Safer and efficient assemblies: Harnessing real time worker movements with digital twins

¹ School of Computing, Engineering and the Built Environment, Edinburgh Napier University, Edinburgh EH10 5DT, UK
² School of Engineering, The University of Edinburgh, Edinburgh EH8 9YL, UK
³ Department of Management Science, University of Strathclyde, Glasgow G1 1XQ, UK
⁴ National Manufacturing Institute Scotland, University of Strathclyde, PA49LJ, UK

^* Corresponding author: s.kumar@napier.ac.uk

Abstract

This paper addresses a critical gap in digital twin simulation within manufacturing environments by focusing on the dynamic representation of worker movements during assembly processes. We introduce an innovative approach that utilises Ultra-Wideband (UWB) sensors to incorporate worker trajectory data into Siemens Process Simulate software, enabling the creation of a digital twin of assembly line operations. Our methodology involves comprehensive data collection using UWB sensors, followed by pre-processing steps such as data cleaning, interpolation, and classification of points into dwell and transit locations. Within the framework of Process Simulate, we develop the assembly process digital twin, integrating simulations of tricycle assembly alongside dynamic worker path and movement simulations. Our digital twin facilitates ergonomic analysis, process optimisation, and worker interaction analysis, offering insights for enhancing factory efficiency and safety. Notably, through visualisation of worker paths and identification of bottlenecks, our digital twin enables optimisation of resource allocation. Quantitative results demonstrate significant improvements, such as a reduction in the time of completion of six products by 11% compared to Discrete Event Simulation under similar process conditions. This study highlights the transformative potential of digital twin technology in manufacturing, providing a robust framework for simulating and optimising worker movements within real-world factory environments.