further promote the significance of simulations by collecting integrated building platform of the MAM machine [22,23].
manufacturing data and component-related information via Then, another conveyor belt after the furnace will move the part
monitoring. The monitoring information would provide the real to the disassembling station, where a robotic arm separates the
boundary/environmental/process conditions necessary for the different products. Integrated functional features, such as the
simulations, while the manufacturing data will provide the fixtures integrated into the MAM building platform, help
initial validations for the simulation results. Subsequently, reducing the lead-time of the production by eliminating further
machine learning algorithms can identify the key performance processing steps. This would also lead to a simplification of the
indicators correlating the manufacturing data variables, overall manufacturing line, the reduction of manufacturing
monitoring data variables and simulated outputs of interest errors and more energy efficiency [24]. In the disassembly
process, each disassembled fixture is picked by a rotating robot

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that will bring it to the final processing steps. The next step for and warehouse planning. This system will ensure a total
finishing is inside a CNC workstation that can include horizontal and vertical integration of the whole industry, in
equipment for quality control of the product (e.g. accordance with Industry 4.0 requirements [27].
photogrammetry or CMM probes). The quality control step can The expected outcome of real-time monitoring is to be able
be performed before the CNC operation, to check the quality of to recognise manufacturing issues and to enable the feedback
the MAM product, and after the operation, to ensure that the system to address them, thus improving the precision of the
desired tolerances are achieved. Similarly, these controls can process or even avoiding errors in the next fabrication trials
be performed also on the drilling/milling bits used for [28,29]. In particular, by analysing the monitoring data and
machining, to check their wear and to send an alert when it identifying the trends, it is possible, as mentioned, to optimise
needs replacing. The robot then transfers the part to the second the process itself. When sufficient amount of data is collected,
station, where the component and the fixture are separated, so trends can be elaborated to predict process evolution. By
the first can proceed to the third station, where some final post- implementing these information into statistical modelling
processes are conducted and the product is ready to use. As approaches such as regression or through more advance AI and
formerly mentioned, example of final finishing processes can machine learning algorithms, it would be possible to first
be EDM or polishing, depending on the tool´s purpose. analyse patterns and the effects of various sensor data on the
Meanwhile, the fixture is moved to an assembly station, to be final quality of the produced part, e.g. dimensional accuracy
reused for the building platform for MAM, after any necessary [28], generated surface quality [30] as well as on system wide
post-processing (e.g. grinding) and then stored (moved by an performance indicators such as cycle time or throughput [29],
AGV system) close to the MAM machine. The robot in charge thereby allowing the creation of a process fingerprint [30].
of the powder removal and the platform movement can pick it Establishing a process fingerprint is vital in increasing
and fix it inside the machine to start the process again. As knowledge on a process which would in turn allow the user to
presented also in Figure 1, it is possible to recognise two main precisely control and tailor process parameters according to the
flows: a product process flow and a platform/fixtures flow. required quality. The proposed digital process chain is designed
to create a continuous learning process that would allow the
2.2. Digital process chain process to optimise itself, with a concurrent feedback loop
between real-time-control sensors and actuators implemented
What makes this proposed production line “smart” and in the manufacturing chain. Again, these corrective action can
“integrated” is how the process is monitored and data are be conducted without direct human intervention, thanks to the
collected and handled. In Figure 2 a data infrastructure is correlation created between process signatures and product´s
proposed: each and every step of the manufacturing line need quality and performance [31–33]. Optimising the process
to be equipped with sensors to fully monitor the process in real- would allow in this sense a FTR process chain, by correcting
time. In particular, real-time monitoring is used to real time eventual issues in the process, a reduction of the lead-
instantaneously capture the conditions of the working time, by optimising the process itself, and ensuring always the
environment for further data processing and feedback optimal product quality and functionality, especially
(correction) and continuous optimisation of the manufacturing considering the high costs related to tooling [34]. Other
process. The corrective measures can be performed important aspects coming from the monitoring of the process
autonomously via software algorithms or manually using are related to the safety of the people in the industrial
human machine interactions (HMI). Data acquisition in real- environment. This is especially true given the fact that all the
time monitoring can be implemented using, for example, smart equipment are always kept under control, not only the product
sensors and thermal cameras in order to inspect the quality of that is undergoing the manufacturing process and thus incidents
the printed products in-line. In our case, the physical system is in production environment will be reduced [35]. From an
AM (L-PBF), and thus the physical features of an L-PBF ecological point of view, the data collected would also include
process such as oxygen content in the build chamber, energy, water, material and other resources consumption for
temperature of the powder, attributes of laser (power, focal each machines and the process optimisation procedures would
distance, spot size, frequency, etc.), the melt pool radiation, include also decreasing these consumptions to minimize the
optical quality of the powder spreading on the platform and environmental impact [24,36,37].
power consumption could be monitored [25,26].
