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Designing the Future of Logistics with Digital Twins

At Labormak, we're constantly pushing the boundaries of industrial design, and our latest project, Twin4Logs, is a prime example. This exciting initiative focuses on creating a digital twin, a virtual replica, of a customizable logistics plant.

Leveraging our longstanding expertise in simulation and design, we're building this twin entirely in-house. The digital twin serves as a powerful blueprint, allowing us to experiment with different configurations of key components like conveyors, sorters, and sensors. This translates to significant benefits, particularly during the sales process. With Twin4Logs, we can showcase virtual models to clients, providing a clear and interactive understanding of how their future logistics system will operate before any physical construction begins.

But Twin4Logs goes beyond just impressive presentations. We envision integrating control software with these digital twins, enabling a process called virtual commissioning. This allows us to test and refine the software that controls the physical plant in a safe, simulated environment. Virtual commissioning has the potential to significantly reduce the time and resources needed for traditional on-site testing, streamlining the entire process.

In essence, Twin4Logs is a testament to Labormak's unwavering commitment to innovation. By embracing digital twin technology, we aim to:

Improve efficiency in our development processes.
Reduce risks associated with physical implementation.
Deliver superior and customized logistics solutions to our valued clients.

We are confident that Twin4Logs will revolutionize the way we design and build logistics systems, ultimately benefiting both Labormak and our clients. We're excited to be at the forefront of this technological transformation.

2 Labormak Streamlines Twin4Logs Project with Work Package Structure

At Labormak, we're committed to efficient project management. To ensure the success of Twin4Logs, we've implemented a clear work package structure:

WP1: Project Management: A dedicated team, led by a project manager, oversees all activities throughout the project lifecycle. Labormak has assembled a team of highly qualified individuals. The Project Manager leads the charge, overseeing progress, addressing challenges, and fostering communication with both internal and external stakeholders. A Mechatronics Engineer brings their expertise in modeling and simulation to the design phase, defining the system's hardware and software architecture. Finally, the development and testing phases rely on the combined skills of a Mechanical Designer, who uses their 3D modeling expertise to create the digital twin, and a PLC Programmer, who ensures software development aligns with project requirements. This team's diverse skillset and experience are crucial for the successful development and implementation of the Labormak Twin4Logs digital twin.
WP2: Requirements Definition: This phase focuses on defining the technical specifications for hardware, software, and data acquisition to guarantee seamless system operation. Through user-friendly interfaces and seamless integration with existing software, the tool aims to streamline workflows for both technicians and sales teams. A secure and flexible platform called Nerve serves as the central hub, facilitating real-time data exchange and visualization using industry-standard protocols. This comprehensive approach empowers departments, enhances collaboration, and ultimately drives overall business performance.
WP3: Design Optimization: We carefully select the optimal infrastructure to ensure the digital twin flawlessly functions and integrates with real-world equipment. The project utilizes a real-world logistics facility equipped with advanced sensors to gather data. Specialized software will be used to create a digital model of this facility, enabling virtual design, testing, and commissioning before physical construction. This software will integrate with the existing control system using standard protocols. To enhance the solution, external suppliers will provide additional software and hardware, while Labormak's internal team will maintain full ownership and execution of the project, leveraging its expertise throughout the design, development, and implementation phases.
WP4: Development and Implementation: This core phase involves building the digital twin application, from the virtual library to the control of a simulated logistics line. The Twin4Logs project is moving from the planning stage to building its core component: a library of digital objects representing real-world equipment. This library will allow for future adaptations and efficient virtual testing. Once the library is complete, these digital objects will be assembled into a virtual model that precisely mirrors the logistics line. Finally, this virtual model will be linked to real-world equipment, enabling us to interact with the physical system through the digital twin.
WP5: Validation and Testing: We rigorously test the application against predefined Key Performance Indicators (KPIs) and ensure its functionality with real equipment. The next stage rigorously tests and validates all components, ensuring they meet the project's Key Performance Indicators (KPIs) explained later. This involves initial testing, followed by a deep examination of the library objects' accuracy and functionality. We'll then activate the customized digital twin for the pilot line, continuously assessing its benefits for Labormak through specific KPIs. Validating the digital model's connection to the real system is a step-by-step process. First, we'll isolate and test individual modules like conveyor belts, comparing their digital counterparts. Then, we'll interconnect these modules to assess their collective behavior and interaction with the control logic, allowing for adjustments. Finally, we'll fine-tune model parameters for optimal system performance. This comprehensive validation ensures the Labormak Twin4Logs digital twin delivers its promises and offers true value to the company.

