implications for learning factories from industry 4.0 .../industry 4.0 - full.pdf · robot...

ESB Business School Reutlingen / Fraunhofer Austria Research / TU Vienna

Implications for Learning Factories from Industry 4.0Challenges for the human factor in future production scenarios

Andreas Jäger, MSc, MBAProf. Dr. Wilfried Sihn

Fraunhofer Austria Research GmbHVienna University of Technology

Fabian Ranz, MScProf. Dr. Vera Hummel

ESB Business School, Reutlingen University

2

Industry 4.0The human factor in cooperation with CPPS

Strategy?Revolution?

CurrentEvent?

Science Fiction?

Future?

Hype? Myth?

Industry 4.0CIM 2.0?

3



CurrentEvent?

Science Fiction?

Future?

Hype? Myth?

Industry 4.0?

CIM 2.0?

4



CurrentEvent?

Science Fiction?

Future?

Hype? Myth?

CIM 2.0? Industry 4.0?

Scenario 1 (autonomous automation): Technology guides Human

Scenario 2 (hybrid collaboration):Human guides Technology

5



CurrentEvent?

Science Fiction?

Future?

Hype? Myth?

Industry 4.0

Ability to improveLearning aptitude

Versatility

Creativity

Experience

Socialinteraction

Senses forperception

Intelligence

Scenario 1 (autonomous automation): Technology guides Human

Scenario 2 (hybrid collaboration):Human guides Technology

CIM 2.0?

6

Industry 4.0Challanges – Qualification and Education

Source: Survey by plattform-i40 (BITKOM, VDA, ZVEI) January 2013, Responses: 284 / Quote 9,2%

Standardization

Process and Work Organization

Available Products

New Business Models

Security / Know-How-Protection

Available Qualified Employees

Research

Qualification

Legal Framework

Number of namings

Required competenciesand skills?

Future job profiles?

7

Real ProductionReal Production

Industry 4.0Essential competence requirements

Digital ProductionDigital Production

Virtual ProductionVirtual Production

AutomationAutomation

Cyb

erSp

ace

Cyber-Physical-Production System

Design –Manufacturing Collaboration

Integrated Planning

Simulation

Process & Layout Planning

Ramp Up & ProductionExecution

Global Production & Supplier Collaboration

Utilization RecyclingSmar

t

Pro

duct

Phys

ical

Wor

ld

8






Cyb

erSp

ace


,Integrated Product andProcess Planning andDesign Competence


Integrated Planning

Simulation





t

Pro

duct

Phys

ical

Wor

ld

9






Cyb

erSp

ace

Phys

ical

Wor

ld


Creativity & MethodsCompetence for systematic

Idea & Innovation Mgmt.



Integrated Planning

Simulation




IdeaEngineering

Innovation Management


t

Pro

duct

10


Smart Devices


Smart Grid

RFID




Cyb

erSp

ace

Phys

ical

Wor

ld

Cyber-Physical-Production SystemInterface

Cloud Computing

Virtual RealityData Mining

Internet ofThings

Software Tools

Wearable Computers

Sensors & Actuators

Social Machines

Control CenterEmbedded

Systems

Systems and Interface Competence

Wireless NetworkAbility to improveLearning aptitude

Versatility

Creativity

Experience

Socialinteraction

Intelligence

Senses forperception





Integrated Planning

Simulation




IdeaEngineering

Innovation Management


t

Pro

duct

11

Manufacturing Engineer

Electronics Technican for Industrial Systems

Industrial Mechanic

Production Technician

System of Systems Engineer

Industry 4.0Job profiles (excerpt) for a cyber-physical working environment

Development & Testing

Technology

Processes

Real ProductionInformation & Communication Technology

Integration & Implementation

Configuration & Optimization

Integration & Implementation

Development & Testing

Mechanical Engineer

Automation Technician

Software Engineer

Cyber Physical Systems

Industrial EngineerInter-disciplinary

Electrical EngineerSpecialisation

Robotics Automation Equipment Engineering

Digital System Design KinematicsCybernetics

Digital Signal Processing

Embedded Systems

KineticsIndustrial Controllers Material ScienceIT

System-Design Electronics

Robot Programmer

InformaticsSpecialist

SPS Programmer

12

ESB Logistics-Learning-FactoryHolistic Approach from Product to Factory

Assembly and intralogistics systems, Jigs & Fixtures

Design & Realization

Assembly and intralogistics systems, Jigs & Fixtures

Design & Realization

System realization andramp-up

System realization andramp-up

ProcessDesign & Validation

ProcessDesign & Validation

Customization ofadaptable product

(high variance)

Customization ofadaptable product

(high variance)




,Integrated Product and Process Planning and Design

Competence

© redorbit

Education Training Research Industry Projects

13

2013New team &

suppliers

Spring 2014

Hardware installation

July 2014 First system

run

Oct 2014First trainings with

students

2015New building

Nov 2014First Industry 4.0

workshop forexternal

SS 2015System

expansion

Spring 2014

Software installation

2015Regular

operation

ESB Logistics-Learning-FactoryIntegrative tie-in of virtual factory and physical system

