**3. Reconfigurable conveyor system**

A production system consists of material handling equipment, production machines and tooling, computer control system, and others that promote the efficient use of energy, material, resources, and equipment. As the main component of production systems, material-handling systems can be defined by the movement, storage, protection, and control of products and materials throughout the processes of manufacturing, disposal, distribution, and consumption of all related materials and goods [28]. In possessing a new production system, a new concept of material handling should be proposed. Since conveyor is the most commonly used material handling equipment in production industries, research was conducted in developing a concept of reconfigurable conveyor system that supports changeability in production.

### **3.1 Reconfiguration in automated conveyor system life cycle**

The development of a conventional and centralized controlled conveyor system lies in a range of activities, which are different from technology and personnel requirements set by the system manufacturer. Current approaches for developing the system, while well-established and using well-proven methods, still follow a rigid sequential model and use an ad hoc collection of poorly integrated tools to translate requirements into the desired system (**Figure 7**) [29]. The planning and design of the system, fabrication of the mechanical structures, construction of electrical components, formation of control systems, and validation of the systems take place sequentially. In such an engineering process, the creation of the control system can only be carried out after all the electrical and mechanical units have been integrated.

In the operational phase, the conveyor system is utilized as it is intended. An operator of the system can monitor the operating status, identify malfunctions, and fix minor problems. In case of major problems, the help of the system provider is needed. Depending on the problem complexity, the system provider will help through a hotline, remote maintenance, or onsite maintenance.

After several years of operations or, in certain cases, changing of control strategies, restructuring or exchanging individual conveyor system units, expansion or modernization of an existing system are necessary. This is normally triggered by an increase in throughput demands, storage and buffer capacity, or a change in product variants. In principle, from the perspective of the system provider, the life cycle of the system will go through again for such cases (**Figure 8**). However, the key difference in these activities is the integration of new components with the existing systems either physical hardware (physical reconfiguration) or control software technology (logical reconfiguration) [26]. Specifically, the adaptation of existing conveyor system control software requires high efforts due to the engagement of all control logic levels. The largest effort lies in reconfiguring, reprogramming, and commissioning of an adapted material-flow control system [30].

#### **3.2 The conceptual framework**

A conceptual framework of a reconfigurable conveyor system can be classified into two categories, which are physical and logical. The physical aspect is the overall design of the conveyor including the shape, size, and material used. The conceptual design is drawn in computer-aided design software to visualize the suitability of the design with the reconfigurability criteria, before their construction. For

**177**

**Figure 8.**

**Figure 7.**

*The life cycle of an automated conveyor system [10].*

*Changes in the life cycle of an automated conveyor system [10].*

the logical aspect, the programmable logic controller (PLC) is used as the control system since it is the most commonly used controller in production industries. The physical reconfigurable conveyor system was designed in modules (**Figure 9**), in which each module consists of few components such as adjustable steel combine stands, adjustable wheels, pneumatic cylinders with turntable, and belt conveyor. This modular concept makes the conveyor system easier to integrate,

*Revolution of Production System for the Industry 4.0 DOI: http://dx.doi.org/10.5772/intechopen.90772*

#### *Revolution of Production System for the Industry 4.0 DOI: http://dx.doi.org/10.5772/intechopen.90772*

#### **Figure 7.**

*Mass Production Processes*

production.

been integrated.

**3. Reconfigurable conveyor system**

A production system consists of material handling equipment, production machines and tooling, computer control system, and others that promote the efficient use of energy, material, resources, and equipment. As the main component of production systems, material-handling systems can be defined by the movement, storage, protection, and control of products and materials throughout the processes of manufacturing, disposal, distribution, and consumption of all related materials and goods [28]. In possessing a new production system, a new concept of material handling should be proposed. Since conveyor is the most commonly used material handling equipment in production industries, research was conducted in developing a concept of reconfigurable conveyor system that supports changeability in

The development of a conventional and centralized controlled conveyor system

In the operational phase, the conveyor system is utilized as it is intended. An operator of the system can monitor the operating status, identify malfunctions, and fix minor problems. In case of major problems, the help of the system provider is needed. Depending on the problem complexity, the system provider will help

After several years of operations or, in certain cases, changing of control strategies, restructuring or exchanging individual conveyor system units, expansion or modernization of an existing system are necessary. This is normally triggered by an increase in throughput demands, storage and buffer capacity, or a change in product variants. In principle, from the perspective of the system provider, the life cycle of the system will go through again for such cases (**Figure 8**). However, the key difference in these activities is the integration of new components with the existing systems either physical hardware (physical reconfiguration) or control software technology (logical reconfiguration) [26]. Specifically, the adaptation of existing conveyor system control software requires high efforts due to the engagement of all control logic levels. The largest effort lies in reconfiguring, reprogramming, and

