| Author: | Wai, Chi Hang |
| Title: | Transform the traditional electronics manufacturing services (EMS) factory into industry 4.0 smart factory by cyber-physical production systems (CPPS) implementation |
| Advisors: | Lee, K. M. Carman (ISE) |
| Degree: | Eng.D. |
| Year: | 2025 |
| Department: | Department of Industrial and Systems Engineering |
| Pages: | v, 222 pages : color illustrations |
| Language: | English |
| Abstract: | A Cyber-Physical Production System (CPPS) is essential for modern factories to adapt to the rapidly evolving manufacturing environment and maintain their competitive edge. The primary challenge in implementing CPPS in the traditional Electronics Manufacturing Services (EMS) industry is upgrading existing equipment without causing significant disruptions to ongoing operations. This research proposes a comprehensive methodology that integrates practical solutions for upgrading legacy systems with IoT sensors and feedback control, bridging gaps through SCADA connectivity while ensuring robust IT/OT data security. Machine Learning (ML) has been a hot topic over the past decade, transforming various industries, including EMS. In the EMS field, the Surface Mount Technology (SMT) process is crucial and serves as a technical barrier to competitors. Although some advanced SMT machines have already implemented closed-loop feedback control and Poke-Yoke mistake proofing, research on using machine learning for self-optimization of SMT process parameters is scarce. This research implements an ML framework for self-optimizing SMT process parameters, aiming to enhance efficiency, accuracy, and adaptability. The methodology includes developing a Cloud-Fog-Edge intelligence CPPS, utilizing LSTM Deep Learning (DL) to empower digital twin (DT) simulations. The results of the proposed method demonstrate substantial improvements in operational metrics. At the station level, the integration of DT-DL led to a 0.86% increase in overall yield rate and a 0.15% reduction in yield rate standard deviation. Station throughput increased by 7.513%, with a 0.361 reduction in its standard deviation, and setup time decreased by 5.2 hours. At the line level, DT-DL implementation resulted in a 6% increase in output units per hour (UPH) and UPH per headcount. Floor-level improvements driven by ANN-DT reduced Defective Parts Per Million (DPPM) by 3.632%. At corporate level, CPPS implementation increased the number of shipped items in accordance with orders by 1.19%, decreased field returns (RMA%) by 0.31%, and reduced product failures by 47.62%. The customer Incoming Quality Control (IQC) pass rate improved by 0.13%, and on-time delivery rates increased by 0.62%. The novelty and significance of this research lie in providing practical solutions to bridge the gap between theory and practice within EMS factories. The research outcomes could further support CPPS implementation, contributing to the industry's gradual transition towards a Smart Factory for Industry 4.0. |
| Rights: | All rights reserved |
| Access: | restricted access |
Files in This Item:
| File | Description | Size | Format | |
|---|---|---|---|---|
| 8113.pdf | For All Users (off-campus access for PolyU Staff & Students only) | 5.78 MB | Adobe PDF | View/Open |
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