A digital twin-based layout optimization method for discrete manufacturing workshop

Abstract

In the discrete manufacturing workshop, an unreasonable workshop layout has a significant impact on the production efficiency, which can result in a large distance between operations, low utilization of tooling, and the backlog of products in production process. However, the existing optimization algorithms for workshop layout rarely take into account the real-time feedback of physical information from the workshop such that the layout cannot be self-adjusted to realize the optimum during manufacturing. Thus, this paper focuses on a discrete manufacturing workshop layout optimization based on digital twin, in which the workshop layout problem is solved by twin data fusion, information and physical interaction fusion, and data analysis and optimization. First, a sub-framework of digital twin-based workshop partitioning is established and the workshop partitioning is optimized via simulation analysis. Second, a sub-framework of digital twin-based equipment layout optimization is presented, in which equipment layout decisions are made by real-time data collection and value-added processing of twin data. Then, a sub-framework of digital twin-based distribution route optimization is developed for the workshop. Finally, the proposed method is applied to a welding production workshop and increased the production capacity o by 29.4%.