Industrial Automation

Magnetic levitation (MagLev) systems have great potential for application in high-mix, low-volume manufacturing due to their scalability and flexibility, enabling highly reconfigurable in-machine material flow. However, their manipulation capabilities remain largely unexploited, as current applications almost exclusively focus on transportation. To enable grasping and manipulation directly on MagLev systems without requiring additional costly handling equipment, such as industrial robot arms, we present the Gripper MagBot, a low-cost parallel 6-DoF manipulator with an integrated 1-DoF gripper that mechanically couples three MagLev movers. The Gripper MagBot supports two operating configurations: a default mode and a single-track mode, selectable depending on the required stability and workspace footprint. To reconfigure a machine, the MagBot can be autonomously dropped off and picked up using a docking station. We showcase pick-and-place examples in simulation, as well as with the real Gripper MagBot using our inverse kinematics controller. CAD files, assembly instructions, a component list, and videos are available at https://sites.google.com/view/gripper-magbot.

Rapid bespoke commissioning of the Cognitive Digital Twin (CDT) is a major challenge in reconfigurable manufacturing. Traditional digital twin (DT) construction methods primarily focus on geometric reconstruction, often neglecting the deep semantic integration and functional interoperability necessary for autonomous reasoning. This paper proposes an agent-based, AI-driven workflow to automate end-to-end CDT debugging. The system utilises LangGraph as a multi-agent orchestration engine to achieve dual-path synthesis: the semantic path extracts technical specifications from unstructured documents using Retrieval Augmented Generation (RAG), while the functional path autonomously discovers and binds to real-time industrial telemetry data using Model Context Protocol (MCP). Experimental validation in a robotic machining cell demonstrates that the system achieves a mean average accuracy (mAP) of 97.2% in perception and reduces the deployment cycle from several weeks to an average of 2 hours, marking a paradigm shift from manual scripting to autonomous orchestration.

The convergence of artificial intelligence (AI), Industrial Internet of Things, cyber-physical systems, and advanced robotics is reshaping manufacturing faster than engineering curricula can adapt, widening the gap between the competencies required on the shop floor and those delivered by traditional engineering and technology education. This paper proposes a Workforce Readiness Level (WRL) framework, which adapts the Technology Readiness Level scale into nine progressive competency stages and a four-pillar rubric, digital and AI literacy, cyber-physical systems fluency, human-machine collaboration, and data-driven decision making, aggregated through a composite stage score and a cohort-level workforce-readiness index under a ``no-thin-pillar'' rule. The framework is instantiated at a university smart-manufacturing teaching laboratory and draws on 89 sponsored capstone projects delivered over four semesters, four of which are analyzed in depth. Four pillars jointly span the relevant ABET student outcomes. Across the highlighted cohorts the workforce-readiness index ranged from 5.2 to 6.4, and the no-thin-pillar rule was diagnostically informative in three of the four cases and the binding certification constraint in one, repeatedly surfacing cyber-physical and data-driven-decision gaps concealed behind strong analytics profiles; advancement to the highest stages was gated by industry-embedded experience rather than additional coursework. WRL offers educators, accreditation bodies, and regional workforce systems a common, evidence-based instrument for diagnosing and advancing workforce readiness; future work will calibrate pillar weights and test reliability and predictive validity.

Modern manufacturing imposes six coupled demands on adaptive control: local decisions with global consequences, partial observability, nonstationarity, reflex speed response with long horizon effects, delayed and diffuse outcomes, and dynamics that resist explicit modeling. Cooperative multiagent reinforcement learning (MARL), posed as a Dec-POMDP under centralized training with decentralized execution, is a particularly natural formalism for these demands. This paper adopts a MARL centered scope and asks where large language models (LLMs) should augment, interface with, train, or, in the strongest competitive case, replace that coordination core. A taxonomy organizes the literature through four LLM attachment points: policy, reward design, communication between agents, and hierarchical planning. A conditional capability profile separates native mechanism, reported performance, formal guarantee, and engineering maturity, and a deployment readiness analysis identifies the evidence behind each role. These stages yield the principal contribution: a three layer MARL centered reference architecture, grounded in evidence, for semantic reasoning, adaptive cooperative control, and independently assured execution. The LLM-Augmented Dec-POMDP is a descriptive comparative notation for that architecture, recording four attachment choices without introducing a new decision process class or algorithm. Under the reviewed evidence, conventional MARL is better suited to frequent, structured, decentralized coordination after task specific training, whereas LLM components are promising for semantic interpretation, reward drafting, human interaction, and slower supervisory planning. Current LLM only manufacturing controllers do not yet establish equivalence for strict real time, decentralized, safety critical control; this conclusion is bounded by the available evidence and does not assert impossibility.