All of these data is then filtered and processed, to select
only the ones that represent the product quality fingerprint, and
so moved to the third level of the infrastructure. Here all the
processed data is collected, interpreted, analysed and correlated
to the information coming from the pre-manufacturing steps
(design and simulation) and post-manufacturing (tool
application, maintenance and end life). This helps to identify
how to optimise each step of the full life cycle of the tool. The
third layer is the one that gets connected to the rest of the
company´s data infrastructure and backbone, where key
information is saved and data from the rest of the company´s
departments are connected, such as the production scheduling
Figure 2 Data infrastructure for the global integrated digital process chain

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One can argue that the smart production line so developed 3.2. Challenges
will produce what are defined as “smart products”. These are
products that can be identified at any time (through for example At the same time, various challenges on the adaptation of an
QR codes, radio-frequency identification (RFID) or near field integrated production line need to be faced. The challenges
communication (NFC) by integrating apposite chips into the mostly depend on the research gap in some of the main fields,
products [38,39]. This helps recognize the status of the part, its for example process monitoring and product quality
manufacturing process and performances during its lifecycle correlation, cloud computing, big data management (essential
“in-service” or maintenance. All information regarding the tool to handle the massive amount of data coming from a fully
life and end life would be recorded in their identifiable code, monitored process chain), and data interpretation. The last one
and this further information would allow for continuous in particular, with the integration of artificial intelligence and
learning about the parts´ functionalities and thus to improve its
machine learning analytics make possible to create a self-
next generation while also generating data that can be used for
optimising process chain and creating a feedback loop on the
conducting life-cycle assessment of products [40].
part quality [33,40,52,53]. Coming from this IT backbone,
aspects like cybersecurity need to be faced to avoid any leaks
3. Advantages and challenges
of confidential and sensitive information [35,47]. Process
simulation and innovative design, also need to be explored and
The manufacturing line presented, as a modular independent
cell that considers holistically the entire production chain for improved further for actual industrial adoption. Other
tooling in a digital and integrated manner, will have many challenges involve the change of the human role in the process
advantages but also will pose challenges during implementation. chain. Though Industry 4.0 principles envision the role of a
human being to remain at the centre of future manufacturing
3.1. Advantages scenarios, it will transform from the direct operation of the
machine to remotely programming and controlling the full
Most of the advantages has been already presented above, chain [34,54]. Traditional manufacturing companies with
but it is worth adding that, especially thanks to the integrated ageing populations in their workforce will need to develop
MAM system, this process chain will ensure full flexibility. strategies to deal with this type of role change by developing
This is intended as the system must be able to adapt to new and programmes for its employees to develop the new skill sets and
innovative production requests. However, since it is completely raise awareness in topics, like deep simulation and coding
digitally controlled, it would require a different type of experience [47,55]. A great amount of time need also to be
machine´s re-programming, but the equipment and the digital devoted to change management, to make sure that the
backbone would be already prepared to face new demands, company´s environment would be ready to the change in terms
behaving as a Flexible Manufacturing System (FMS) [41,42]. of resources and of mindset. Mindset especially represents a
Apart from the flexibility there is also the responsiveness of the key aspect of the adoption of a process chain aligned with
system, defined as its capability to react quickly to change. This Industry 4.0 concepts, since the lack of preparation and
advantage is very important today and it will become even education activity can lead to a complete failure of the system,
more important in the future considering the high speed of even if it is perfectly functioning from an equipment point of
growth of the economy and the increase of competitiveness view, if the people are not ready to face the change [37,49].
represented by the newly developing markets [35,43,44]. People’s trust will play a major role in the success of
A modular system that is fully digitalized also presents the implementation of a fully digital system. Especially since the
possibility to easily decentralise production in locations closer nature of work changes, it is important to underline that such a
to the customers or to the materials suppliers, where it is more
system does not want to eliminate the direct role of humans,
convenient, while maintaining the centralised control of the
but it wants to instead change its role to a more efficient,
production remotely from the headquarters [45,46]. On the
productive and safe one, but it requires readiness of learning
other hand, the structure and the monitoring system of the line
will guarantee full traceability of products and tools used for new skills and acceptance of the change. A challenge is also the
the manufacturing (e.g. fixtures, drill bits, building platform) lack of shared list of clear requirements that are necessary for
and will be capable to capable of visualising the full life cycle. an Industry 4.0 frameworks, even if this gap is getting filled in
This would generate an holistic view of the process that would the recent years in literature [27,34,40,47,56,57]. How to face
allow the management to take informed decisions when the change management will depend mostly on the reality of
necessary This represents one of the main pillars of the Industry the industry (number of employees, level of digitisation, etc.)
