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Prognostic Health Management (PHM) is a predictive maintenance strategy, which is based on Condition Monitoring (CM) data and aims to predict the future states of machinery. The existing literature reports the PHM at two levels: methodological and applicative. From the methodological point of view, there are many publications and standards of a PHM system design. From the applicative point of view, many papers address the improvement of techniques adopted for realizing PHM tasks without covering the whole process. In these cases, most applications rely on a large amount of historical data to train models for diagnostic and prognostic purposes. Industries, very often, are not able to obtain these data. Thus, the most adopted approaches, based on batch and off-line analysis, cannot be adopted. In this paper, we present a novel framework and architecture that support the initial application of PHM from the machinery producers’ perspective. The proposed framework is based on an edge-cloud infrastructure that allows performing streaming analysis at the edge to reduce the quantity of the data to store in permanent memory, to know the health status of the machinery at any point in time, and to discover novel and anomalous behaviors. The collection of the data from multiple machines into a cloud server allows training more accurate diagnostic and prognostic models using a higher amount of data, whose results will serve to predict the health status in real-time at the edge. The so-built PHM system would allow industries to monitor and supervise a machinery network placed in different locations and can thus bring several benefits to both machinery producers and users. After a brief literature review of signal processing, feature extraction, diagnostics, and prognostics, including incremental and semi-supervised approaches for anomaly and novelty detection applied to data streams, a case study is presented. It was conducted on data collected from a test rig and shows the potential of the proposed framework in terms of the ability to detect changes in the operating conditions and abrupt faults and storage memory saving. The outcomes of our work, as well as its major novel aspect, is the design of a framework for a PHM system based on specific requirements that directly originate from the industrial field, together with indications on which techniques can be adopted to achieve such goals.

Industry 4.0 emerged in the last decade as the fourth industrial revolution aiming at reaching greater productivity, digitalization and operational efficiency standard. In this new era, if compared to automated assembly systems, manual assembly systems (MASs) are still characterized by wide flexibility but poor productivity levels. To reach acceptable performances in terms of both productivity and flexibility, higher automation levels are required to increase the skills and capabilities of the human operators with the aim to design next-generation assembly systems having higher levels of adaptivity and collaboration between people and automation/information technology. In the current literature, such systems are called adaptive automation assembly systems (A3Ss). For A3Ss, few design approaches and industrial prototypes are available. This paper, extending a previous contribution by the Authors, expands the lacking research in the field and proposes a general framework guiding toward A3S effective design and validation. The framework is applied to a full-scale prototype, highlighting its features together with the technical- and human-oriented improvements arising from its adoption. Specifically, evidence from this study show a set of benefits from adopting innovative A3Ss in terms of reduction of the assembly cycle time (about 30%) with a consequent increase of the system productivity (about 45%) as well as relevant improvements of ergonomic posture indicators (about 15%). The definition of a general framework for A3S design and validation and the integration of the productivity and ergonomic analysis of such systems are missing in the current literature, representing an element of innovation. Globally, this research paper provides advanced knowledge to guide research, industrial companies and practitioners in switching from traditional to advanced assembly systems in the emerging Industry 4.0 era matching current industrial and market features.

The assembly of large and complex products such as cars, trucks, and white goods typically involves a huge amount of production resources such as workers, pieces of equipment, and layout areas. In this context, multi-manned workstations commonly characterize these assembly lines. The simultaneous operators’ activity in the same assembly station suggests considering compatibility/incompatibility between the different mounting positions, equipment sharing, and worker cooperation. The management of all these aspects significantly increases the balancing problem complexity due to the determination of the start/end times of each task. This paper proposes a new mixed-integer programming model to simultaneously optimize the line efficiency, the line length, and the workload smoothness. A customized procedure based on a simulated annealing algorithm is developed to effectively solve this problem. The aforementioned procedure is applied to the balancing of the real assembly line of European sports car manufacturers distinguished by 665 tasks and numerous synchronization constraints. The experimental results present remarkable performances obtained by the proposed procedure both in terms of solution quality and computation time. The proposed approach is the practical reference for efficient multi-manned assembly line design, task assignment, equipment allocation, and mounting position management in the considered industrial fields.

