2019
Authors
Santos, R; Basto, J; Alcalá, SGS; Frazzon, E; Azevedo, A;
Publication
Proceedings of the International Conference on Industrial Engineering and Operations Management
Abstract
The industry faces more and more the challenge of deploying and taking advantage of evidence-based strategic decisions to enhance profit gain. In this research, the possibility of having a fully integrated system composed by a simulator and an IoT platform with the capability of collecting real-time data from the shop floor and returning performance indicators to support decision making is evaluated. The suggested approach involves a Manufacturing Executing System (MES) producing a production schedule, an IoT Platform composed by a message broker and a real-time database, a Simulator including simulation software and a wrapper, and a user application serving as an interface between the user and the IoT Platform and Simulator integrated system. A detailed analysis of the functionalities and integration of the Simulator and the IoT Platform will also be explored. To evaluate the approach, one use case of a production line in the automotive industry is used. The application of the integrated IoT Simulation system permits its validation and consequent future work. © 2019, IEOM Society International.
2021
Authors
Santos, R; Toscano, C; de Sousa, JP;
Publication
IFAC PAPERSONLINE
Abstract
The principles and tools made available by the Industry 4.0, smart factories, or the Internet of Things (IoT), along with the adoption of more comprehensive simulation models, can significantly help the industry to face the current, huge external and internal challenges. This paper presents a new simulation-based approach to support decision making in the design and operational management of manufacturing systems. This approach is used to evaluate different layouts and resources allocation, and help managing operations, by integrating a simulation software with real-time data collected from the production assets through an IoT platform. The developed methodology uses a digital representation of the real production system (that may be viewed as a form of a digital twin) to assess different production scenarios. A set of key performance indicators (e.g. productivity) provided by the simulation can be used by the Manufacturing Execution System (MES) to generate production schedules. The developed approach was implemented and assessed in a real case study, showing its robustness and application potential. Its extension to other industrial contexts and sectors seems, therefore, quite promising. Copyright (C) 2021 The Authors.
2025
Authors
Teles, ,; Santos, F; Guardao, L; Figueira, G;
Publication
Procedia Computer Science
Abstract
The Maintenance, Repair and Overhaul (MRO) activities in the aviation industry face constant challenges due to the uncertainty and variability of their operations. Aircraft engine maintenance, which is fundamental to the safety of aircraft operations, is particularly challenging due to its job-shop nature. Each engine requires a specific intervention process, based on its condition and the needs identified. The inherent uncertainty in task duration, resource availability, and the scope of required repairs adds complexity to capacity planning. Traditional capacity planning methods often fall short in accounting for these uncertainties, leading to potential inefficiencies and bottlenecks. Discrete Event Simulation (DES) emerges as a powerful tool to address these challenges. By modelling the entire MRO process, DES can consider various scenarios, incorporating the stochastic nature of task times, machine downtimes, and labour availability. This study explores the application of DES to evaluate capacity planning and quantify the impact of uncertainty on operational efficiency. The proposed methodology enables the anticipation of delays and enhances resource management. The primary contribution of this work is the ability to predict delays and quantify their impact. The future application of this tool in real-world MRO operations has the potential to enhance operational efficiency and reliability. © 2025 Elsevier B.V., All rights reserved.
2025
Authors
Rema C.; Santos R.; Piqueiro H.; Matos D.M.; Oliveirat P.M.; Costa P.; Silva M.F.;
Publication
2025 IEEE INTERNATIONAL CONFERENCE ON AUTONOMOUS ROBOT SYSTEMS AND COMPETITIONS, ICARSC
Abstract
Industry 4.0 is transforming manufacturing environments, with robotics being a key technology that enhances various capabilities. The flexibility of Autonomous Mobile Robots has led to the rise of multi-robot systems in industrial settings. Considering the high cost of these robots, it is essential to determine the best fit of number and type before making any major investments. Simulation and modeling are valuable decision-support tools, allowing the simulation of different setups to address robot fleet sizing issues. This paper introduces a decision-support framework that combines a fleet manager software stack with the FlexSim simulator, helping decision-makers determine the most suitable mobile robots fleet size tailored to their needs. Unlike previous approaches, the developed solution integrates the same real robot coordination software in both simulation and actual deployment, ensuring that tested scenarios accurately reflect real-world conditions. A case study was conducted to evaluate the framework, involving multiple tasks of loading and unloading materials within a warehouse. Five different scenarios with varying fleet sizes were simulated, and their performances assessed. The analysis concluded that, for the case study under consideration, a fleet of three robots was the most suitable, considering relevant key performance indicators. The results confirmed that the developed solution is an effective alternative for addressing the problem and represents a novel technology with no prior state-of-the-art equivalents.
2025
Authors
Carvalho, C; Pinho De Sousa, J; Santos, R; Marques, M;
Publication
Transportation Research Procedia
Abstract
By connecting maritime and land transport, container terminals play a critical role in global logistics systems, as part of broader intermodal networks. The evolution of containerisation and technological advances, along with increased demand and volumes, led to significant adaptations in these terminals, as a way to improve productivity, reduce costs and increase competitiveness, while coping with spatial and operational constraints. For strategic decision-making, managing these complex systems can be enhanced by simulation models allowing the analysis of different scenarios in dynamic, uncertain environments. This work, presents a simulation-based decision support tool developed in the FlexSim software, to analyse different container terminal configurations, with a particular focus on automation and on sustainable practices to reduce the energy consumption of terminals. A discrete event simulation model was developed to study multiple scenarios impacting productivity, resource utilisation, and waiting times. The proposed approach allows the test and evaluation of management strategies for port operations, with preliminary results showing that sizing and planning of the fleets of automated guided vehicles (AGV) can significantly affect the total operating time, the energy consumed, and the costs associated with battery charging operations. Future research should explore additional factors affecting container terminal operations, such as the reorganisation of the storage area, while incorporating optimisation elements for work planning and resource allocation. Moreover, the simulation model will be tested and validated in a real case study, designed for the Port of Sines in Portugal. © 2024 The Authors.
2024
Authors
Silva, C; Santos, F; Senna, P; Borges, M; Marques, M;
Publication
Springer Proceedings in Business and Economics
Abstract
Warehouses and distribution centres play a key role in any Supply Chain, particularly in the retail sector, where a network of stores needs to be replenished in a highly dynamic and increasingly uncertain context. In this regard, companies need to improve their intralogistics systems daily to ensure long-term competitiveness and sustainable growth. This is especially true in picking-by-line systems where many time-consuming and manual tasks are usually involved. This study introduces a new decision support tool based on simulation methods to aid the decision-making process in a picking-by-Line system, aimed to improve the overall picking operations efficiency, through human-centric perspective. A Discrete-Event-Simulation model is proposed to assess a set of parameters under several scenarios, driving a more informed decision-making process towards cost-effective strategies. The proposed approach was validated through an empirical case study showing its effectiveness in assisting operational planning decisions related to capacity and resource allocation. The system demonstrates promising versatility for application across varied warehouse environments. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2024.
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