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Procedia Computer Science 00 (2018) 000–000
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Procedia Computer Science 00 (2018) 000–000
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Procedia Computer Science 159 (2019) 2232–2239

23rd International Conference on Knowledge-Based and Intelligent Information & Engineering

23rd International Conference on Knowledge-Based
Systems and Intelligent Information & Engineering
Systems
Smart Virtual Product Development (SVPD) to Enhance Product
Smart Virtual Product Development (SVPD) to Enhance Product
Manufacturing in Industry 4.0
Manufacturing in Industry 4.0
Muhammad Bilal Ahmeda* , Cesar Saninbb, Edward Szczerbickicc
Muhammad Bilal Ahmed , Cesar Sanin , Edward Szczerbicki
a*
a
The University of Newcastle, [email protected], Newcastle 2230, Australia
a
The
b
University
The of Newcastle,
University [email protected],
of Newcastle, Newcastle
[email protected], Newcastle 2230,
2230, Australia
Australia
c b
The University
Gdansk of Newcastle,
University [email protected],
of Technology, Newcastle 2230,
[email protected], Australia
Gdansk, Poland
c
Gdansk University of Technology, [email protected], Gdansk, Poland

Abstract
Abstract
This paper presents a system capable of enhancing product development process for industrial manufactured products. The system
This paperaspresents
is known a system
Smart Virtual capable
Product of enhancing(SVPD),
Development product and
development
it helps inprocess formaking
decision industrial
by manufactured
using explicit products.
knowledgeThe of system
formal
is knownevents.
decision as Smart
It Virtual Product
stores and reusesDevelopment (SVPD),events
the past decisional and it helps
or setinofdecision making
experiences by using
related explicit activities
to different knowledge of formal
involved in
decision
industrialevents.
productItdevelopment
stores and reuses
processthei.e.past decisional
product design,events or set of and
manufacturing, experiences related to different
product inspection. activities
This system can beinvolved in
potentially
industrial
used in largeproduct development
enterprises process ai.e.
manufacturing product
range design,
of similar manufacturing,
products and productorinspection.
in mass production, a group ofThis
smallsystem can be enterprises
and medium potentially
used in large
(SMEs). Thisenterprises manufacturing
research explains that how a range of similar
product productscan
manufacturing in mass production,
be enhanced by or a group
using SVPDof small and medium
in Industry enterprises
4.0, where cyber-
(SMEs). systems
physical This research
have toexplains
play thethat
keyhow
role.product manufacturing
The analysis can be enhanced
of basic concepts by using SVPD
and implementation methodin proves
Industry 4.0,
that thiswhere
is an cyber-
expert
physicalfacilitating
system systems have to play
product the key role.which
manufacturing The analysis ofabasic
can play vital concepts and Industry
role towards implementation
4.0. method proves that this is an expert
system facilitating product manufacturing which can play a vital role towards Industry 4.0.
© 2019 The Author(s). Published by Elsevier B.V.
©© 2019
2019 The The Author(s).
Authors. Published
PublishedbybyElsevier
Elsevier B.V.
B.V.
This
This isis an
an open
open access
access article
article under
under the
the CC
CC BY-NC-ND
BY-NC-ND license
license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is an open
Peer-review access
under article under
responsibility of the CC
KES BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
International.
Peer-review under responsibility of KES International.
Peer-review under responsibility of KES International.
Keywords: Smart Virtual Product Development, Product Development, SOEKS, Manufacturing Capability Analysis and Process planning,
Keywords: Smart
Manufacturing Virtual
Process Product Development, Product Development, SOEKS, Manufacturing Capability Analysis and Process planning,
Planning
Manufacturing Process Planning

1. Introduction
1. Introduction
Manufacturing organizations which produce similar products are facing shear competition due to: continuous
Manufacturing
market changes, needorganizations which lifecycles,
for short product produce similar products are customer’s
and accomplishing facing shear competitionfordue
expectations to: continuous
producing quality
market changes, need for short product lifecycles, and accomplishing customer’s expectations for producing
products at lower cost. This forces them to adopt new product development strategies regularly and systematically quality
1
.
Product design and manufacturing are vital steps involved in product development process, as they require robust.
products at lower cost. This forces them to adopt new product development strategies regularly and systematically 1

