How to Optimize Intra Logistics to Streamline and Speed Industry 4.0 Supply Chains
AMRs, AGVs, and robots operate with high levels of predictability and repeatability, and their use in Industry 4.0 can simplify the use of digital twin technology. Including them in the digital twin supports fleet optimization and management in the facility and enables preventative maintenance with minimal impact on operational efficiencies. Digital twins are supported by large quantities of real-time data, including environmental conditions as well as functional and operational data about the state of machines and processes. The digital twin uses that data to simulate the actual systems and predict the condition of complete machines and individual
components like the battery packs in AGVs and AMRs to optimize their performance. The closer the digital twin simulates the real world, the greater the benefits. An infra logistics system typically integrates automated systems with people. Including human activities in the digital twin can further enhance the accuracy of the simulations and the benefits of intra logistics. The combination of intra logistics, digital twins, and digital threads with artificial intelligence and machine learning are expected to be important elements supporting the emergence of fully automated Industry 4.0 factories and warehouses.
Summary Intra logistics is the movement of materials within an industrial facility like a warehouse or factory. AGVs and AMRs are important tools used to automate and speed the flow of materials. While both have advantages and disadvantages, AMRs are more suited for use in Industry 4.0 applications. When combined with digital twins, AI, and ML, intra logistics can support the development of fully automated factories and warehouses.
Figure 3: A digital twin (left) can provide real-time simulations to support higher productivity in Industry 4.0 factories. (Image source: Getty Images)
case of AMRs, the suite of sensors can require maintenance, and software updates are periodically needed. The requirement that AGVs travel in areas separated from people often means that they travel longer distances to reach a destination compared with AMRs. Longer travel distances increase wear on AGVs, potentially increasing maintenance costs. So, the question of which needs more maintenance — AGVs or AMRs — is application dependent. Cost. AGVs are simpler machines and cost less than AMRs. Installation cost differences are more complex to define since AGVs require the installation of guide tracks, while AMRs need a suite of external sensors and wireless
connectivity. Operating costs are higher for AGVs since their guide tracks require more maintenance than the infrastructure needed to support AMRs. Finally, AMRs can usually be deployed faster, reducing the costs associated with downtime in the facility and making them more suitable for use in Industry 4.0 applications. Digital twins, digital threads, and intra logistics Digital twins and digital threads can be valuable tools for intra logistics deployments. Digital twins are detailed virtual models of complex cyber-physical systems like those used for intra logistics. Digital twins are created using data
from various sources, including sensors in the facility, computer- aided design (CAD) models of the facility, feedback from sensors on equipment operating in the facility, and so on. They are used to provide real-time simulations of the warehouse or factory operation to help optimize processes and pinpoint potential problems before they arise (Figure 3). A digital thread accompanies the digital twin and includes the complete history of all activities in the digital twin throughout its operational lifetime. Digital twins and digital threads in intra logistics are in the early stages of development. Predictable operations are important to efficient intra logistics systems.
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