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Different network architectures are being used to build remote laboratories. Historically, it has been difficult to integrate industrial control systems with higher level IT systems like enterprise resource planning (ERP), manufacturing execution systems (MES), and manufacturing operations management (MOM). Getting these systems to communicate with one another has proven to be relatively difficult due to the absence of shared protocols between them. The Open Platform Communications United Architecture (OPC-UA) protocol was introduced as a remedy for this issue and is gaining popularity, but what if open-source protocols that are widely used in the IT industry could be used instead? This paper presents the development of an IT-Architecture for a cyber-physical industrial control systems laboratory that enables a seamless interconnection and integration of its elements. The architecture utilises Node-Red technology. Node-RED is an open-source programming platform developed by IBM that is focused on making it simple to link physical components, APIs, and web services. This cyber-physical laboratory is for learning principles of an industrial cascaded process control factory. Finally, this text will also discuss future work relating to digital twin (DT). A coupled tank system is selected as a teaching factory to illustrate a range of fluid control application in a typical chemical process factory.
The fifth generation of mobile communication (5G) is a wireless technology developed to provide reliable, fast data transmission for industrial applications, such as autonomous mobile robots and connect cyber-physical systems using Internet of Things (IoT) sensors. In this context, private 5G networks enable the full performance of industrial applications built on dedicated 5G infrastructures. However, emerging wireless communication technologies such as 5G are a complex and challenging topic for training in learning factories, often lacking physical or visual interaction. Therefore, this paper aims to develop a real-time performance monitoring system of private 5G networks and different industrial 5G devices to visualise the performance and impact factors influencing 5G for students and future connectivity experts. Additionally, this paper presents the first long-term measurements of private 5G networks and shows the performance gap between the actual and targeted performance of private 5G networks.
Since its first publication in 2015, the learning factory morphology has been frequently used to design new learning factories and to classify existing ones. The structuring supports the concretization of ideas and promotes exchange between stakeholders.
However, since the implementation of the first learning factories, the learning factory concept has constantly evolved.
Therefore, in the Working Group "Learning Factory Design" of the International Association of Learning Factories, the existing morphology has been revised and extended based on an analysis of the trends observed in the evolution of learning factory concepts. On the one hand, new design elements were complemented to the previous seven design dimensions, and on the other hand, new design dimensions were added. The revised version of the morphology thus provides even more targeted support in the design of new learning factories in the future.
The increase in product variance and shorter product lifecycles result in higher production ramp-up frequencies and promote the usage of mixed-model lines. The ramp-up is considered a critical step in the product life cycle and in the automotive industry phases of the ramp-up are often executed on separated production lines (pilot lines) or factories (pilot plants) to verify processes and to qualify employees without affecting the production of other products in the mixed-model line. The required financial funds for planning and maintaining dedicated pilot lines prevent small and medium-sized enterprises (SMEs) from the application. Hence, SMEs require different tools for piloting and training during the production ramp-up. Learning islands on which employees can be trained through induced and autonomous learning propose a solution. In this work, a concept for the development and application which contains the required organization, activities, and materials is developed through expert interviews. The results of a case study application with a medium-sized automotive manufacturer show that learning islands are a viable tool for employee qualification and process verification during the ramp-up of mixed-model lines.
Development of an IoT-based inventory management solution and training module using smart bins
(2023)
Flexibility, transparency and changeability of warehouse environments are playing an increasingly important role to achieve a cost-efficient production of small batch sizes. This results in increasing requirements for warehouses in terms of flexibility, scalability, reconfigurability and transparency of material and information flows to deal with large number of different components and variable material and information flows due to small batch sizes. Therefore, an IoT-based inventory management solution and training module has been developed, implemented and validated at Werk150 – the Factory on campus of the ESB Business School. Key elements of the developed solution are smart bins using weight mats to track the bin’s content and additional sensors and buttons which are connected to an IoT – Hub to collect data of material consumption and manual handling operations. The use of weight mats for the smart bins offers the possibility to measure the container content independent of the specific component geometry and thus for a variety of components based on the specific component weights. The developed solution enables focusing on key for success elements of the system to provide synchronization of the flow of materials and information resulting an increase of flexibility and significantly higher transparency of the material flow. AIbased algorithms are applied to analyse the gathered data and to initiate process optimizations by providing the logistics decision makers a profound and transparent basis for decision making. In order to provide students and industry visitors of the learning factory with the necessary competences and to support the transfer into practice, a training module on IoT-based inventory management was developed and implemented.
