Safer and Efficient Assemblies: Harnessing Real Time Worker Movements with Digital Twins

Kasarapu, Satya Saravan Kumar; Vasantha, Gokula; Marzano, Adelaide; Corney, Jonathan; Hanson, Jack; Quigley, John; El-Raoui, Hanane; Thompson, Nathan; Sherlock, Andrew

Abstract

This paper addresses a critical gap in digital twin simulation within manufacturing environments by focusing on the dynamic representation of worker movements during assembly processes. We introduce an innovative approach that utilizes Ultra-Wideband (UWB) sensors to incorporate worker trajectory data into Siemens Process Simulate software, enabling the creation of a digital twin of assembly line operations. Our methodology involves comprehensive data collection using UWB sensors, followed by pre-processing steps such as data cleaning, interpolation, and classification of points into dwell and transit locations. Within the framework of Process Simulate, we develop the assembly process digital twin, integrating simulations of tricycle assembly alongside dynamic worker path and movement simulations. Our digital twin facilitates ergonomic analysis, process optimization, and worker interaction analysis, offering insights for enhancing factory efficiency and safety. Notably, through visualization of worker paths and identification of bottlenecks, our digital twin enables optimization of resource allocation. Quantitative results demonstrate significant improvements, such as a reduction in the time of completion of six products by 11% compared to Discrete Event Simulation under similar process conditions. This study highlights the transformative potential of digital twin technology in manufacturing, providing a robust framework for simulating and optimizing worker movements within real-world factory environments.

Citation

Kasarapu, S. S. K., Vasantha, G., Marzano, A., Corney, J., Hanson, J., Quigley, J., El-Raoui, H., Thompson, N., & Sherlock, A. (2024, August). Safer and Efficient Assemblies: Harnessing Real Time Worker Movements with Digital Twins. Presented at 21st International Conference on Manufacturing Research (ICMR2024), Glasgow

• Presentation Conference Type: Conference Paper (published)
• Conference Name: 21st International Conference on Manufacturing Research (ICMR2024)
• Start Date: Aug 28, 2024
• End Date: Aug 30, 2024
• Acceptance Date: May 1, 2024
• Online Publication Date: Aug 27, 2024
• Publication Date: Aug 27, 2024
• Deposit Date: May 2, 2024
• Publicly Available Date: Aug 28, 2025
• Peer Reviewed: Peer Reviewed
• Volume: 401
• Article Number: 08001
• DOI: https://doi.org/10.1051/matecconf/202440108001