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McGinnis, Leon F.

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Item Type: Publication × search.filters.applied.f.isOrgUnitOfPublicationTitle: Supply Chain and Logistics Institute × search.filters.applied.f.resourcesubtype: Paper ×

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A Modular and Flexible Design of Hyperconnected Assembly Factory

2024-05 , Bao, Wencang , McGinnis, Leon F. , Roberto Campos Murcia, Miguel , Liu, Zhihan , Maurice, Julien , Montreuil, Benoit , Babalou, Sevda

Modern assembly factories increasingly encounter the challenges posed by highly diversified products and fluctuating market demand. Hyperconnected mobile production, which organizes the core production equipment in standard production modules and allows them to be shared among multiple participants in the Physical Internet, is a solution in response to these challenges. In this paper, we adapt the hyperconnected mobile production concept to the assembly industry and introduce a fractal layout design. In our design, a fractal center is a standard assembly module with a predetermined throughput rate and is equipped to assemble all variants of products. All assembly tasks of an individual product, from subassembly to finishing, are performed in one fractal center. In addition, fractal centers employ mobile material handling and assembly equipment and operators that do not have to continuously occupy fixed locations. We illustrate the shareability, scalability, reconfigurability, and adaptability of the proposed hyperconnected modular design and present a design framework for fractal centers.

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Modeling and Simulation of an Agile Assembly Center in a Physical Internet inspired Manufacturing System

2023-06 , Campos, Miguel , McGinnis, Leon , Montreuil, Benoit

Globalization, high competitiveness, and highly customized products are factors that increase the complexity of product development and production systems. Such complexity makes conventional mathematical or analytical models unsuitable for properly analyzing such systems, for which simulation emerges as an alternative for evaluating, designing, improving, and operating complex systems. This Paper focuses on the design, modeling, and simulation of an agile assembly center (AAC) that produces durable big-sized products with the capacity of serving several projects and clients concurrently leveraging Physical Internet (PI) concepts while embedding the decision-making agents’ intelligence. This work is the cornerstone for implementing a digital twin of an AAC that will help make operational, tactical, and strategic decisions towards improving the performance of PI inspired assembly facilities.

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Unleashing the Potential of Digital Twin-Enhanced Hyper Hubs

2024-05 , Barenji, Ali V. , Montreuil, Benoit , McGinnis, Leon F.

Parcel logistics hubs play a crucial role in aggregating and distributing packages, requiring significant capital and labor investments, primarily determined by conveyor infrastructure. Recently, the HyperHub concept has emerged, employing PI-Boxes and racks for parcel consolidation and transport. HyperHub functions as a cross-dock, transferring PI-Boxes between inbound and outbound trucks. However, challenges persist in developing a practical, cost-effective, and risk-free implementation methodology for HyperHub, despite advancements in its conceptualization, design, and execution system. To address this challenge, the authors present a comprehensive methodology for designing and developing a HyperHub based on the concept of digital twin (DT) in the early stages of the design process. A digital replica of the system is used in the early stages of design to create a physical layout and test the control system in a risk- and cost-effective environment. This is accomplished by integrating a modelbased system into the digital copy of the real system. Firstly, we propose a concept of a generic digital twin cellular logistic hub (DT-CLH) methodology for the HyperHub, inspired by the cellular manufacturing (CM) and cellular warehousing (CW) concepts. Secondly, we formulate and define a cellular logistic hub (CLH), considering the objective of minimizing total movement.

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Digital Twin Design Requirements for Durable Goods Distribution in Physical Internet

2021-06 , Campos, Miguel , Derhami, Shahab , McGinnis, Leon F. , Montreuil, Benoit , Barenji, Ali

Today the practice for distributing large products manufactured at few original equipment manufacturers (OEMs) consists of a dedicated Point-to-Point (PtP) logistics system, typically requiring long haul transport from the factory to the wholesale destination. A growing problem is the shortage of commercial drivers willing to be away from home for several days to move products cross-country. Hub relay network logistics systems are an alternative solution to P2P logistics systems that allow reducing drivers' away-from-home times. Operating a relay-based logistics system requires accounting for multiple interrelated operational decisions that become more complicated as the system becomes larger and encompasses more players. To deal with such complexity we propose utilizing a digital twin of the distribution and logistics system as a decision-making support tool to manage the system and make operational decisions efficiently. This paper explores the design and assessment of a hyperconnected relay network of transport hubs supporting the movement of durable goods from factory to wholesale destinations. It describes requirements and challenges in developing and implementing a digital twin for such systems.

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Kit Fulfillment Centers Serving Distributed Small-Series Assembly Centers in Hyperconnected Supply Chain Networks

2023-06 , Li, Mingze , Campos, Miguel , Barenji, Ali , McGinnis, Leon F. , Montreuil, Benoit

In the context of Physical Internet (π, PI) enabled hyperconnected supply chain networks, we focus on the design and performance assessment of π-enabled kit fulfillment centers (KFCs) distributed over a territory to concurrently feed multiple agile assembly centers (AACs) in their region. The AAC production is often associated with the realization of major projects for which short product runs are needed. The KFCs are designed to produce multi-level modular container kits (Montreuil et al., 2015). The multi-level kits of the KFCs have 4 levels, task, skill, workstation, and product. The kit assembly processes are categorized into A, B, and C, according to the shape, weight, and size of their parts. The resource balancing and scheduling is done using a mixed integer programming model, whose performance is validated with a comparison experiment using synthetic data for automobile manufacturing. The process design reduces intermediate inventory space between levels of kit production to encourage space efficiency. The modular design of kitting cells enables easy and quick reconfiguration under variable demand. The multi-level modular container kits allow easy and smart transportation in the hyperconnected supply chain network and handling at AACs.

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