Development of tools utilization monitoring system on labor-intensive manufacturing industries

Abstract

Industry 4.0 implementation faces crucial problem when applied in labor-intensive manufacturing industries, which are common industries in Indonesia. The problem is that it requires a well-connected and transparent data among production elements. The purpose of this study was to solve the aforementioned problem by building a cyber-physical workstation system as bridges between the production elements in real world with object models in virtual world. The system acts as a tools monitoring system for obtaining real-time information of actual tools utilization, especially for hand tools which are mostly used in labor-intensive manufacturing industries. The utilization of cyber-physical workstation system model may be the best method for determining the actual utilization of production tool with simple architecture, affordable and minimum negative impact. Workstation monitoring system transforms attendance data tools in the work area and start-finish operation time event into actual tool utilization information. The major contribution of this paper is that the implementation of industry 4.0 on labor-intensive manufacturing industry has become enabled by using cyber- physical workstation system. It was shown that the usage time of each tool on each production operation can be monitored. Furthermore, the estimation of the actual duration of each tool utilization can be calculated. The resulted data will be further utilized as primary data input for building smart tools model.