Application of Modeling and Simulation in a Self-Reprogrammable Prototype of a Manufacturing System

Shorter product life cycles and the growing demand for mass customization have led to the development of complex production systems, which are crucial for maintaining competitiveness. In this context, digital technologies and simulation tools play a fundamental role in integrating virtual and physical systems to enhance operational performance. This study presents a prototype for self-programming manufacturing systems, achieved through the integration of computer simulation and production management tools, leveraging the Digital Twin (DT) concept. To validate this approach, a prototype capable of interacting with a simulation model was developed. In the event of a failure that compromises product delivery conditions, the simulation model is activated to reprogram the production system’s operating parameters, ensuring compliance with initial production requirements and minimizing the impact of disruptions. The tests confirmed effective data exchange between the physical and virtual environments. Additionally, intentional failures were introduced in the real environment to assess system behavior. Each time a failure occurred, the simulation model generated new operating parameters, adjusting the working speed in the real environment and thereby maintaining the production system’s ability to meet its requirements. Consolidating the application of self-reprogramming.