In the contemporary landscape, roughly one-fourth of worldwide carbon dioxide emissions stem from industrial energy usage. In the industrial sector, improving the efficient and flexible coupling among different energy demands (electricity, heating, and cooling) and exploiting the integration of Renewable Energy Sources (RESs) and waste heat can lead to a drastic reduction in CO2 emissions, these are also the goals of the EU founded Horizon Europe FLEXIndustries project. This study aims to establish a cost-optimized decarbonization strategy for an energy-intensive industry, focusing on an Italian pharmaceutical company. It delves into the exploration of potential pathways and diverse energy mix configurations. The approach undertaken involves coupling a customized energy system simulation framework, specifically designed for the industrial site, with a Multi-Objective Evolutionary Algorithm (MOEA). The study, conducted with a focus on the year 2024, involves a comparative analysis of three distinct scenarios. Within the intricate and challenging constraints of the industrial demo site, 13 technologies were investigated. The outcomes of each scenario identify a set of 500 Pareto optimal solutions, obtained through 40,000 simulations. These results shed light on the compelling potential of hybrid solutions, showcasing the feasibility of achieving substantial decarbonization with only moderate increases in costs. The availability of land for RES technologies, along with the existence of a biomass supply chain in the region, emerge as pivotal determinants.

The design, development and performance evaluation of a fluorescence-based pH sensor for on-line measurements is presented. The pKa of the sensing element has been calculated to be 7.9, thus the sensor is suitable for measurement of near neutral solutions. The sensor consists of a low-cost disposable polymer sensing probe, in contact with the solution under test, interrogated by an optoelectronic transduction system. The pH sensitive dye is based on fluorescein O-methacrylate, which has been covalently linked to a hydrogel matrix, realized through the use of HEMA (2-hydroxyethyl methacrylate), HDDA (1,6-hexanediol diacrylate) and PEGDA (polyethylene glycol diacrylate). The optical interrogation setup, together with the electronics, has been developed to acquire and process the fluorescence signal. The sensor works over a pH range between 6.5 and 9.0. In the range between 7.0 and 8.0, the sensor shows a linear behavior with a maximum linearity error of 5%. Thanks to the good performance of the sensing element and transduction system, the short term drift of the reading (measured over 40 min) is lower than 0.15%. The measuring system also exhibits good performance in terms of response time and reproducibility.

A novel type of covalently cross-linked semi-crystalline polymer with shape-memory and biocompatibility properties was prepared from alkoxysilane-terminated poly(ε-caprolactone) (PCL) by sol–gel process that allowed the generation of silica-like cross-linking points. A fine tuning of the cross-linking density and thermal properties (melting temperature) of the materials was obtained by controlling the molecular weight of the PCL precursor (and thus the molecular structure of the resulting network) and the curing conditions. The shape-memory behaviour was investigated with bending tests. Recovery times of less than one second were observed in water depending on the temperature, and a linear correlation of the recovery time with cross-linking density and molecular weight of PCL network precursor was observed.