Injection molding is the cornerstone of mass-producing plastic components. While current algorithms can automate mold design for basic geometries using standard two-piece molds, complex parts featuring undercuts, side holes, or re-entrant features present a significant challenge. These geometries often necessitate auxiliary components beyond the primary upper and lower molds. In practice, designing these intricate assemblies is a laborious process that relies heavily on expert knowledge. Furthermore, the scarcity of public datasets has hindered the development of effective learning-based solutions. To bridge these gaps, we introduce MoldCAD, a curated dataset that pairs complex single-body CAD parts with industry-standard mold assemblies. Each entry includes the upper and lower molds, parting surfaces, demolding orientations, and necessary auxiliary components. The dataset comprises 4,934 CAD models and over 3,850 mold assemblies, totaling more than 23k individual models. Building upon this dataset, we propose a comprehensive pipeline that predicts demolding orientations, identifies auxiliary components, and constructs parting surfaces to derive a complete, manufacturing-ready mold assembly for downstream CAD/CAM workflows. Our results demonstrate a promising path toward fully automated industrial mold design and contribute to the broader advancement of manufacturing-aware CAD generation.

This letter presents an automated robotic manufacturing system for soft capacitors which operate as actuators and sensors. Emphasis is placed on the two processes that most directly govern device quality, dielectric layer formation by spin coating and carbon nanotube (CNT) electrode application by stamping. Twenty multilayer DEAs, each comprising 12 dielectric layers with a mean thickness of 55.37 +- 2.04 um and 11 alternating CNT electrodes, were fabricated reducing total process time by 14.2% and removing the operator from 56.1% of it.

Dynamic manufacturing environments require multi-agent systems to coordinate effectively under frequent operational disturbances such as machine failures, urgent job arrivals, and processing time variations. Existing multi-agent reinforcement learning approaches treat each disturbance episode independently, discarding valuable coordination experience that could accelerate future adaptation. In this paper, we propose a Graph-Structured Experiential Memory (GSEM) framework for multi-agent coordination in dynamic manufacturing. The framework encodes historical coordination episodes as heterogeneous relational graphs that capture task dependencies, machine states, and inter-agent collaboration patterns. When a new disturbance occurs, a graph neural network-based retrieval mechanism identifies structurally similar past episodes, enabling experience-guided policy adaptation rather than learning from scratch. Experiments on dynamic flexible job-shop scheduling benchmarks with three disturbance types show that GSEM reduces makespan by 4.1%-10.0% and adaptation time by 33%-38% compared to the strongest memory-augmented baseline, with the advantage increasing under higher disturbance frequency. Ablation studies and cross-disturbance transfer experiments further validate the necessity of graph-structured encoding and similarity-based retrieval and demonstrate the cross-disturbance generalizability of learned coordination patterns.

The permutation flow shop scheduling problem (PFSP) is a classical NP-hard combinatorial optimization problem in intelligent manufacturing. In practice, PFSP is commonly addressed using metaheuristic algorithms, among which the iterated greedy (IG) algorithm is widely adopted due to its simplicity and strong empirical performance. However, classical IG relies on a single fixed destruction operator, which often limits exploration and leads to search stagnation on large and complex problem instances. To address this issue, this work proposes a multi-operator IG algorithm, termed IG-DOE, which enhances exploration by switching among heterogeneous destruction operators along a single search trajectory. The core mechanism, called stagnation-triggered sequential switching, activates the next destruction operator in an ordered destruction operator ensemble (DOE) when stagnation is detected, thereby enriching the perturbation behavior of classical IG. Moreover, to reduce reliance on expert-crafted operators, a large language model (LLM)-assisted framework, termed SCOE, is introduced to automatically construct a high-quality DOE through stagewise evolution, state-awareness, and cooperative evaluation. Experiments on the challenging VRF-hard-large benchmark show that the DOE evolved from smaller problem instances generalizes well to larger unseen instances. Under the same CPU-time limit, IG-DOE obtained much better average performance than QIG, a state-of-the-art IG algorithm. Additional experiments on real-world industrial-data-derived instances further show that the evolved DOE can generalize effectively to different data distributions without additional adaptation.