4.0, regarding the Internet of Things (IoT) [47–49]. The high but investments in education and training is fundamental.
level of automation of the line will increase the robustness and
the reliability of the process, improving the repeatability of the 4. Discussion
production, since the experience and the capabilities of the
users will not influence the results of the products [50,51]. One of the most important aspect in the new production
chain in accordance with Industry 4.0 concepts is that it looks
in a holistic way at the entire process as a unique entity: it must
become an independent, organic modular system behaving as a
single unit, to ensure a flexible manufacturing line. In this way,

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it is possible to be always fully aware that any change at any 4. Conclusion

step will generate a modification in the other step of the
process, and if the process is already controlled globally, the This paper has presented the concept of a smart, integrated
impact of these changes can be precisely measured and and modular production system, designed for a hybrid process
predicted to not create any waste or issues [48,58,29,59,60]. To chain aiming to manufacture tooling in small lot sizes, that is
achieve this vision, the compatibility and open but secured with the context of industry 4.0. Several different causes of
machine to machine communication for all the manufacturing reflections have been discussed with a comprehensive list of
assets and with reliable IT infrastructure must be ensured. An advantages and challenges that need to be faced. The main
open- communication protocol will be necessary, like OPC benefits for companies in starting such a change can be
UA, with machines that are open platforms, which allows full summarised as follow:
sharing of data, as well as user-friendly Human-Machine • Full monitoring of the system to early identify issues to
Interaction (HMI) interfaces [61–63]. Open communication be handled, creating the fundaments for FTR production.
and trust cannot refer to machine and equipment only, but also • The data collected from the process help gain consequent
inside the company across departments: considering the knowledge about the process which in turn can facilitate
increase of complexity and the diversification of skills required automatic feedback loops for process optimisation to be
in the new manufacturing system, totally open communication integrated in the future.
with robust and reliable methodologies to share confidential • Total traceability of products and tools used for
information real time will be essential. The equipment between manufacturing ensures fully understanding the effect of
each other need to be compatible through the use of matching the manufacturing choice in the full life cycle of the AM
devices, like the platform-fixture system above presented. The product, also by identifying product’s fingerprints.
overall manufacturing system and planning, especially in a • By the analysis of the data regarding consumptions the
large production framework, where multiple modules are process can be optimised to reduce them, to make it more
necessary, and/or for industries working with batch size of one, environmentally friendly.
needs to be carefully prepared and controlled with a robust and • Safer work environment were all the machinery and
appropriate Manufacturing Execution System (MES) and equipment is constantly under controlled.
Enterprise Resource Planning (ERP) capable of handling
• Scalable and flexible modular setup, to be quickly
machines coming from different suppliers and various
reactive to changes in production demands.
products. The increased focus on open communication,
The integration of such a manufacturing system is disruptive
planning management and monitoring data analytics open up
compared to the current solutions, since it take a holistic look
also the requirements of strong and robust data infrastructure
inside the company, to store safely and share fast information, at the overall process chain. It must cover the entire process
reacting promptly to any circumstances [64,65]. chain to get the full benefits, not just sections of it. The
Regarding benefits coming from an integrated line integration in a company must start with education campaigns
manufacturing smart product, a direct reduction of costs cannot to create the fundamental knowledge and understanding of the
be expected, because of the expensive initial investment of effects of it, together with change management on all levels, to
equipment and IT infrastructure. The major benefits would be ensure the right mindset when the 4th Industrial revolution gets
reduction of lead time and scraps, thanks to the reduction of fully underway. The digital transformation will affect the
manual intervention required, and the FTR management of the whole aspect and every sector of the organisation and for these
process, where potential issues are either predicted through reason new business models need to be introduced to handle it.
simulation or machine learning, based on previous experiences,
or identified in time to be corrected through the monitoring, Acknowledgements
together with preventive maintenance of tools and equipment.
This in turns will bring eventual cost savings [34,40,66–69]. This project has received funding from the European
The topic of the change of human role has already been Union’s Horizon 2020 research and innovation programme
presented, but another observation is important to be discussed: under the Marie Skłodowska-Curie grant agreement N 721383.
not only it changes the worker´s role in the production line, but
also leadership approach need to change. This is necessary to References
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