A conceptual framework of a reconfigurable conveyor system can be classified into two categories, which are physical and logical. The physical aspect is the overall design of the conveyor including the shape, size, and material used. The conceptual design is drawn in computer-aided design software to visualize the suitability of the design with the reconfigurability criteria, before their construction. For

lies in a range of activities, which are different from technology and personnel requirements set by the system manufacturer. Current approaches for developing the system, while well-established and using well-proven methods, still follow a rigid sequential model and use an ad hoc collection of poorly integrated tools to translate requirements into the desired system (**Figure 7**) [29]. The planning and design of the system, fabrication of the mechanical structures, construction of electrical components, formation of control systems, and validation of the systems take place sequentially. In such an engineering process, the creation of the control system can only be carried out after all the electrical and mechanical units have

**3.1 Reconfiguration in automated conveyor system life cycle**

through a hotline, remote maintenance, or onsite maintenance.

commissioning of an adapted material-flow control system [30].

**3.2 The conceptual framework**

**176**

*The life cycle of an automated conveyor system [10].*

#### **Figure 8.**

*Changes in the life cycle of an automated conveyor system [10].*

the logical aspect, the programmable logic controller (PLC) is used as the control system since it is the most commonly used controller in production industries.

The physical reconfigurable conveyor system was designed in modules (**Figure 9**), in which each module consists of few components such as adjustable steel combine stands, adjustable wheels, pneumatic cylinders with turntable, and belt conveyor. This modular concept makes the conveyor system easier to integrate,

#### *Mass Production Processes*

customize, and convert when all the modules are connected in order to form a system. **Figure 9** shows the module of the reconfigurable conveyor system.

The concept for reconfigurable conveyor systems used adjustable magnetic locking systems to connect the modular components. It had replaced the fasteners with a better quick-change performance and fewer tools required. Based on its modularity, several possible layouts can be created by using the modules that had been designed. Some of the basic possible layout arrangements for the

**Figure 9.** *Modules of the reconfigurable conveyor system.*

**179**

**Figure 11.**

*The architecture of reconfigurable conveyor system.*

*Revolution of Production System for the Industry 4.0 DOI: http://dx.doi.org/10.5772/intechopen.90772*

ment (**Figure 10**).

Dedicated conveyor

Reconfigurable conveyor system

system

**Table 3.**

system.

reconfigurable conveyor system are straight-line layout arrangement, L-shape layout arrangement, U-shape layout arrangement, and closed-loop layout arrange-

The overall changeover operations have become less complex and faster. Maynard Operation Sequence Technique (MOST) analysis is used to conduct the predetermined time system of the conveyor system. The unit used for the MOST analysis is time measurement units (TMU) where 100,000 TMUs are equivalent to 1 hour. Two sequence models will be used to analyze the setup time of the existing conveyor system and conceptual reconfigurable conveyor system. A total of five operations are needed to carry out the dedicated conveyor system, whereas only three operations are carried out by a reconfigurable conveyor

**Table 3** shows the comparison of the total time needed to assemble the L-shape layout between a dedicated conveyor system and a reconfigurable conveyor system. The reconfigurable conveyor system only needs 39.24 min to make the L-shaped configuration compare with a dedicated conveyor system, which takes 81.72 min.

**Type of conveyor Operation Changeover time (min) Total time (min)**

33.6 20.64 10.32 10.32 6.84

12.00 21.00 6.24

81.72

39.24

Fasten 14 steel bars Fasten 8 support stands Fasten 4 steel bars Loosen 4 steel bars Miscellaneous

Fasten 10 combine stand Fasten 10 bolts for 2 modules Miscellaneous

*The MOST analysis of the reconfigurable conveyor system.*

**Figure 10.** *Possible layout configuration.*

reconfigurable conveyor system are straight-line layout arrangement, L-shape layout arrangement, U-shape layout arrangement, and closed-loop layout arrangement (**Figure 10**).

The overall changeover operations have become less complex and faster. Maynard Operation Sequence Technique (MOST) analysis is used to conduct the predetermined time system of the conveyor system. The unit used for the MOST analysis is time measurement units (TMU) where 100,000 TMUs are equivalent to 1 hour. Two sequence models will be used to analyze the setup time of the existing conveyor system and conceptual reconfigurable conveyor system. A total of five operations are needed to carry out the dedicated conveyor system, whereas only three operations are carried out by a reconfigurable conveyor system.

