This special issue focuses on the theme of "Building Logistics Systems for Intelligent Manufacturing," analyzing needs, discussing problems, providing ideas, and sharing experiences regarding the core elements of enterprise intelligent logistics construction, such as smart supply chains, intelligent logistics system solutions, intelligent logistics-related technologies and equipment, and intelligent logistics information systems.
Overview of the construction of logistics systems supporting intelligent manufacturing
In the era of intelligent manufacturing, manufacturing enterprises need to conduct large-scale customized production based on user needs and control production costs. This undoubtedly places many new demands on their logistics systems. This is why intelligent logistics must be a key focus when studying intelligent manufacturing. With intelligent logistics and warehousing systems being listed as one of the five core intelligent manufacturing equipment that my country is focusing on developing, more and more manufacturing enterprises are launching or preparing to launch intelligent logistics projects.
2017 can be considered a pivotal year for my country's advancement of intelligent manufacturing. Under this trend, how manufacturing enterprises should upgrade and optimize their logistics systems, information systems, and supply chains has become a crucial and widely discussed issue. Therefore, this special issue focuses on the theme of "Logistics System Construction for Intelligent Manufacturing," analyzing needs, discussing problems, providing insights, and sharing experiences regarding the core elements of enterprise intelligent logistics construction, including smart supply chains, intelligent logistics system solutions, intelligent logistics-related technologies and equipment, and intelligent logistics information systems.
Construction of intelligent logistics systems to support intelligent manufacturing
Within the framework of intelligent manufacturing, intelligent logistics will be built upon technologies such as the Internet, the Internet of Things (IoT), cyber-physical systems (CPS), and big data. It aims to achieve real-time transparency and discrete intelligent control of the logistics system, aligning with Industry 4.0 technologies. It seeks to intelligently connect and integrate all internal and external logistics processes within an enterprise, ultimately realizing full transparency and discrete real-time control of the logistics network. This article briefly describes the components of an intelligent logistics system under intelligent manufacturing and related technological developments, and finally discusses the challenges and coping strategies for implementing intelligent logistics.
In the era of Industry 4.0, the starting point for production activities is no longer the manufacturing enterprise, but the end user. The entire value chain has shifted from a company-driven model to a user-driven model, meaning that the starting point for all production and operations is now the end user. User needs have become more personalized and sophisticated, emphasizing participation and rapid response. Manufacturing enterprises need to be able to involve users in product design and produce according to user needs. This is the so-called mass customization model, where users decide what and how much the enterprise produces, while also keeping costs low.
Under this new production model, the logistics sector of manufacturing enterprises is the first to be impacted. To meet user demands for customization and rapid response, material distribution needs to be more flexible and automated, with the ability to respond quickly to orders. This is why intelligent logistics must be a key focus when studying intelligent manufacturing.
I. Requirements of Intelligent Manufacturing for Intelligent Logistics
In the era of intelligent manufacturing, the demand for mass customization has placed many new requirements on intelligent logistics systems. For example, in the automotive industry, consumers used to have very few car models to choose from, but now not only are there more diverse models from various brands, but more significantly, consumers have a wider selection of parts; especially with the explosive growth in the number of parts, the total number of various configurations can reach 10 to the power of 32, which means that within a month or even longer, no two identical car models will roll off the production line. To support this production model, the intelligent logistics system within the intelligent manufacturing system must meet the requirements of full-process digitalization, networking, high flexibility, automation, and intelligence.
1. End-to-end digitalization
Within the framework of future intelligent manufacturing, intelligent logistics systems can intelligently connect and integrate all internal and external logistics processes of an enterprise, achieving full transparency and discrete real-time control of the logistics network. The core of achieving this goal lies in digitalization. Only by achieving full-process digitalization can the logistics system possess intelligent functions.
2. Networking
In intelligent logistics systems, various devices no longer operate in isolation. They are intelligently connected through the Internet of Things (IoT) and internet technologies, forming a comprehensive network structure that enables rapid information exchange and autonomous decision-making. This network structure not only ensures the high efficiency and transparency of the entire system but also maximizes the role of each piece of equipment.
3. Highly flexible automation
In the era of mass customization, production itself is a flexible process. Building upon automation, this demands even greater flexibility from the corresponding logistics system. A flexible logistics system encompasses not only process requirements but also flexibility in hardware and layout. For example, in logistics process design, a many-to-many approach should be used instead of a one-to-one approach; and in terms of hardware and layout, the possibility of future adjustments based on production needs should be considered.
4. Intelligent
Intelligentization is the core requirement of intelligent logistics systems and its biggest difference from the past. Faced with large-scale customization demands, as well as cost reduction and efficiency optimization, it is necessary to improve the level of intelligence in every link of production, connecting them intelligently to enable them to make autonomous decisions, while also decentralizing them, making them not only executors of tasks but also initiators.
