Integrated analysis of a digital production section in R-Pro using simulation modelling, virtual commissioning and lean manufacturing tools

Abstract

Digital simulation of production sections is widely used in the design of manufacturing systems; however, spatial layout, robotic cell programming, production flow analysis and product quality inspection are typically treated as separate tasks. This results in an implicit relationship between equipment configuration, control logic, flow characteristics and geometric verification outcomes. This paper presents a methodology for integrated analysis of a digital manufacturing system that combines four interrelated stages: spatial layout modelling, virtual commissioning of a robotic cell, production flow analysis and optimisation, and geometric inspection of the finished part. The object of study is a digital model of a metal bracket production section implemented in R-Pro. The robotic cell featuring a KUKA manipulator is described at the level of an executable KRL program with verified coordinate frames and discrete gripper control logic. Production flow analysis is performed using VSM, Yamazumi and Spaghetti analysis tools; optimisation targets the reduction of non-value-added movements without altering equipment speeds. Geometric inspection is carried out in PolyWorks using a PMT ALPHA ARM measuring arm. The proposed methodology enables a digital manufacturing system to be treated as a coherent engineering object in which each subsequent stage builds upon the parameters of the previous one. The practical value lies in the applicability of the methodology to the design and verification of digital production section models in virtual commissioning tasks.