**Table 3** shows the comparison of the total time needed to assemble the L-shape layout between a dedicated conveyor system and a reconfigurable conveyor system. The reconfigurable conveyor system only needs 39.24 min to make the L-shaped configuration compare with a dedicated conveyor system, which takes 81.72 min.


#### **Table 3.**

*Mass Production Processes*

customize, and convert when all the modules are connected in order to form a system. **Figure 9** shows the module of the reconfigurable conveyor system.

The concept for reconfigurable conveyor systems used adjustable magnetic locking systems to connect the modular components. It had replaced the fasteners with a better quick-change performance and fewer tools required. Based on its modularity, several possible layouts can be created by using the modules that had been designed. Some of the basic possible layout arrangements for the

**178**

**Figure 10.**

**Figure 9.**

*Modules of the reconfigurable conveyor system.*

*Possible layout configuration.*

*The MOST analysis of the reconfigurable conveyor system.*

#### **Figure 11.**

*The architecture of reconfigurable conveyor system.*

Almost 50% of the changeover time is reduced by using a reconfigurable conveyor system.

The architecture of the reconfigurable conveyor system concept consists of two controllers, which are the main system controller and a subsystem controller (**Figure 11**). The main system controller is using a Siemens controller as its main control. An application-oriented integration of three software programs is used in a realizing concept for reconfiguration. This software includes Siemens TIA Portal, Siemens Step 7 Professional V13, and Siemens Simatic WinAC RTX-F 2010 SP2. In this research, Siemens Simatic WinAC RTX-F is used as the software controller. A PC-based controller is used as the basis for the connection. All software used must support each other to make sure the connection and program control can be transferred without any error.

Furthermore, a Profibus card reader is installed at Siemens SIMATIC ET200SP to exchange data between high-level controllers to the Inputs/Outputs (I/Os) module. After that, the control program will be transferred to the I/Os module through a TP-Link router. The control program consists of logic control programs. All the relevant I/Os need to be considered based on the program that has been

**181**

concepts with all dimensions.

*Revolution of Production System for the Industry 4.0 DOI: http://dx.doi.org/10.5772/intechopen.90772*

ing sensor, actuator, and motor drive will be functioning.

**4. Discussion: production system for the future**

ways and bring the smart factory up to the next level.

designed according to the mechanical structure. The control logic is drawn in a ladder diagram. The control program will be transferred to six modules of Omron CP1L-EL20DR-D through the Open Platform Communications (OPC) server and the Factory Interface Network Service (FINS)/Transmission Control Protocol (TCP) network by using local area network cables. OPC is used for communication of real-time implementation between controllers that have different manufactures. Meanwhile, the FINS/TCP Ethernet network is used to connect PLCs through multiple segments at the same network to obtain an IP address. Omron CP1L-EL20DR-D comes with an Ethernet function for communication. The Ethernet is used as a communication method between each controller in this system. IP and MAC address from each controller will be considered to transfer the control program to each sequence of operation. After all, the program is transferred successfully, and the reconfigurable conveyor system outputs includ-

Lastly, the main system controller software connected to I/Os modules will receive the signal from the physical equipment. If the condition is satisfied, the conveyor will continue to move based on the control program. But, if there are any errors, the main system controller PC will show the errors and the user can change

The logical (re-)configuration of the reconfigurable conveyor system is designed

The term Industry 4.0 and its reference architecture model are originated from Germany (Industry 4.0). It was first introduced in 2011. Now, the vision—and reality—of the Industry 4.0 has caught the attention of organizations across the globe. Moreover, even though Industry 4.0 originally was used only for production, it is de facto going further. We clearly see nowadays how the several parties that were involved in Industry 4.0 themselves move it to smart transportation and logistics, smart buildings, smart oil and gas plant, smart healthcare, and even smart cities. In the fourth industrial revolution (**Figure 13**), the production industry is moving from 'just' the Internet and the client-server model to ubiquitous mobility, that integrates digital and physical environments referred to as Cyber-Physical Systems. This can be achieved through the integration of information and communication technologies (such as Internet of Things—IoT and Big Data) with operation technologies (such as collaborative robots and artificial intelligence/smart cognitive), which allows Industry 4.0 factories to automate and optimize in completely new

Research has been performed by Qin et al. [31] to analyze the current production system and comparing them with the concepts of the Industry 4.0 requirements. Based on their research outcome (**Figure 14**), it is obvious that the current implemented production system has not yet achieved the Industry 4.0 level comprehensively, although many researchers and companies are working on this topic. There is still a long way to go to improve production up to the required level to match all

and modify the program online directly without stopping the conveyor.

by using function blocks. Each function of the physical components (sensors and actuators) has its own function block, which are stored in the function block library. The program of each module consists of combinations of function blocks from different numbers of sensors, pushers, pneumatic cylinders, and motors. Depending on the layout (re-)configurations, the main control program for the reconfigurable conveyor system can be designed by combining the module's function block. **Figure 12** illustrates the overall reconfiguration concept of the system.