The dramatic growth of online shopping worldwide in the last few years generated negative consequences for local small retailers who do not adopt information technologies. Furthermore, the e-commerce sector is considered a good opportunity to develop sustainable logistic processes. To reach this goal, the proposed paper presents a mathematical model and a metaheuristic algorithm to solve a multi-objective capacitated vehicle routing problem (CVRP) distinguished by economic, green, and ethical objective functions. The proposed algorithm is a multi-objective simulated annealing (MOSA) that is implemented in a software architecture and validated with real-world instances that differ for the product type delivered and the geographic distribution of customers. The main result of each test is a tri-dimensional Pareto front, i.e., a decision-support system for practitioners in selecting the best solution according to their needs. From these fronts, it can be observed that if the economic and environmental performances slightly deteriorate by 1.6% and 4.5%, respectively, the social one improves by 19.4%. Furthermore, the developed MOSA shows that the environmental and social objective functions depend on the product dimensions and the geographic distribution of customers. Regarding the former aspect, this paper reports that, counter-intuitively, the metabolic energy consumption per driver decreases with bigger products because the number of necessary vehicles (and drivers) increases, and, thus, the workload is divided among more employees. Regarding the geographic distribution, this manuscript illustrates that, despite similar traveled distances, highly variable altitudes cause more carbon emissions compared to flat distributions. Finally, this contribution shows that delivering small goods decreases the distance that vehicles travel empty by 59%, with a consequent cost reduction of 16%.

The 4th industrial revolution (Industry 4.0, I4.0) is based upon the penetration of many new technologies to the industrial world. These technologies are posed to fundamentally change assembly lines around the world. Assembly systems transformed by I4.0 technology integration are referred to here as Assembly 4.0 (A4.0). While most I4.0 new technologies are known, and their integration into shop floors is ongoing or imminent, there is a gap between this knowledge and understanding the form and the impact of their full implementation in assembly systems. The path from the new technological abilities to improved productivity and profitability has not been well understood and has some missing parts. This paper strives to close a significant part of this gap by creating a road map to understand and explore the impact of typical I4.0 new technologies on A4.0 systems. In particular, the paper explores three impact levels: strategic, tactical, and operational. On the strategic level, we explore aspects related to the design of the product, process, and the assembly system. Additionally, the paper elaborates on likely changes in assembly design aspects, due to the flexibility and capabilities that these new technologies will bring. Strategic design also deals with planning and realizing the potential of interactions between sub-assembly lines, kitting lines, and the main assembly lines. On the tactical level, we explore the impact of policies and methodologies in planning assembly lines. Finally, on the operational level, we explore how these new capabilities may affect part routing and scheduling including cases of disruptions and machine failures. We qualitatively assess the impact on performance in terms of overall flow time and ability to handle a wide variety of end products. We point out the cases where clear performance improvement is expected due to the integration of the new technologies. We conclude by identifying research opportunities and challenges for advanced assembly systems.

The advances in Industry 4.0 provide both challenges and opportunities for digital manufacturing and assembly systems. This paper first addresses the state-of-the-art readiness for Industry 4.0 concerning assembly and manufacturing systems through a literature review of the relevant papers recently published. Then it assesses the challenges faced nowadays by assembly and manufacturing systems. Third, it focuses on the most promising future developments and evolution of such production systems as well as their digitalisation. Finally, this manuscript illustrates the content of the papers selected for this special issue. Through the study presented in this special issue, valuable contributions to both theory and application in this area have been achieved, and a useful reference for future research is given.

Delivery platforms in urban logistics connect providers with customers through distribution riders, who are usually distinguished by low incomes and limited social rights. This paper aims to compare and analyze the freelance and employment models for riders in different European countries in terms of social sustainability, i.e., work motivation and labor rights. To reach this goal, two activities were performed. On the one hand, qualitative interviews with German and Italian riders were carried out. On the other hand, a dynamic metaheuristic algorithm was developed and implemented to simulate an employment model with a central provider that manages order requests in real-time. The qualitative interviews indicate that riders’ motivations differ between freelance riders and employed riders: freelance riders do feel more controlled. Using a quantitative algorithm, this manuscript shows that when an efficient centralized order–rider assignment strategy is applied, a socially sustainable and simultaneously profitable employment model for food delivery businesses is possible. The results have the potential to legitimize adequate rights and salaries for riders while allowing digital platforms to operate profitably. Such win–win situations could support the implementation of platform structures across different logistics sectors and overcome conflicts regarding working rights in such contexts.