Development of a biology inspired manufacturing system for machining transmission cases

Disruptions in automated manufacturing systems for machining automotive parts caused by system changes and disturbances reduce the productivity, and increase the downtime as well as the cost of products. To cope with these challenges, the paper presents a biology inspired manufacturing system (Bio-MS). The model of Bio-MS is inherited from the organization of the living systems in biology and nature such as ant colony, school of fish, bee’s foraging behaviors, and so on. In which, the resources of the manufacturing system are considered as biological organisms, which are autonomous entities so that the manufacturing system has the advanced characteristics inspired from biology such as self-adaptation, self-diagnosis, and self-healing. To realize the Bio-MS, the cognitive agent and swarm intelligence were proposed. The disturbances happening when machining the transmission cases at an automotive company in Korea were analyzed to classify them and to find out the corresponding management methods. Currently, the system utilization was too low due to the manual recovery, only 70–76 percent of total production time is used for manufacturing and the rest of the time is wasted in different disturbances. The Bio-MS with autonomous behaviors adapts efficiently to the changes of the manufacturing environment. It enables to increase the system utilization more than 80 percent.