Fault diagnostics and recovery in smart factories is challenging because critical information is dispersed across manuals of multiple machines which are interconnected through the manufacturing process. Large Language Models (LLMs) can provide a promising approach. In this paper, we propose FactoryLLM, a safe and open-source AI playground designed for evaluating different LLM-based retrieval-augmented generation (RAG) models by analysing documents from multiple machines across the manufacturing process. FactoryLLM enables the user to configure the LLM, and assess performance when reasoning over multiple documents, through a dual evaluation setup using both RAGAS and NVIDIA's LLM-as-a-Judge metrics. FactoryLLM is safe because it allows users to run local or open-source LLMs without sharing sensitive industrial data, providing a controlled environment for experimentation. We demonstrate the efficacy of FactoryLLM through a case study which involves an Autonomous Intelligent Vehicle and its Mobile Planner software, evaluating three LLMs across 30 maintenance queries derived from approximately 600 pages of cross-machine documentation. The results suggest that FactoryLLM is effective in cross-machine document reasoning: every model achieved a groundedness score above 0.88. The full code and documentation for community to test FactoryLLM with their manufacturing specific scenarios are publicly available.

We introduceWorkBenchMark, a LEGO Duplo-based robotic assembly benchmark motivated by the RoboCup Smart Manufacturing League. Robotic assembly couples low-level manipulation with task-level symbolic reasoning under physical constraints, a combination that current end-to-end learning methods do not yet solve reliably. The benchmark provides 400 tasks across four complexity tiers. We provide an open-vocabulary perception, Assembly-by-Disassembly baseline solution. Our planning-based pipeline outperforms a modern vision-language-action approach across all tiers. The benchmark, simulation environment, and baseline implementation will be released openly to support the broader robotic assembly community.

In semiconductor manufacturing, lithography projects circuit layouts onto silicon wafers through an optical mask. As circuit features shrink below the wavelength of light, optical diffraction causes the printed patterns to deviate from their intended layouts. Inverse Lithography Technology (ILT) addresses this challenge by generating optimized masks that enhance the fidelity of pattern transfer onto wafers. While ILT resembles an image synthesis task, its reliance on explicit physical metrics for mask evaluation limits the applicability of existing generative models. We introduce LithoGRPO, an ILT framework that integrates the flow-matching paradigm with GRPO-based reinforcement learning (RL) fine-tuning, enabling efficient exploration of diverse masks for a given target layout. Unlike purely generative or optimization-based approaches, RL in LithoGRPO exploits the explicitly defined, physics-based reward function of ILT, enabling optimization under complex, process-aware constraints. To the best of our knowledge, this is the first framework that unifies flow matching and RL for mask optimization. To improve RL sampling efficiency, we propose a fast shot-counting algorithm for manufacturability evaluation, achieving over 130x speedup while preserving the mask ranking of the traditional shot-count metric. Extensive experiments demonstrate that LithoGRPO achieves state-of-the-art performance over both optimization-based and learning-based methods, while maintaining efficient mask generation.

Federated learning (FL) has broadened the horizon for multivariate time series anomaly detection (MTSAD). However, benchmarking such anomaly detection methods within FL paradigm poses data-centric challenges. The existing datasets do not counteract these challenges since they do not simultaneously provide sufficient scale, accurate labels, and freedom from common flaws. In addition, the role of cyclic process behavior, which is common in discrete industrial automation, remains underexplored for MTSAD for the current state of research. This paper aims to shed more light on the literature and address these gaps by introducing a dataset designed with cyclic dynamics arising from the repetitive nature of discrete automation processes and evaluates selected MTSAD methods on both the proposed dataset and a public benchmark dataset.