**Figure 12.**

*The conceptual framework of the reconfigurable conveyor system.*

*Revolution of Production System for the Industry 4.0 DOI: http://dx.doi.org/10.5772/intechopen.90772*

*Mass Production Processes*

transferred without any error.

system.

Almost 50% of the changeover time is reduced by using a reconfigurable conveyor

The architecture of the reconfigurable conveyor system concept consists of two controllers, which are the main system controller and a subsystem controller (**Figure 11**). The main system controller is using a Siemens controller as its main control. An application-oriented integration of three software programs is used in a realizing concept for reconfiguration. This software includes Siemens TIA Portal, Siemens Step 7 Professional V13, and Siemens Simatic WinAC RTX-F 2010 SP2. In this research, Siemens Simatic WinAC RTX-F is used as the software controller. A PC-based controller is used as the basis for the connection. All software used must support each other to make sure the connection and program control can be

Furthermore, a Profibus card reader is installed at Siemens SIMATIC ET200SP

to exchange data between high-level controllers to the Inputs/Outputs (I/Os) module. After that, the control program will be transferred to the I/Os module through a TP-Link router. The control program consists of logic control programs. All the relevant I/Os need to be considered based on the program that has been

**180**

**Figure 12.**

*The conceptual framework of the reconfigurable conveyor system.*

designed according to the mechanical structure. The control logic is drawn in a ladder diagram. The control program will be transferred to six modules of Omron CP1L-EL20DR-D through the Open Platform Communications (OPC) server and the Factory Interface Network Service (FINS)/Transmission Control Protocol (TCP) network by using local area network cables. OPC is used for communication of real-time implementation between controllers that have different manufactures. Meanwhile, the FINS/TCP Ethernet network is used to connect PLCs through multiple segments at the same network to obtain an IP address. Omron CP1L-EL20DR-D comes with an Ethernet function for communication. The Ethernet is used as a communication method between each controller in this system. IP and MAC address from each controller will be considered to transfer the control program to each sequence of operation. After all, the program is transferred successfully, and the reconfigurable conveyor system outputs including sensor, actuator, and motor drive will be functioning.

Lastly, the main system controller software connected to I/Os modules will receive the signal from the physical equipment. If the condition is satisfied, the conveyor will continue to move based on the control program. But, if there are any errors, the main system controller PC will show the errors and the user can change and modify the program online directly without stopping the conveyor.

The logical (re-)configuration of the reconfigurable conveyor system is designed by using function blocks. Each function of the physical components (sensors and actuators) has its own function block, which are stored in the function block library. The program of each module consists of combinations of function blocks from different numbers of sensors, pushers, pneumatic cylinders, and motors. Depending on the layout (re-)configurations, the main control program for the reconfigurable conveyor system can be designed by combining the module's function block. **Figure 12** illustrates the overall reconfiguration concept of the system.

## **4. Discussion: production system for the future**

The term Industry 4.0 and its reference architecture model are originated from Germany (Industry 4.0). It was first introduced in 2011. Now, the vision—and reality—of the Industry 4.0 has caught the attention of organizations across the globe. Moreover, even though Industry 4.0 originally was used only for production, it is de facto going further. We clearly see nowadays how the several parties that were involved in Industry 4.0 themselves move it to smart transportation and logistics, smart buildings, smart oil and gas plant, smart healthcare, and even smart cities.

In the fourth industrial revolution (**Figure 13**), the production industry is moving from 'just' the Internet and the client-server model to ubiquitous mobility, that integrates digital and physical environments referred to as Cyber-Physical Systems. This can be achieved through the integration of information and communication technologies (such as Internet of Things—IoT and Big Data) with operation technologies (such as collaborative robots and artificial intelligence/smart cognitive), which allows Industry 4.0 factories to automate and optimize in completely new ways and bring the smart factory up to the next level.

Research has been performed by Qin et al. [31] to analyze the current production system and comparing them with the concepts of the Industry 4.0 requirements. Based on their research outcome (**Figure 14**), it is obvious that the current implemented production system has not yet achieved the Industry 4.0 level comprehensively, although many researchers and companies are working on this topic. There is still a long way to go to improve production up to the required level to match all concepts with all dimensions.

#### **Figure 13.**