CAS / CAD / PDMCAS / CAD / PDM Order DataOrder Data

Production ProgramProduction Program

Configuration ofproduction systemConfiguration of

production systemProcess- and work station

designProcess- and work station

design

Manufacturing ExecutionManufacturing Execution

SimulationSimulationEngi

neer

ing

&

O

pera

tions

Cock

pit

Phys

ical

Syst

em

Le

arni

ng F

acto

ry

Quick Adaption to Turbulences

Exemplaryaspects ofIndustry 4.0

Transparency& Traceability

Smart, low-costsolutions forSME requirements

Customer requirements

Customer orders

14

ESB Logistics-Learning-FactoryIndustry 4.0– Flexible conveyor system

Unlimited layoutopportunities with minimized

changeover times

Touch-screen control andmonitoring

Plug-and-play for goods, power &

informationflow

Forerunner-Follower-Identification

Automatedtopologyfeedback

Autonomousrouting with no

dead-locks

Destination IP: 192.1…

Start IP: 192.0…

Systems andInterface

Competence

Integrated Product and Process Planning and Design

Competence

Pictures courtesy of:

15

……

ESB Logistics-Learning-FactoryIndustry 4.0– Flexible conveyor system Use Case

Initial order scenario(quantity, variants, dates)

Turbulences affecting thescenario

Realization of ideal plant layout

Result: adaptedproduction system

Flexible conveyor for changing logistical requirements

Systems and Interface Competence,Integrated

Product and Process Planning and Design

Competence

I Development of use applications for the industry

E Short-cyclical re-design of logistical systems, including planning as well as technical realization

R Automated planning of multimodal intralogisticssystems (e.g. with unsteady conveyor)

Aspe

cts

for

Educ

atio

n,

Res

earc

h an

dIn

dust

rySupply outageSupply outage

Demand changeDemand change

Technological changeTechnological change

Equipment defectEquipment defect

16

ESB Logistics-Learning-FactoryIndustry 4.0– Technical Assistance System

Technical assistance with collaborative robots

Intuitive teaching:Job enrichment

for operators

Situative integrationinto assembly, logistics, QC…

2D-Laser forauto-movement

Tactile sensors andcognitive

capabilities

Open-source ROS for creativesolutions &

innovation sharing

Conventional robots

Stationary use

Complex config

Fenced operation

Defined task

Fit for the future robots

Autonomous routing andnavigation within thesystem

High-level programming

Shoulder-to-Shouldercollaboration

Flexible deployment

Use Case ESB Logistics Learning Factory

Systems andInterface

Competence

Creativity & MethodsCompetence for

systematic Idea & Innovation Mgmt.

© Kawada Industries.© v-quadrat.

17

ESB Logistics-Learning-FactoryIndustry 4.0– Technical Assistance System Use Case

Technical assistance with collaborative robots

Work tasks(required abillity)

Task-specific teachingand deployment of the

assisting system

MTM-basedergonomic

workload analysisResult


I Cost-benefit evaluation of collaborative assisting systems andbest-practices of applicationAs

pect

sfo

rEd

ucat

ion,

R

esea

rch

and

Indu

stry

Situative assistance insteadof human substitution ->

standardized CWSM

Situative assistance insteadof human substitution ->

standardized CWSM

Technology follows theworker, not worker the

technology

Technology follows theworker, not worker the

technology

Demographic-change readyworkplaces

Demographic-change readyworkplaces

© Onexia, Inc.

[VDI2860] Assembly: Mating (e.g.. Screwing, Plugging,,

Gluing, Clipsing) Handling (e.g. Picking, Placing) Checking (e.g.. Measuring) Adjusting (e.g. Tuning) Support Ops (e.g. Cleaning)Functions of handling: Store Adjust quantity Move Check

Design and planning ofcollaborative

Works Systems

E Integral workplace optimization and expertise enhancement in the deployment of smart local automation solutions

R Development of „ability and attribute based" standardizedmodules for collaborative workings systems (CWSM)

18

TU Vienna Learning & Innovation Factory„i-PEP“ (integrative product emergence process)

Process Steps

From Idea to Product

19

TU Vienna Learning & Innovation Factory„i-PEP“ (integrative product emergence process)

2011Formation& initiation

2011 / 2012Development & installation

April 2012

Pilot Run

10th May 20122nd Conference on LF in Vienna

2012 / 2013Optimization oftraining concept

April 20132nd lecture

Lecture forcontentpreparation

Independent learning

Hands-on training

Teamwork

Presentationwith feedback

Teambuilding

Didactic Approach

2013 / 2014Integration of PM & creative tools

May 20143rd lecture

2014 - 2016Industry 4.0use cases

20

TU Wien Learning & Innovation FactoryProceeding

21


Funding of physical equipment anddigital infrastracture: Austrian Ministry for Science & Research 3 years, started in January 2014 300k€ for investments 170k€ inkind performance