Design for manufacturing plays a critical role in advanced aeroengine development, where complex components necessitate careful consideration of manufacturability. However, current practices in pipe routing remain largely decoupled from down-stream manufacturing, leading to labor-intensive, trial-and-error iterations to achieve manufacturable designs. To address this problem, this study proposes the Frenet-based pipe routing optimization (FPRO) framework, a manufacturability knowledge-integrated reinforcement learning approach for free-form pipe design in aeroengines. FPRO formulates the routing problem as a boundary value problem in the Frenet frame. In this framework, the pipe path is represented by curvature and torsion profiles, which are generated using cubic Hermite interpolation. To integrate design and manufacturing, domain-specific manufacturing knowledge is embedded as constraints on the permissible ranges of curvature and torsion. The path optimization is performed using the proximal policy optimization algorithm with stochastic exploration and a stage-guided reward mechanism. A unified mapping formulation then translates the optimized path into motion trajectories for the bending die, enabling direct fabrication on a six-axis free-bending machine. Experimental results demonstrate that FPRO consistently generates collision-free, manufacturable paths with smoother geometric profiles compared to Cartesian-based methods. It also achieves faster convergence and superior performance in terminal alignment, path length, obstacle avoidance, and manufacturability compared to state-of-the-art reinforcement learning baselines. Real-world validation confirms the close geometric correspondence between the manufactured pipe and its digital design, validating the practical feasibility of FPRO.

Automatic generation of computer-aided design (CAD) models is a core technology for enabling intelligence in advanced manufacturing. Existing generation methods based on large language models (LLMs) often fall short when handling complex CAD models characterized by long operation sequences, diverse operation types, and strong geometric constraints, primarily because reasoning chains break and effective error-correction mechanisms are lacking. To address this problem, this paper proposes a memory-augmented reinforcement learning framework for CAD generation agents. The framework encapsulates the underlying geometric kernel into a structured toolchain callable by the agent and builds a closed-loop mechanism of design intent understanding, global planning, execution, and multi-dimensional verification. It also designs a dual-track memory module consisting of a case library and a skill library, and proposes a dynamic utility retrieval algorithm. By introducing reinforcement learning into retrieval and policy optimization, the agent can effectively avoid retrieval traps in which examples are semantically similar but geometrically infeasible, enabling online self-correction and continual evolution without additional large-scale annotated data. Experiments show that the proposed method significantly improves both the success rate and geometric consistency on complex CAD model generation tasks.

Task allocation in smart manufacturing systems needs to operate under decentralized decision-making, dynamic workloads, and shared resource constraints. In circular manufacturing settings, these challenges are further intensified by the need to balance operational efficiency with resource and energy sustainability. While learning-based approaches have been explored, many focus on predicting absolute performance metrics that do not necessarily translate into improved allocation outcomes, since decentralized assignment is governed by the relative ordering of candidate machines. This work proposes an Edge-AI-driven decentralized task allocation framework based on ranking-aware negotiation, where lightweight decision intelligence is embedded at the machine level to enable low-latency coordination without centralized control. The framework is developed progressively: a resource-aware heuristic first establishes the decentralized bidding structure, an Edge-AI-based regression model then provides learned local bid approximation, and a ranking-aware formulation finally reshapes the learning objective to align with the ordering-based nature of winner selection. Each machine evaluates incoming tasks using local information, including processing capability, queue state, and resource contention. The framework is evaluated via discrete-event simulation under high-load and tight-deadline scenarios using delay, deadline violations, throughput, and energy consumption. Results show improved delay and deadline adherence under high load, and enhanced energy efficiency under tighter constraints, leading to more resource-efficient operation aligned with circular manufacturing objectives. These findings demonstrate that aligning learning objectives with decentralized decision structures is critical for effective negotiation-driven task allocation.

