Utilização da simulação no contexto da Learning Factory: aplicação inserida na fase 1 do gêmeo digital

Abstract

Industry 4.0 has driven profound transformations in production models, standing out for the use of enabling technologies such as simulation and digital twins. In this context, the objective of this dissertation was to develop a computational model representing the manufacturing flow of a product in a Learning Factory, using simulation as Phase I of the Digital Twin. The study is justified by the growing demand for industrial digitalization and by the lack of practical cases of implementation of technologies such as Digital Twins, especially in low-automation environments. Thus, the research proposes the use of simulation as an initial stage for the development of digital twins in Learning Factories, contributing to local innovation and to applied studies in the field. Methodologically, the study adopted an applied and explanatory approach, with a quantitative basis and technical procedures involving case study and action research. Discrete-event simulation was employed using the FlexSim® software, version 24.2.1. The model development followed DMAIC methodology (Define, Measure, Analyze, Improve, and Control), integrating Industry 4.0 concepts and emerging digital technologies. The simulated environment was a 60 m² Learning Factory with 19 workstations and capacity for 17 operators, arranged in a serial production layout. The results obtained from the simulation made it possible to validate the proposed Learning Factory layout and to perform productivity analyses based on simulated data, providing support for optimizing production flows without interventions in the real environment. The computational model proved viable for testing different improvement scenarios, anticipating bottlenecks, and facilitating the planning of physical and operational changes. Computational simulation is an efficient tool for the development of digital models of production environments, playing a strategic role in the first phase of Digital Twin implementation. The study highlights the importance of Learning Factories as innovation laboratories and demonstrates the applicability of simulation for process optimization and support for industrial digitalization, contributing to the advancement of Industry 4.0 in the national context.