Overlapping Workflows for Enhanced Efficiency

Our Gantt chart reflects a degree of overlap between work packages. This intentional strategy allows us to revisit and refine previous solutions as the project progresses. Additionally, the chart outlines the deadlines for achieving six predetermined milestones, which will be further elaborated on in Chapter 3.

This structured approach ensures clarity, efficiency, and effective communication throughout the Twin4Logs project.

3 Key Milestones and Measurable Benefits

To ensure successful project execution and track progress, Labormak has established a series of milestones for Twin4Logs:

M1: Project Roadmap: This initial milestone defines a detailed activity plan with clear deadlines for each project phase.
M2: System Architecture Integration: The virtual model is imported into the chosen Nerve solution, including the installation of development tools and software architecture definition.
M3: Digital Twin Model Design: Core mechatronic modules are developed based on Labormak's intra-logistics standards. These modules form a library that can be combined to create various layouts and scenarios.
M4: Building the Final Model: Using the library objects, Labormak defines a standard intra-logistics plant layout and builds a corresponding virtual model.
M5: Model-to-Equipment Connection and Performance Validation: The digital twin is connected to the real control system for validation and performance assessment.
M6: DT Integration into Labormak Workflow: The developed tools are incorporated into Labormak's standard workflow to evaluate the benefits of the digital twin approach.

To quantify the impact of Twin4Logs, Labormak has defined a set of Key Performance Indicators (KPIs):

KPI_1: Reduced Offer Preparation Time: The ability to define and test logistics plant layouts virtually reduces the time needed to formulate offers. This allows for more precise details, such as sensor quantity and actuator selection, to be determined upfront. (Target: 20% time reduction)
KPI_2: Streamlined Plant Design: Utilizing a virtual model enables a more accurate design phase, allowing for testing of the mechatronic components before physical construction. This leads to project validation, early identification of critical issues, and significant time savings. (Target: 20% time reduction)

KPI_1 and KPI_2 are interconnected. During the bidding phase, close collaboration between sales and technical teams establishes a potential layout and initial sizing. The digital twin facilitates rapid refinement of this initial layout, leading to more accurate data for the technical team's final precision dimensioning.

KPI_3: Faster Software Debugging: Virtual commissioning, enabled by the digital model's connection to the control solution, allows for parallel commissioning – a process traditionally initiated after plant construction. This significantly impacts project timelines, particularly in terms of time savings and indirectly, cost reduction. (Target: 40% time reduction)

Accounting for Project Complexity

It's important to acknowledge that the complexity of customer logistics lines can vary significantly. This translates to highly variable project timelines, from bidding to design and commissioning phases. Labormak addresses this by assigning a "difficulty coefficient" to each project. This coefficient is then multiplied by a minimum baseline time established for relatively simple lines to estimate the total project timeline.

Deliverables: Showcasing Success

To effectively present the project's achievements, Labormak will deliver two key items:

D1: Digital Twin Model: This deliverable showcases the project's progress by presenting the virtual model, the library objects used, and a detailed description of the digital twin's features, performance, and real-world application connectivity. Images, photographs, videos, and other visual content will be incorporated into a document or presentation for enhanced understanding.
D2: Final Report with Achieved Objectives and KPIs: This report presents the project's final results, demonstrating the multifaceted benefits of the digital twin approach and its positive impact on various aspects of Labormak's workflow. It will highlight how the digital twin facilitates plant layout optimization, selection of optimal mechatronic elements, efficient control strategies, and improved deal-closing success through faster and more precise cost estimates.

