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  • 1.
    Massouh, Bassam
    University West, Department of Engineering Science, Division of Production Systems.
    Planning and Control of Safety-Aware Plug & Produce2024Licentiate thesis, comprehensive summary (Other academic)
    Abstract [en]

    The Plug & Produce manufacturing system is a visionary concept that promises to facilitate the seamless integration and adaptation of manufacturing resources and production processes. The Plug & Produce control system allows for the automatic addition and removal of manufacturing resources, minimizing human intervention. However, the reconfigurability and autonomous decision-making features of Plug & Produce control systems pose challenges to safety design and control functions.

    In contrast to conventional manufacturing systems with fixed layouts and processes, ensuring safety in Plug & Produce systems is complicated due to the complex risk assessment process, the difficulty of implementing non-restrictive safety measures covering all possible hazards, and the challenge of designing a reliable controller for consistent safe operation.

    This thesis addresses these challenges through various contributions. It introduces an automatic hazard identification method, considering emergent hazards after reconfiguration. A novel domain ontology is developed, incorporating safety models specific to Plug & Produce systems. The work also proposes a generic, model-based, and automatic risk assessment method, along with a method for the safe execution of plans based on the results of the risk assessment.

    The results of this research offer benefits to process planners, who are responsible for coordinating the manufacturing processes with product design in the Plug & Produce system. The proposed solution provides tools for process planners to validate their plans and reduces their safety-related responsibilities. The proposed safety assurance method seamlessly integrates into the multi-agent control of Plug & Produce, providing the control system with risk scenarios associated with process plans. This enables proactive and reliable control, effectively avoiding potential risks during system operation.

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  • 2.
    Massouh, Bassam
    et al.
    University West, Department of Engineering Science, Division of Production Systems.
    Danielsson, Fredrik
    University West, Department of Engineering Science, Division of Production Systems.
    Ramasamy, Sudha
    University West, Department of Engineering Science, Division of Production Systems.
    Khabbazi, Mahmood Reza
    University West, Department of Engineering Science, Division of Production Systems.
    Zhang, Xiaoxiao
    University West, Department of Engineering Science, Division of Production Systems.
    Online Hazard Detection in Reconfigurable Plug & Produce Systems2024In: Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems.: FAIM 2023 / [ed] Silva, F.J.G., Pereira, A.B., Campilho, R.D.S.G., Springer Nature, 2024, p. 889-897Conference paper (Refereed)
    Abstract [en]

    Plug & Produce is a modern automation concept in smart manufacturing for modular, quick, and easy reconfigurable production. The system’s flexibility allows for the configuration of production with abstraction, meaning that the production resources participating in a specific production plan are only known in the online phase. The safety assurance process of such a system is complex and challenging. This work aims to assist the safety assurance when utilizing a highly flexible Plug & Produce concept that accepts instant logical and physical reconfiguration. In this work, we propose a concept for online hazard identification of Plug & Produce systems, the proposed concept, allows for the detection of hazards in the online phase and assists the safety assurance as it provides the hazard list of all possible executable alternatives of the abstract goals automatically. Further, it combines the safety-related information with the control logic allowing for safe planning of operations. The concept was validated with a manufacturing scenario that demonstrates the effectiveness of the proposed concept.

  • 3.
    Massouh, Bassam
    et al.
    University West, Department of Engineering Science, Division of Production Systems.
    Ramasamy, Sudha
    University West, Department of Engineering Science, Division of Production Systems.
    Svensson, Bo
    University West, Department of Engineering Science, Division of Production Systems.
    Danielsson, Fredrik
    University West, Department of Engineering Science, Division of Production Systems.
    A Framework for Hazard Identification of a Collaborative Plug&Produce System2022In: Communications in Computer and Information Science, ISSN 1865-0929, E-ISSN 1865-0937, Vol. 1616 CCIS, p. 144-155Article in journal (Refereed)
    Abstract [en]

    Plug&Produce systems accept reconfiguration and have the attribute of physical and logical flexibility. To implement the Plug&Produce system in a manufacturing plant, there is a need to assure that the system is safe. The process of risk assessment provides information that is used to implement the proper safety measures to ensure human and machine safety. An important step in the risk assessment process is hazard identification. Hazard identification of Plug&Produce system is unique as the hazard identification method provided in the safety standards do not consider system flexibility. In this paper, a framework for hazard identification of a collaborative Plug&Produce system is presented. A study case that includes a collaborative Plug&Produce system is presented and the framework is applied to identify the system’s hazards. Also, the generalisation of the framework application is discussed. © 2022, The Author(s), under exclusive license to Springer Nature Switzerland AG.

  • 4. Mosa, Waddah
    et al.
    Massouh, Bassam
    University West, Department of Engineering Science, Division of Production Systems.
    Khabbazi, Mahmood Reza
    University West, Department of Engineering Science, Division of Production Systems.
    Eriksson, Mikael
    Danielsson, Fredrik
    University West, Department of Engineering Science, Division of Production Systems.
    Software-supported Hazards Identification for Plug & Produce Systems2024In: Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems: FAIM 2023 / [ed] Silva, F.J.G., Pereira, A.B., Campilho, R.D.S.G., Springer Nature, 2024, p. 603-610Conference paper (Refereed)
    Abstract [en]

    This paper presents a model-based safety software that performs Hazard Identification (HI) for Plug&Produce (P&P) systems automatically. P&P systems, inspired by Plug&Play in computers, aim to integrate devices and tools into the manufacturing system with minimum integration efforts and costs. When plugging a new resource, it will exchange all the required information with the manufacturing system and be ready to operate within minutes rather than days or weeks. One of the challenges that face this concept is performing proper risk assessment after each change in the system. Therefore, the risk assessment needs to be automated as much as possible. This paper is about automating one risk assessment step: Hazard Identification. A new safety model is designed to identify hazards. The presented software analyses this model by implementing a novel algorithm that uses lookup tables to cover various possible hazards when resources work together. This software will support the risk reduction team by drastically reducing the time needed for HI and being ready for the next steps in risk analyses. Automating identifying hazards is an essential step towards automating the entire risk assessment process and achieving safe P&P systems.

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