Product design
information andand manufacturing
knowledge arecustomers’
regarding vital steps demands
involved2.inSuccessful
product development process, as
product development they requireacquire
organizations robust
information and knowledge regarding customers’ demands 2
. Successful product development organizations
at least two types of design knowledge; first one is regarding the product itself, and the second one is concerned aboutacquire
at least
its two types ofindesign
manufacturing knowledge;
an effective firstmeet
way to one cost,
is regarding
quality,the product
and short itself,
productanddevelopment
the second one
timeis3concerned about
. Manufacturing
its manufacturing in an effective way to meet cost, quality, and short product development time3. Manufacturing
* Corresponding author.E-mail address: [email protected]
* Corresponding author.E-mail address: [email protected]
1877-0509 © 2018 The Authors. Published by Elsevier
1877-0509 © 2018under
B.V. Peer-review The Authors. Published
responsibility by International
of KES Elsevier
B.V. Peer-review under responsibility of KES International

1877-0509 © 2019 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review under responsibility of KES International.
10.1016/j.procs.2019.09.398
 Muhammad Bilal Ahmed et al. / Procedia Computer Science 159 (2019) 2232–2239 2233
Author name / Procedia Computer Science 00 (2018) 000–000

knowledge is an expression with enormous meanings, it may include: knowledge of the effect of material properties
in decision making, machine and process selections, and understanding the unintended consequences of design
decisions on manufacturing4. Designers have to do manufacturing planning to evaluate manufacturability in terms of
criteria and metrics, such as cost and time. Therefore, the use of inappropriate manufacturing knowledge can lead to
mistakes during product development and can harm the environment. These mistakes are likely to be caused by
designers relying on poor or inadequate manufacturing knowledge during the product design process5.
Electronics and IT have played a key role in the 3rd industrial revolution by increasing automation of production.
Now, the global manufacturing industry is moving towards Industry 4.0, which is the 4th industrial revolution.
Conventional manufacturing processes will be replaced by smart manufacturing, which consists of new concepts, i.e.
Internet of Things (IoT), Internet of Services (IoS), Cyber-Physical Systems (CPS), Mass collaboration, High-speed
internet, and affordable 3-D printing6. Fourth industrial revolution has addressed several changes to the conventional
manufacturing systems and this has resulted in the development of more complex and smarter products with new
capabilities. Therefore, it has an impact on the whole product lifecycle and is causing the emergence of advanced
digital tools for product development and prototyping, which comprise of advanced computing platforms. Producing
these smart products means profound changes in classical product development processes, who have experienced
several achievements in the last few decades in terms of theory, methods, and approaches7. Therefore, relationship
between the product development process and fourth industrial revolution is un-explored, but the huge amount of data
retrieved from smart manufacturing makes it interesting. It arises different types of questions in terms of product
development process, such as: how can it help in satisfying the customers’ requirements, minimizing the development
cycle time, and controlling the product development cost. This all has created a great potential for the development of
new smart knowledge-based product development frameworks for the design and development of smart products8.
The concept of smart manufacturing is also closely related to knowledge-driven decision making to meet
customers’ demands for new products. In order to make decisions at various stages of product development, it is very
important to have complete knowledge of each manufacturing process and its possible outcomes. Furthermore,
engineering knowledge is embedded in various stages in the product lifecycle in the form of rules, logical expressions,
ontologies, predictive models, statistics, and information extracted from previous experiences and sensors in real-
world situations, such as production, inspection, product use, supplier networks, and maintenance. Currently,
knowledge is not completely captured and stored in a digital form during all phases of product life cycle. Therefore,
organizations are aiming at achieving streamlined knowledge capture and curation through knowledge management9.
We try to cope this problem by proposing a system that uses a collective, team-like knowledge created from
relevant past experiences; we named this system as Smart Virtual Product Development (SVPD). This approach uses
a smart knowledge management technique called Set of Experience Knowledge Structure (SOEKS or SOE in short)
and Decisional DNA10. It captures, stores, and shares the experiential knowledge in the form of set of experiences
during important phases of industrial product development i.e. product design, manufacturing, and product inspection
(quality aspects). Whenever a similar query is presented during the problem solving process, this stored knowledge is
recalled to overcome the problem. It provides a list of proposed optimal solutions according to the priorities set by the
user. By the passage of time, system achieves more expertise in specific domains as it stores relevant knowledge and
experience related to formal decision events.
This paper is organized as: in Section 2, basic concepts are introduced i.e. Product development, Set of experience
knowledge structure (SOEKS), Smart manufacturing, and Cyber-physical systems. Section 3 introduces the proposed
Smart Virtual Product Development (SVPD) system and explains its architecture. Design of test case study for one of
the important modules of proposed system i.e. manufacturing capability and process planning (MCAPP) is presented
in Section 4. Section 5, presents results and discussion. Finally, conclusions and future work are given in Section 6.

