The purpose of this thesis is to present and describe the concept of manufacturing personalized cosmetics and the development of management and control of manufacturing of cosmetics products using the robot cell.
The investor, Vastok d.o.o., presented a business idea and a challenge to the project team; how to easily and in just a few steps create a personalized cosmetic product from natural ingredients through a great user experience. I accepted the challenge and this thesis presents my contribution towards the realization of this business idea and reaching the business goal.
My role in the project team was designing, developing and implementing a control and supervisory system in accordance with the concepts of Industry 4.0 and with smart factory guidelines.
The thesis presents the mechanical and technological building blocks for the robot cell as well as the building blocks for the supervisory and control system. The main and also the most attractive parts of the robot cell are the two-handed Yaskawa robot, interactive helmet, FS100 control unit, teaching unit and grippers. The robot cell is also comprised of the empty packaging storage, system for basic component dosing, system for dosing of liquid components, mixing device, system for checking the correctness of the packaging, a system for opening and closing of the packaging, system for disinfection and air preparation, labeling system, safety system, laboratory equipment and power distribution cabinets with control electrical equipment.
The computer system consists of computer hardware and software and elements, which are a part of the process. The building blocks of the control and supervisory system are actuators, servo regulators Bosch Rexroth, Sartorius scale, sensors and electrical and pneumatic equipment, which connect these elements with the computer equipment in charge of the automation. Siemens and Beckoff logic controller equipment was chosen for control equipment. Siemens programmable logic controller from the S7-1500 family, together with the Beckoff input-output modules, was chosen for controlling the process. Siemens TP1200-Comfort operating panel was chosen for the process control.
The control and the supervisory equipment is connected in the computer system architecture using modern industrial communications and protocols: Profibus and Profinet. For accessing the information level classical Ethernet communication over network switch is used.
The automation system for the robot cell is developed in accordance with the guidelines for lean production, which ensures speed, repeatability, reliability, and process optimization. Total automation for the control and monitoring system is achieved by using modern software tool Siemens TIA portal and with development of the application software for the command and control level. Development of the application software for personalized cosmetics manufacturing process management followed a modular concept and ANSI/ISA-S88.01-1995, ANSI/ISA-95.00.01-2000 recommendations. Development of the application software for the command level followed the principles that the processes are adaptive, predictable and flexible according to the number of different combinations during the personalized cosmetics manufacturing process. Development of the application software for the control level followed good engineering practices, which led to a transparent and user-friendly system visualization. Visualization allows monitoring of the manufacturing process and alarms, inventory control, setting of technical parameters and system maintenance.
Consistent with the business idea and the complete concept the robot cell is just one of the links in the chain that comprises the personalized cosmetics manufacturing. The user experience starts with the creation of the personalized product in the web shop. In this shop the user creates the product, pays for it whereupon the order of the product starts. The product with the corresponding recipe is transferred over the communication interfaces, through the Manufacturing execution system and the application for transferring of recipe parameters to the control and supervisory level. It reports in real time and records data about the state of the manufacturing process, process parameters, alarms and warnings, amounts and raw materials inventory to the production information system. Production information system then after the manufacturing is finished stores all the data about a particular product, allows tracking of products and material flow, analytics and a review of archived process parameters.
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