Explicit dynamic finite element (FE) simulations are widely used for large deformation engineering analysis, but repeated simulations remain costly during design space exploration and optimisation. In explicit FE analysis, nodal kinematics and element level deformation measures evolve through coupled node element updates. This motivates graph learned simulators that approximate one step FE state transitions and roll them out autoregressively. However, many mesh based graph surrogates are node centred, which makes element level variables and native nodal elemental exchange less direct to represent. This work proposes CAttBiGNN, a cross attention based bipartite graph neural network for coupled nodal elemental learning. The graph represents FE mesh nodes and elements as distinct entities linked by directed node element edges, enabling nodal displacement increments and element level deformation states to be predicted on their native discretisation domains. An edge aware cross attention processor uses geometric edge embeddings to modulate directional node element message passing. For larger graphs, CAttBiUGNN combines the bipartite processor with graph downsampling and upsampling to improve long-range information propagation. The method is evaluated on dome shaped cold forming and corner shaped hot forming benchmarks. Comparisons with node centred baselines and bipartite and attention ablations show improved accuracy and balance in nodal displacement and elemental thinning prediction during autoregressive rollout. The results indicate that the proposed finite element inspired learned simulator can support manufacturability oriented field prediction and efficient design space exploration in large deformation sheet material forming.

Graph-based machine learning has emerged as a promising approach for manufacturability analysis by learning directly from CAD models represented as Boundary Representations (B-reps), exploiting both surface geometry and topological connectivity. However, purely geometric representations often lack the process-specific semantics required for accurate manufacturability prediction: many manufacturing factors, such as surface roles or bend intent, are not explicitly encoded in shape alone and are difficult for data-driven models to infer reliably. We propose a hybrid approach that addresses this challenge by enriching B-rep attributed adjacency graphs with manufacturing features recognized through a rule-based module. Applied to sheet metal bending, recognized features, such as bend characteristics, flange lengths, and surface roles are integrated as node attributes, concentrating the learning signal on process-relevant geometric patterns. Experiments on both a large-scale synthetic manufacturability benchmark and a real-world industrial dataset with measured bending times, one of the first such validations on genuine production data, demonstrate that combining domain knowledge with graph-based learning improves prediction accuracy across both tasks. The results demonstrate that hybrid modeling offers a feasible and effective path toward deployable tools for manufacturability assessment and effort estimation in industrial CAD environments.

Advanced manufacturing technologies allow for the production of intricate parts featuring high shape complexity and spatially-varying material composition. Data fusion of point clouds with chromatic attributes provides 4D point clouds, a compact and informative representation that encodes both shape and material information. In this paper, we present a registration-free framework for Simultaneous Monitoring of shApe and Color (SMAC) via 4D point clouds. The proposed framework leverages Laplace-Beltrami operator spectral properties to capture and monitor geometric features and the relationship between shape and surface color. A combined monitoring scheme is proposed to effectively detect shape deformations and color anomalies, along with a spatially-aware post-signal diagnostic procedure to determine the source of change and localize color anomalies. Importantly, neither component relies on registration or mesh reconstruction, eliminating error-prone and computationally expensive preprocessing steps. A Monte Carlo simulation study and a case study on functionally graded materials demonstrate that SMAC achieves effective detection performance, particularly for subtle defects, while providing diagnostic capabilities to identify the source and location of anomalies.

As time-to-market is crucial in the Integrated Circuit (IC) industry, speeding up layout manufacturability verifi-cation is essential. Chemical-Mechanical Polishing (CMP) plays a vital role in IC fabrication but is significantly influenced by Layout-Dependent Effects (LDE). An accurate and efficient CMP model enables design teams to correct surface unevenness before fabrication, reducing costs and accelerating the design phase. However, existing models often rely on Density Step Height (DSH) modeling, which is time-consuming for calibration and requires substantial hardware resources for fine-grained predictions. In this paper, we propose combining the advantages of two surface analysis techniques, White Light Interfer-ometry (WLI) and Atomic Force Microscopy (AFM), to train a deep learning model. This model aims to predict full-chip post-CMP nanotopography with nanometer-scale accuracy. Our deep learning model is based on a Convolutional Neural Network (CNN) and follows a two-step pipeline. The model is trained on each technique separately, resulting in a detailed full-chip CMP model.