2. Background

2.1 Product Development

Product development is a series of interconnected processes and sub-processes, which covers product design,
production design, product introduction process, and the start of its production 11. The main aim of product
development process is to integrate engineering and industrial design requirements through a structural process that
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Author name / Procedia Computer Science 00 (2018) 000–000

allows the achievement of lower production cost, higher quality, and shorter development time with quick access to
market, so that it can contribute to customers’ satisfaction and companies’ financial benefits 12. In past, various
classical methods such as Stage-Gate model process, Product development process by Ulrich and Eppinger,
Development funnel product model process, Simultaneous engineering (SE), Concurrent engineering (CE), Integrated
product development (IPD), and Lean product and process development (LPPD) have played key roles in the product
development process13.
As mentioned earlier the arrival of fourth industrial revolution, which encompasses a set of advancements in both
products and manufacturing processes. Therefore, the adaptation of this new industrial pattern and the production of
smart and connected products means intense changes in the whole organizations value chain, especially in product
development process. Henceforth, organizations that produce smart products need to adopt the most suitable product
development approaches. Resource optimization and waste elimination are one of the important factors to consider
during development of the smart products in order to increase company’s competitiveness. This can be achieved by
introducing and developing new technological tools which can eliminate mistakes during early stages of product
development7. Lean product and process development have achieved a great success in recent past by integrating
engineering knowledge into product development process. Few of the core lean enablers for product development
process are: Knowledge based engineering, Mistake proofing (Poka-Yoke), and Continuous improvement culture
(Kaizen)14. This research also uses a smart knowledge management technique called Set of Experience Knowledge
Structure (SOEKS) and Decisional DNA (DDNA) to enhance the product manufacturing process, which is one of the
important step in industrial product development.

2.2 Set of Experience Knowledge Structure (SOEKS) and Decisional DNA (DDNA)

Set of experience knowledge structure (SOEKS) has the ability to store and share the formal decision events in an
explicit manner15. It is basically a smart knowledge-based decision support tool which stores and maintains the
experiential knowledge. This experiential knowledge is used for future decision-making enhancement whenever a
new query is generated or presented. A set of experience (SOE, a shortened form of SOEKS) has four basic
components: variables (V), functions (F), constraints (C), and rules (R).
Variables define SOE’s functions, while functions create relationships between variables and are used to develop
multi-objective goals. Constraints are special functions which are applied by SOE to get feasible solutions and to
control system’s performance with respect to defined goals and limits. Rules, on the other hand, are the conditional
relationships among the variables and are defined in terms of IF-THEN- ELSE logical statements. Therefore, a formal
decision event is represented by a unique set of variables, functions, constraints, and rules within the SOE. Groups of
SOEs create chromosomes, which represent the specific area/domain within the given decision-making area, and they
store decisional strategies for a given domain. Accurately, structured and grouped sets of decisional chromosomes are
collectively known as its DDNA15.
Set of experience and DDNA have been successfully applied in various fields such as industrial maintenance,
semantic enhancement of virtual engineering applications, state-of-the-art digital control system of the geothermal
and renewable energy, storing information and making periodic decisions in banking activities and supervision, e-
decisional community, virtual organization, interactive TV, and product innovation16.