22



PhD College: Ressources (Students) for

CPPS research Transfer of use cases into

the Learning Factory

23



PhD College: Ressources (Students) for

CPPS research Transfer of use cases into

the Learning Factory

Endowed Professorship: Focus: Production of the Future Supervison of I4.0 qualification and

development activities

24

TU Vienna Learning & Innovation FactoryExpansion of Manufacturing Technologies

External procurementNC -turning machine & milling machine

Initi

al s

ituat

ion

25



Laser cutting machine Laser welding system Bending machine Thermoforming machine

Initi

al s

ituat

ion

Targ

et s

ituat

ion

26


Preliminary, activity-based costing vs. post calculation with real time data

Make-or-buy decisionComparision of production costs from different manufacturing methods


Laser cutting machine Laser welding system Bending machine Thermoforming machine

Initi

al s

ituat

ion

Targ

et s

ituat

ion


27

TU Vienna Learning & Innovation FactoryInstallation of Software – Siemens Teamcenter

Red Bull Racing Team

Project Management

Digital Product Development

Real-time Engineering Collaboration

TU Vienna Slotcar Teams

Integrated Idea Capture and Management

Collaborative Data Management




28

Variant n

Variant B

Variant A

Evaluation

of

variants

TU Vienna Learning & Innovation FactoryIndustry 4.0 Use Case – Siemens Process Designer (Tecnomatix)

DesignProduction

of Jig

Assembly of Slotcar incl. Time Measurement



29

Variant n

Variant B

Variant A

TU Vienna Learning & Innovation FactoryIndustry 4.0 Use Case – Siemens Process Designer (Tecnomatix)

DesignProduction

of Jig

Evaluation

of variantsbeforeSOP

withMTM

(TiCon tool)

Simulation


Assembly of Slotcar

30

TU Vienna Learning & Innovation FactoryIndustry 4.0 Use Case


,Integrated Product and Process Planning and Design

Competence

from virtual to real

31

System

TU Vienna Learning & Innovation FactoryIndustry 4.0 Use Case

NC-Turning Machine

Slotcar Component: Wheel Rim

Transport Pallet with RFID Chip

Control Center

Transfer Station

Physical Automated and Digital / Virtual Production Cell

Mobile Device with App

Driverless Transport Systemwith integrated Roller Conveyor

Articulated Robot

Safty Eye

Systems and Interface CompetenceSimulation

32

Questions

Andreas Jäger, MSc, MBA

Fraunhofer Austria Research GmbHDivision Production and Logistics Management

Vienna University of TechnologyInstitute of Management ScienceDivision for Industrial and Systems Engineering

Theresianumgasse 27 | A-1040 Vienna | AustriaMobil: +43 676 888 616 [email protected]

Fabian Ranz, MSc

ESB Business School Hochschule ReutlingenLogistics Network Planning and Design

Alteburgstraße 150 | 72762 Reutlingen | GermanyTel.: +49(0)7121 271 [email protected]

Thank you!

33

Industry 4.0Change of qualification requirements

Elimination ofmanual and tedious work

Elimination ofmanual and tedious work

Increased technicalrequirements

Increased technicalrequirements

Systems overview knowledgeis required

Systems overview knowledgeis required

Enrichment of tasksEnrichment of tasks

Shop Floor Planners

Design of rules fordecision making

Design of rules fordecision making

Working in an „ArtificialIntelligence Environment“Working in an „ArtificialIntelligence Environment“

De‐skillingDe‐skilling

Digitalization and virtualizationof real objects

Digitalization and virtualizationof real objects

Gain of information andcommunication flow

Gain of information andcommunication flow

Increased mental work via learning by doing

Increased mental work via learning by doing

Technology asassistance systemTechnology as

assistance system

CPPSCPPS

Increased spectrum ofresponsibilities

Increased spectrum ofresponsibilities

Participation in planning andconfiguring tasks

Participation in planning andconfiguring tasks

Know How, Decision‐making competence, Problem‐solving competence

Lack of process knowledgeLack of process knowledge

Restricted by technicalpredefined decisionsRestricted by technicalpredefined decisions

34

Applied Research / Mobility ProjectNetwork of Innovative Learning Factories (NIL)

Activities related to Learning Factories:

Standardization of the „System Learning-Factory“, including jointdevelopment of learning modules on Industry 4.0

Intensification of academic exchangebetween the involved institutes on thelevel of researchers and students, including a summer school on Learning Factories(start: summer 2015)

Dissemination of related researchresults in a series of papers on Learning Factories(start: Summer 2014)

Members

Sponsors

35

Applied Research ProjectLOPEC

Human specific addressed aspects ofIndustry 4.0:

Initiating of lifelong-learning througha blended learning approach-> self studying via an LMS-> hands-on training in the LF

Fostering work-life balance by self-assessment of personal, professional and business objectives

Sensitizing of demographic changeon shop floor level with the initiationof knowledge transfer betweendifferent age groups

Learning Mgmt. System

Fraunhofer Austria Lean Assembly

Self-Assessment Tool

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