Foundation models, particularly large language models, are increasingly integrated into agent architectures for industrial tasks such as decision support, process monitoring, and engineering automation. Yet evidence on their purposes, capabilities, and limitations remains fragmented across domains. This work examines how mature foundation-model-based agent systems are in industrial contexts, how their functional profile differs from conventional agent systems, and which limitations persist. A systematic literature survey following the PRISMA 2020 guideline is presented, screening 2,341 publications and synthesising a corpus of 88 publications through a structured coding scheme. The results show that reported systems are predominantly at prototype and early validation stages (75.0% at TRL 4-6), with deployment-oriented evidence remaining rare (9.1%). Operational goals are most frequently positioned in user assistance, monitoring, and process optimisation, while conventional production-control purposes such as planning and scheduling are less prominent. Compared with an established baseline for industrial agent systems, the capability profile reveals substantial gains in human interaction (+37%) and dealing with uncertainty (+35%), but a pronounced deficit in negotiation (-39%). The most widely reported limitations concern lack of generalization, hallucination and output instability, data scarcity, and inference latency. A working definition of foundation-model-based industrial agents is also proposed, bridging conventional agent theory, automation-engineering standards, and the foundation-model paradigm.

Autonomous science is transforming how we discover materials and chemical systems for advanced energy technologies. However, many initially promising systems never reach deployment. This "valley of death" stems from optimization that prioritizes laboratory metrics over industrial viability. We propose a new strategy: "born-qualified" autonomous development, which embeds manufacturability, cost, and durability constraints from the outset. This approach is enabled by four pillars, including the development of multi-objective metrics, causal models, a modular infrastructure, and embedding manufacturing in the discovery loop. Realizing this vision will require sustained, community-wide commitment, but the potential return on that investment is commensurate with the scale of the challenge.

The recent emergence of planar transport systems necessitates re-evaluation of Flexible Manufacturing Systems (FMS) to address the simultaneous scheduling of internal logistics and production operations. By operating on a tile-based planar grid, these systems allow independent movers full two-dimensional freedom, mitigating inefficiencies inherent to traditional sequential lines. This paper applies a planar FMS framework to a real-world use case in the pharmaceutical industry: the automated production of personalized drugs. Implementing this system requires solving optimization problems at both tactical and operational levels. The tactical level involves decisions regarding production line layout and the positioning of drug dispensers. A Mixed-Integer Quadratic Programming model is utilized for the packing problem to exploit drug co-occurrence patterns found in historical patient data. Subsequently, we solve the placement problem - a bi-level problem combining an assignment problem with Shortest Hamiltonian paths with neighborhoods - to arrange dispensers in a layout minimizing expected travel distances. The operational level is encountered daily, scheduling individual movers to process new orders as quickly as possible. This scheduling problem is formulated using Constraint Programming, modeling movers as reservoir resources to ensure order completeness, complemented by a routing phase using an iterative conflict-resolution mechanism and DAG-based reasoning to convert schedules into conflict-free paths. Evaluation using real-world prescription data for 40 drugs shows the framework scales efficiently across several layout topologies for up to 500 orders, with schedules that are highly effective and computationally tractable for daily operations.

Human-machine interfaces in industrial automation need sensing modules that monitor operator actions and physiological state. This is important in factories, vehicles, machinery cabins, and human-robot collaboration, where workload, stress, fatigue, or reduced attention can affect safety. RGB monitoring is limited by low light, shadows, and privacy concerns, while thermal infrared imaging captures skin temperature dynamics without visible illumination. This paper studies thermal video as a contactless computer vision modality for estimating electrodermal activity (EDA), heart rate (HR), and breathing rate (BR), with the goal of supporting adaptive human-machine interfaces and operator-state awareness. We propose a signal-processing pipeline that tracks facial regions, aggregates thermal signals, and separates slow sudomotor trends from faster cardiorespiratory components. HR is estimated using orthogonal matrix image transformation (OMIT) across multiple facial regions, while BR is estimated from nasal and cheek thermal signals using spectral peak detection. We characterize 288 ROI-method configurations against contact references with lag-tolerant metrics using 31 sessions from the public SIMULATOR STUDY 1 (SIM1) driver monitoring dataset. The best fixed EDA configuration reaches a mean absolute correlation of $0.40 \pm 0.23$ against palm EDA, with individual sessions reaching $0.89$. BR estimation achieves $3.1 \pm 1.1$ bpm mean absolute error, while HR estimation yields $13.8 \pm 7.5$ bpm MAE, limited by the $7.5$ Hz thermal camera frame rate. The results show that thermal video provides useful respiratory and sudomotor cues, while revealing limitations caused by ROI selection, polarity changes, latency, and subject variability. These findings provide baseline design guidance for thermal computer vision as an auxiliary sensing layer in adaptive industrial HMI systems.