2.3 Smart Manufacturing and Cyber-Physical Systems

Smart manufacturing refers to the combination of advanced manufacturing capabilities and digital technologies to
improve the productivity, agility, and sustainability of manufacturing systems. It uses the Cyber-physical system
concept through the collaboration of computational elements to control various physical entities in the manufacturing
environment17. It is an emerging form of production which integrates manufacturing assets of today and tomorrow
with sensors, computing platforms, communication technology, control, simulation, data intensive modelling and
predictive engineering.
Cyber-physical systems (CPSs) are the key part of smart manufacturing along with internet of things, cloud
computing, artificial intelligence and data science. They can be described as the transformative technologies for
managing interconnected systems between its physical assets and computational capabilities with the possibility of
human machine interaction18. CPSs are increasingly important in manufacturing due to the digitization of the industry
driven by advances in technology and connectivity. They have advanced machines and sensors capable of producing
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high volumes of data. Therefore, data analysis tools can be used with these machines to create intelligent, autonomous,
and robust systems19. In modern manufacturing organizations, especially high-tech industries, CPS can be further
designed for managing knowledge and experience in the form of Big Data and leveraging the interconnectivity of
machines to reach the goal of intelligent factories 20.

3. Smart Virtual Product Development System (SVPD)

Smart Virtual Product Development (SVPD) system is a decision support tool for product development process
which stores, uses, and shares the experiential knowledge of past decisional events in the form of SOEs. It is developed
to overcome the need for capturing knowledge in the digital form in product design, production planning, and
inspection planning in smart manufacturing9. This will help in enhancing the product quality and development time
as required by Industry 4.0 concepts.

3.1 Architecture of Smart Virtual Product Development

Our proposed Smart Virtual Product Development (SVPD) system consists of three main modules, i.e. design
knowledge management (DKM), manufacturing capability analysis and process planning (MCAPP), and product
inspection planning (PIP). These modules interact with the decisional DNA of the system which holds all the relevant
knowledge of similar products. This knowledge repository is filled with past formal decisional events involved in
manufacturing of these similar products in existing facility. The proposed system stores decisional DNA knowledge
in the form of SOEs. The architecture of the SVPD system is shown in Fig. 1.

Fig. 1. Architecture of Smart Virtual Product Development (SVPD).

These modules have further different steps to perform particular decisional activity. Design knowledge
management deals with material selection process and product geometric features generation; manufacturing
capability analysis and process planning provides solution regarding manufacturing process planning, machines’
selection, and machines’ capability to perform particular manufacturing operations; and inspection planning involves
selection of different measuring equipment and gauges for product inspection during manufacturing and at final stage.
Once all of these modules are successful, it provides validation that a product can be easily manufactured in an
existing facility. Detailed working of design knowledge management module has been explained in our previous
work21. The aim of this research is to explain the working mechanism of MCAPP module, which will illustrates that
how manufacturing knowledge can be provided to design experts during early stages of product development.
2236 Muhammad Bilal Ahmed et al. / Procedia Computer Science 159 (2019) 2232–2239
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4. Design of a Test Case Study for the MCAPP-Module

Design and development of a threading tap (a tool to create screw threads which is called threading) is our case
study, as it was also used for DKM module in our previous work21. We are considering a machine-use threading tap,
as shown in Fig. 2 with few important dimensions. As mentioned above, this research copes with important variables
involved in the MCAPP module, so we will explain the working of manufacturing process planning, which is one of
the important steps in this module.

Fig. 2. Important dimensions in threading tap.

4.1 Working Algorithm of Manufacturing Process Planning

Manufacturing process planning is part of manufacturing capability analysis and process planning module of
SVPD. It deals with the processes required to manufacture the product in the existing facility13. The existing facility
for the case study (Threading Tap) is a small tool manufacturing factory which comprises of a design office, a well-
equipped machine shop (including conventional and non-conventional machines), metrology (inspection unit), and
heat treatment section. In this step, we have to decide which machining operations are required to manufacture the
product under consideration. Every process will start by inputting the query into the decisional DNA of the system
based on initial objectives. For the present case study of threading tap, let us consider that selected material is high
speed steel and the initial objective is to define manufacturing processes for this product. These manufacturing
operations can be simply recalled from an existing virtual engineering process (VEP) of a family of similar products.
Whereas, a VEP is a knowledge representation of manufacturing process-planning involving the required operations,
their sequence, and resources22. This data is stored in the form of VEP in a comma-separated values (CSV) file.
For illustrative purpose CSV file for manufacturing process planning is shown in Table 1. As the DDNA is
constructed in Java, the parser for manufacturing process planning is also written in Java programming by using
Windows 10 operating system. The pseudocode for parser reading CSV file for manufacturing process planning is
shown below:
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Author name / Procedia Computer Science 00 (2018) 000–000

• Reads variables, functions, constraints, and rules.

