A Novel Methodology for Assessing and Modeling Manufacturing Processes: A Case Study for the Metallurgical Industry

Historically, researchers and practitioners have often failed to consider all the areas, factors, and implications of a process within an integrated manufacturing model. Thus, the aim of this research was to propose a holistic approach to manufacturing processes to assess their status and performance. Moreover, using the conceptual model, manufacturing systems can be modelled, considering all areas, flows, and factors in the respective areas of production, maintenance, and quality. As a result, the model serves as the basis for the integral management and control of manufacturing systems in digital twin models for the regulation of process stability and quality with maintenance strategies. Thus, a system dynamics simulation model based on the conceptual model is developed for a metallurgical process. The results show how the monitoring of all flows together with the optimal strategies in the quality and maintenance areas enable companies to increase their profitability and customer service level. In conclusion, the conceptual approach and the applied simulation case study allow better decision making, ensuring continuous optimization along the manufacturing asset lifecycle, and providing a unique selling proposition for equipment producers and service engineering suppliers as well as industrial companies.