DigiIndustry - Towards the Digitalization of Industrial Processes

Digitalization is a transformative factor for any industry. In the context of WP10 of the PRODUTECH R3 agenda, possibilities are being explored in the manufacturing sector with two specific end-users: Sonae Arauco in the wood industry and Colep Packaging in the packaging industry.

With a focus on flexibility, productivity, precision, safety, and sustainability, CCG/ZGDV, the University of Minho, and INEGI have contributed their expertise in the fields of modeling and simulation, digital twin, systems integration, computer vision, and intelligent energy management to WP10, in the development of innovative solutions. Microprocessador, as a specialist in automation systems and industrial management software, will enhance these solutions by incorporating them into their commercial products.

The DigiIndustry project focuses on three key areas: automation, production scheduling and sequencing, and energy decarbonization. In automation, the goal is to increase the efficiency and effectiveness of production processes, both in the manufacturing of decorative wood-based panels and in packaging solutions, aerosols, and general line packaging.

The area of production scheduling and sequencing aims to improve the management of production lines, ensuring a more agile and accurate response to market demands. Meanwhile, energy decarbonization involves adopting solutions that allow real-time energy consumption adjustments, promoting both efficiency and sustainability, with a focus on specific cases as well as the adoption of clean energy sources. The latest developments in WP10 include: Scheduling and Sequencing Optimization Software (Sonae Arauco): Machine learning algorithms have been developed to predict manufacturing defects and machine stoppages, with a confidence rate of 75%. This solution opens new opportunities for integrating predictive capabilities, optimizing efficiency, and reducing costs throughout the production chain. Automatic Integration of Information Flows (Sonae Arauco and Colep Packaging): The automation of information flows is enabling more efficient production chain management, allowing for greater real-time visibility and facilitating the optimization of industrial processes, with a direct impact on decision-making. Automatic Production Setup (Sonae Arauco): The reduction of setup times and the elimination of manual errors through an automatic configuration system are transforming production management. Traceability technologies will be validated, offering new opportunities for innovative industrial logistics.

Digital Simulation Model of Industrial Processes (Sonae Arauco and Colep Packaging): Stochastic digital simulation of production processes allows operations to be tested and validated without interrupting production, creating space for optimized and predictive management, crucial for increasing efficiency and safely anticipating operational scenarios. Intelligent Dynamic Energy Adjustment System (Sonae Arauco): This system enables real-time energy consumption adjustments, promoting energy efficiency and sustainability. The solution will be particularly beneficial for Sonae Arauco, contributing to decarbonization and more efficient resource management. Currently, algorithms are being developed for the following modules: 1) consumption as a function of production, 2) production and consumption of photovoltaic energy, and 3) a forecasting module for wholesale electricity market prices. WP10 of the PRODUTECH R3 is providing technological innovations that can be adapted to the specific needs of each company, offering a flexible platform for implementing tailored solutions across different industrial contexts.