• Develops set of variables, set of functions, set of constraints, and set of rules.
• Creates a Set of Experience (SOE) = Set of variables + Set of functions +Set of rules.
• Form a chromosome of manufacturing process planning by collecting SOEs of the same category.
• Provide top 5 proposed solutions.
• User selects the final solution and it is saved as SOE in DDNA of SVPD for future reference.

Table 1: CSV File format for manufacturing process planning

Variables

P_tool P_material P_operation1 P_operation2 P_operation3 P_operation4 P_operation5 P_operation6

Threading Tap T11301 Material Cutting Turning Milling Heat Treatment Cylindrical Grinding Thread Grinding

Threading Tap T11302 Material Cutting Turning Milling Heat Treatment Cylindrical Grinding Thread Grinding

Threading Tap T12001 Material Cutting CNC Turning CNC Milling Heat Treatment Cylindrical Grinding Thread Grinding

Threading Tap T12002 Material Cutting CNC Turning CNC Milling Heat Treatment Cylindrical Grinding Thread Grinding

Similarly, the data for machines’ selection process is saved in the form of a VEP in a CSV file and is recalled by
putting an input query. However, the data about machines’ capability is stored in the form of a virtual engineering
object (VEO) in a CSV file and is recalled by placing an input query. Whereas, a VEO is the knowledge representation
of an engineering object that embodies its associated knowledge and experience. It is specialization of CPS in terms
of its extension into knowledge gathering and reuse23.Working mechanism of all steps/sub-modules of MCAPP
modules is depicted in Fig.3.

Fig. 3. Working of MCAPP module.

2238 Muhammad Bilal Ahmed et al. / Procedia Computer Science 159 (2019) 2232–2239
Author name / Procedia Computer Science 00 (2018) 000–000

5. Results and Discussion

Case study for manufacturing process planning was carried out on a Dell laptop with windows 10 Enterprise 64-
bit operating system having Intel ® Core ™ I5-7300u CPU @ 2.60 and 8 GB of RAM. Parser for manufacturing
process planning reads the data from a CSV file having information about 10 different types of threading types
according to material classification and type of use. This CSV file stores manufacturing processes in the form of 22
variables, 2 functions, and 3 constraints. The parsing process for manufacturing process planning was executed,
producing an average parsing time of 0.098 seconds, as depicted in Fig.4. This is considered a very good time, taking
into account that those SOE are quite complex due to the substantial number of variables, functions, and constraints.
Similarly parsing time for different SOE elements was; time to read variables 0.035 seconds, time to read functions
0.046 seconds , and time to read constraints was 0.012 seconds.

Fig. 4. Parsing time vs SOE elements for manufacturing process planning.

6. Conclusion and Future Work

This research revealed a system to support product development process by using experiential knowledge. The
system is composed of three modules, namely design knowledge management module (DKM), manufacturing
capability analysis and process planning (MCAPP), and product inspection planning (PIP). Working of MCAPP
module has been explained by developing one of its sub-modules i.e. manufacturing process planning in JAVA. It is
evident from the results of the case study that this system is capable of enhancing the technique of manufacturing
process planning by using the manufacturing related experiential knowledge of the similar products.
Decisional DNA of the whole system is capable of finding the suitable solution for the query according to the set
priorities and constraints. The user then selects the final solution, and this process is stored in in the Decisional DNA
of the product development system as experiential knowledge that can be used in future for solving a similar query.
The SVPD System behaves as a group of experts as it captures, stores, maintains, and reuses the experiential
knowledge of all similar products. Future work includes the extension of the SVPD system to explain the important
variables involved in working of product inspection planning (PIP) module.
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