US 12,085,930 B2
AI-enabled process recovery in manufacturing systems using digital twin simulation
Sarbajit K. Rakshit, Kolkata (IN); Laxmikantha Sai Nanduru, Secunderabad (IN); and Pritpal S. Arora, Bangalore (IN)
Assigned to International Business Machines Corporation, Armonk, NY (US)
Filed by International Business Machines Corporation, Armonk, NY (US)
Filed on Jan. 5, 2022, as Appl. No. 17/568,776.
Prior Publication US 2023/0213930 A1, Jul. 6, 2023
Int. Cl. G05B 23/02 (2006.01); G05B 19/418 (2006.01)
CPC G05B 23/0294 (2013.01) [G05B 19/4183 (2013.01); G05B 19/4184 (2013.01); G05B 23/0243 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A computer-implemented method for providing solutions to self-recovery in a manufacturing process, the computer-method comprising:
collecting an initial factory data;
identifying and categorizing one or more shop floor activities;
creating a digital twin copy of the factory;
detecting a failure in the manufacturing process;
in response to detecting a failure in the manufacturing process, determining an initial recovery process;
performing one or more initial simulation scenarios with the digital twin copy, wherein the one or more initial simulation scenarios includes an initial recovery process;
generating one or more initial factory recovery plans based on the one or more initial recovery process and the one or more initial simulation scenarios;
executing the one or more factory recovery plans;
collecting a subsequent factory data;
updating the digital twin copy of the factory based on the subsequent factory data;
performing one or more subsequent scenarios based on the subsequent factory data; and
creating one or more subsequent factory recovery plans based on the one or more subsequent scenarios; and
executing a first recovery plan and a second recovery plan of the one or more subsequent factory recovery plans, wherein the second recovery plan comprising:
detecting faulty machines or subsystems that are beyond repair; and
initiating replacements of the faulty machine or subsystems.