II. Composition and Functional Characteristics of Intelligent Logistics Systems
Intelligent unitized logistics technology, intelligent logistics equipment, Internet of Things (IoT) technology, and intelligent logistics information systems are the core elements for building intelligent logistics. In this intelligent logistics system, all equipment, whether unitized or automated, will be autonomously decision-making, decentralized, and discretely controlled, possessing a high degree of automation and flexibility.
1. Intelligent unitized logistics technology
Unitized logistics can be categorized based on the container used: containerized logistics, palletized logistics, and crate-based logistics. In modern unitized logistics technology, unit containers not only carry materials but also information. The function of unitized logistics is to effectively integrate previously separate logistics links into a whole, thereby rationalizing the entire logistics system. Within the Industry 4.0 smart factory framework, intelligent logistics unitization technology is a crucial link connecting suppliers, manufacturers, and customers, thus forming the cornerstone of building future smart factories. Smart pallets/crates will become the basic intelligent units in the Industry 4.0 era, issuing action commands to the logistics system and leveraging intelligent logistics unitization technology to drive the entire supply chain.
The German Institute for Logistics Research (FraunhoferIML) has independently developed a smart turnover box technology called inBin, which realizes the intelligence of logistics units by adding sensing and intelligent control units to the turnover box.
InBin smart lockers can autonomously manage the goods inside and report their status to the upper-level system in a timely manner, enabling automatic ordering and replenishment. The conveyor system based on these smart lockers can employ distributed control technology; the smart locker is no longer a passive unit but rather a "master" that issues commands to the conveyor system. Under the command of the smart locker, the conveyor system can automatically deliver the lockers to their destination.
2. Intelligent logistics equipment
By integrating technologies and equipment such as Radio Frequency Identification (RFID), photoelectric sensing, infrared sensors, ultrasonic sensors, laser scanners, and machine vision recognition, and according to agreed-upon protocols, these technologies are incorporated into logistics equipment (such as handling, loading/unloading, conveying, sorting, and shelving equipment), enabling autonomous decision-making through data sharing. In recent years, the development of automated logistics equipment technology has shown trends towards intelligence, networking, flexibility, lightweighting, energy efficiency, and environmental friendliness. Product design emphasizes modularity, serialization, and standardization to improve product quality, reduce manufacturing costs, and shorten production time.
The highly flexible CTS (Cellular Transport Systems) technology developed by the German Logistics Research Institute differs from traditional shuttle vehicles. In this system, each vehicle is an independent unit that replaces inflexible transport equipment. It can autonomously accept suitable orders based on its location and status, and intelligently interact with production equipment and other vehicles to solve problems encountered during its journey.
This small vehicle is based on Internet of Things (IoT) technology, enabling autonomous control. It can use swarm intelligence technology to complete complex transportation tasks, has on-demand transportation capabilities, and can move amphibiously on shelves and the ground, exhibiting good flexibility.
In addition to CTS technology, the German Logistics Research Institute has also developed Bin:Go, an intelligent handling technology that can roll and fly.
Thanks to its ingenious design, Bin:Go can roll on the ground and on a spiral platform, autonomously planning its own path. When rolling becomes difficult or inefficient, it can fly to reach its destination and complete its task. These vehicles are no longer limited to flat surfaces or fixed paths; they can autonomously perform transport operations and system-assigned tasks in two-dimensional or three-dimensional space.
3. Internet of Things (IoT) technology
As illustrated in the examples of intelligent unitized logistics and intelligent logistics equipment, the direct exchange of information between devices requires the Internet of Things (IoT) as a carrier. The IoT meets the networking needs of intelligent logistics and is also key to achieving end-to-end digitalization. Currently, the main technologies for preliminary IoT applications are WiFi and Bluetooth, but their data accuracy is low and power consumption is high. Wide-area IoT can use fiber optics, but this is only suitable for connecting broadband terminals such as cameras. To achieve efficient intelligent interconnection, there is a need for continuous improvement in IoT technology.
Narrowband Internet of Things (NB-IoT) is an emerging technology in the IoT field that supports low-power devices for cellular data connections over wide-area networks (LPWA). It features simpler device connectivity, high coupling, low terminal costs, plug-and-play functionality, high reliability, and unified service platform management. It primarily targets IoT applications requiring low data rates, deep coverage, low power consumption, and large data connections. This technology aligns well with the requirements of smart logistics, enabling low-level communication and decision-making between various smart logistics units and equipment, truly achieving a dense mesh connection and improving the efficiency and accuracy of information exchange.
4. Intelligent Logistics Information System
The Internet of Things (IoT) technology enables the mesh connectivity and communication of various devices in smart logistics. At the very top of this smart logistics system lies an intelligent cloud system—the smart logistics information system. This system stores all data in the cloud, shares and processes data through established protocols and rules, and ensures data security and accuracy during use, enabling the entire smart logistics system to operate normally. Relying on technologies such as the Internet, Cyber-Physical Systems (CPS), artificial intelligence, and big data, the smart logistics information system can achieve full network transparency and discrete real-time control, facilitating the technological integration of Industry 4.0 and smart manufacturing.
