Design and Simulation of an Automated Production Plant and Warehouse Management System

This paper illustrates the implementation of a practical model that can simulate one of the applications in modern industries while also displaying the results remotely. Moreover, three steps of the automation pyramid have been achieved, starting from the field level and ending with the supervisory level (SCADA), which allows us to catch up with the fourth industrial revolution that is trending. The article can be summarized into three sections. The first one is about building a virtual automated warehouse system that utilizes a conveyor and a PLC to control the production line. The simulation of these processes has been implemented via the Factory I/O platform. It is subdivided into four subcategories: color-based sorting, material-based sorting, box size-based sorting, and packaging optimization. The Human-Machine Interface (HMI) design is also discussed, which optimizes stock requests. The second aspect of this paper focuses on practical work, specifically sorting by size. It also explores the use of pneumatic cylinders in separating boxes based on different dimensions. These cylinders are actuated through solenoid valves, which receive instructions from sensors and transmit signals to the PLC for efficient control. Finally, the Internet of Things (IoT) has a share in this project, which allows remote monitoring of the production line to increase safety and efficiency.