By outlining clear milestones, measurable KPIs, and valuable deliverables, Labormak ensures the successful execution of Twin4Logs while demonstrating the project's significant contributions to efficiency and overall business performance.

4 Twin4Logs: Anticipating and Mitigating Project Risks

Labormak acknowledges that potential risks can arise during Twin4Logs implementation. Here's a breakdown of the key challenges and our planned mitigation strategies:

Risk 1: Library Object Detail Optimization

Striking a balance between object complexity in the digital library and simulation performance is crucial. Overly detailed models require significant processing power, while under-developed models may necessitate rework later.

To address this, we will prioritize building a core library with essential objects. New objects will be progressively added based on project needs. Early involvement of various departments (sales, engineering) in object modeling ensures practical considerations are addressed. By creating simplified digital subsystems, we can identify and address potential issues early, minimizing rework.

Risk 2: Hardware Limitations

The chosen hardware must be able to run the entire software architecture without performance issues.

Pre-emptive testing will be conducted on the selected device before project deployment. If limitations arise, a more powerful alternative will be chosen from TTTech's compatible hardware list. Additionally, we can leverage the IEC 61499 standard, which allows code distribution across multiple hardware units, reducing the load on any single device. This can be implemented without additional development time. Furthermore, maintaining open communication with Change2Twin support ensures swift action in case of unforeseen hardware delays.

Risk 3: User Adoption of Digital Twin Workflows

Some personnel may struggle to adapt their work practices to the new digital twin approach.

To mitigate this, key personnel from various departments will be involved from project inception to understand the benefits of the approach. Clear and user-friendly instructions will be provided to facilitate the adoption of the new workflows.

Risk 4: Hardware and Software Delivery Delays

Potential delays in obtaining necessary hardware or software licenses due to external factors could arise.

We will initiate software licensing and hardware acquisition early to minimize delays. Backup plans will be established to identify alternative software or hardware solutions if necessary. Open communication with Change2Twin support ensures prompt action in case of unexpected delivery delays.

By proactively identifying potential risks and implementing effective mitigation strategies, Labormak aims to ensure the smooth execution and successful completion of the Twin4Logs project.

5 Labormak: Standards for Innovation and Efficiency

At Labormak, we believe adherence to relevant standards is vital for successful project execution. For Twin4Logs, we've carefully evaluated various automation software programming standards and selected the IEC 61499 standard. While this standard may have limited widespread adoption, our team's experience and research background allow us to effectively navigate any challenges and leverage its potential benefits.

We're also exploring the applicability of the ISO 23247 Digital Twin framework to ensure our digital twin model aligns with industry best practices. Additionally, we're continuously evaluating standards related to modeling, simulation, real-time communication, automation, and cybersecurity.

A significant achievement for Twin4Logs is the integration of Schneider Electric's EcoStruxure Automation Expert (IEC 61499 runtime software) with the Nerve edge node device. This integration allows us to leverage IEC 61499 for logistics solutions while ensuring seamless connectivity within the Nerve system.

Furthermore, Labormak leverages its expertise in communication protocols like OPC UA, Modbus, MQTT, and oneM2M. This combination, along with the Nerve system's built-in communication capabilities, facilitates efficient data exchange and real-time communication, crucial for project effectiveness.

Security is paramount, and the Nerve product's recent achievement of IEC 62443-4-1 certification, a globally recognized cybersecurity standard for industrial automation systems, provides peace of mind.

Our commitment to established standards and exploration of emerging frameworks underscores Labormak's dedication to remaining at the forefront of technological advancements. This unwavering focus allows us to deliver innovative and efficient solutions that push the boundaries of industrial automation.