Citation: Vavrík, V.; Fusko, M.;
Buˇcková, M.; Gašo, M.; Furmannová,
B.; Štaffenová, K. Designing of
Machine Backups in Reconfigurable
Manufacturing Systems. Appl. Sci.
2022, 12, 2338. https://doi.org/
10.3390/app12052338
Academic Editor: Antonella Petrillo
Received: 1 February 2022
Accepted: 22 February 2022
Published: 23 February 2022
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Article
Designing of Machine Backups in Reconfigurable
Manufacturing Systems
Vladimír Vavrík , Miroslav Fusko * , Monika Buˇcková , Martin Gašo , Beáta Furmannová
and Katarína Štaffenová
Department of Industrial Engineering, University of Žilina, 010 26 Zilina, Slovakia;
vladimir.vavrik@fstroj.uniza.sk (V.V.); monika.buckova@fstroj.uniza.sk (M.B.); martin.gaso@fstroj.uniza.sk (M.G.);
beata.furmannova@fstroj.uniza.sk (B.F.); katarina.staffenova@fstroj.uniza.sk (K.Š.)
* Correspondence: miroslav.fusko@fstroj.uniza.sk
Abstract:
The article presents the results of machine backup designing in reconfigurable industrial
processes. The development of manufacturing systems is moving towards intelligent, automated,
autonomous, and reconfigurable manufacturing systems. Factories that want to ensure long-term
sustainable and competitive manufacturing processes must be designing their processes to respond
flexibly to changing changes in customer requirements. The article’s introduction characterizes
concepts such as cold backup and warm backup machines and indicators relationship as the time
between faults and repairs. The materials and methods describes prerequisites as the creation of the
product family creation and resource availability with many formulas, simulation models, and its
verification for the creation of the family products in the results of this article. The results describes
the results from the calculations of the backups and family products of their use in reconfigurable
manufacturing systems. The developed methodology for line design uses the principles of recon-
figuration in designing configurations regarding advanced approaches in factories. A significant
milestone will be the rapid integration of disruptive technologies and approaches into manufacturing
systems. The complexity of future manufacturing systems in the Factories of the Future will only be
possible with new innovative factory technologies using the digital twin.
Keywords:
machine backups; reconfigurability; modular manufacturing lines; competent islands;
Factories of the Future; simulation; advanced industrial engineering
1. Introduction
The European Union has defined sustainable manufacturing as its primary strategic
goal for the coming years. This manufacturing must create products with high added value
for the customer. Forecasters have identified digitization and digital technologies as the
main drivers of productivity growth and competitiveness at the beginning of the 21st cen-
tury. Future needs in industrial technologies result from customers’ changing requirements,
needs, and possibilities. New generations of manufacturing systems correspond to this.
The condition for success is the rapid, practical use of technological research results, i.e.,
the commercialization of technologies [
1
]. The closure of the cycle will support this: basic
research—applied research—development—prototype—product—profit from sales—new
investment in research.
The latest developments in industrial technology are referred to as key enabling
technologies (KETs). These technologies are knowledge-intensive and capital-intensive,
combined with cutting-edge research and development. KETs are the driving force behind
rapid innovation cycles, require highly qualified researchers and experts, are multidisci-
plinary and trans-sectoral, condition and enable product, process, and service innovation.
These technologies form the core of innovation in the most advanced products. Factories of
the Future (FoF) must have adjustability properties, i.e., reconfigurability. Future businesses
must have reconfigurability features [2,3].
Appl. Sci. 2022, 12, 2338. https://doi.org/10.3390/app12052338 https://www.mdpi.com/journal/applsci