Circular economy aims to support reuse and extends the product life cycles through repair, remanufacturing, upgrades and retrofits, as well as closing material cycles through recycling. To successfully manage the necessary transformation processes to circular economy, manufacturing enterprises rely on the competency of their employees. The definition of competency requirements for circular economy-oriented production networks will contribute to the operationalization of circular economy. The International Association of Learning Factories (IALF) statesin its mission the development of learning systems addressing these challenges for training of students and further education of industry employees. To identify the required competencies for circular economy, the major changes of the product life cycle phases have been investigated based on the state of the science and compared to the socio-technical infrastructure and thematic fields of the learning factories considered in this paper. To operationalize the circular economy approach in the product design and production phase in learning factories, an approach for a cross learning factory network (so called "Cross Learning Factory Product Production System (CLFPPS)") has been developed. The proposed CLFPPS represents a network on the design dimensions of learning factories. This approach contributes to the promotion of circular economy in learning factories as it makes use of and combines the focus areas of different learning factories. This enables the CLFPPS to offer a holistic view on the product life cycle in production networks.
The world is becoming increasingly digital. People have become used to learning and interacting with the world around them through technology, accelerated even further by the Covid-19 pandemic. This is especially relevant to the generation currently entering education systems and the workforce. Considering digital aids and methods of learning are important for future learning. The increasing online learning needs open the case for integrating digital learning aspects such as serious gaming within education and training systems. Learning factories fall amongst the education and training systems that can benefit from integration with digital learning extensions. Digital capabilities such as digital twins and models further enable the exploration of integrating digital serious games as an extension of learning factories. Since learning factories are meant for a range of different learning, training, and research purposes, such serious games need to be adaptable across stakeholder perspectives to maximize the value gained from the time and cost invested into such design and development. Research into the development of adaptive serious games for multiple stakeholder perspectives must first determine whether such development can be developed that reaches the objectives set for different included stakeholder perspectives. The purpose of this research is to investigate this at the hand of the practical development of a digital adaptive serious game for stakeholder perspectives.
Product engineering and subsequent phases of product lifecycles are predominantly managed in isolation. Companies therefore do not fully exploit potentials through using data from smart factories and product usage. The novel intelligent and integrated Product Lifecycle Management (i²PLM) describes an approach that uses these data for product engineering. This paper describes the i²PLM, shows the cause-and-effect relationships in this context and presents in detail the validation of the approach. The i²PLM is applied and validated on a smart product in an industrial research environment. Here, the subsequent generation of a smart lunchbox is developed based on production and sensor data. The results of the validation give indications for further improvements of the i²PLM. This paper describes how to integrate the i²PLM into a learning factory.
Digital twins deployed in production are important in practice and interesting for research. Currently, mostly structured data coming from e.g., sensors and timestamps of related stations, are integrated into Digital Twins. However, semi- and unstructured data are also important to display the current status of a digital twin (e.g., of a machinery or produced good). Process Mining and Text Mining in combination can be used to support the use of log file data to understand the current state of the process as well as highlight issues. Therefore, issue related reactions can be taken more quickly, targeted and cost oriented. Applying a design science research approach; here a prototype as an artefact based on derived requirements is developed. This prototype helps to understand and to clarify the possibilities of Process Mining and Text Mining based on log data for production related Digital Twins. Contributions for practice and research are described. Furthermore, limitations of the research and future opportunities are pointed out.
Industrial practice is characterized by random events, also referred to as internal and external turbulences, which disturb the target-oriented planning and execution of production and logistics processes. Methods of probabilistic forecasting, in contrast to single value predictions, allow an estimation of the probability of various future outcomes of a random variable in the form of a probability density function instead of predicting the probability of a specific single outcome. Probabilistic forecasting methods, which are embedded into the analytics process to gain insights for the future based on historical data, therefore offer great potential for incorporating uncertainty into planning and control in industrial environments. In order to familiarize students with these potentials, a training module on the application of probabilistic forecasting methods in production and intralogistics was developed in the learning factory 'Werk150' of the ESB Business School (Reutlingen University). The theoretical introduction to the topic of analytics, probabilistic forecasting methods and the transition to the application domain of intralogistics is done based on examples from other disciplines such as weather forecasting and energy consumption forecasting. In addition, data sets of the learning factory are used to familiarize the students with the steps of the analytics process in a practice-oriented manner. After this, the students are given the task of identifying the influencing factors and required information to capture intralogistics turbulences based on defined turbulence scenarios (e.g. failure of a logistical resource) in the learning factory. Within practical production scenario runs, the students apply probabilistic forecasting using and comparing different probabilistic forecasting methods. The graduate training module allows the students to experience the potentials of using probabilistic forecasting methods to improve production and intralogistics processes in context with turbulences and to build up corresponding professional and methodological competencies.
Especially, if the potential of technical and organizational measures for ergonomic workplace design is limited, exoskeletons can be considered as innovative ergonomic aids to reduce the physical workload of workers. Recent scientific findings from ergonomic analyses with and without exoskeletons are indicating that strain reduction can be achieved, particularly at workplaces with lifting, holding, and carrying processes. Currently, a work system design method is under development incorporating criteria and characteristics for the design of work systems in which a human worker is supported by an exoskeleton. Based on the properties of common passive and active exoskeletons, factors influencing the human on which an exoskeleton can have a positive or negative effect (e.g. additional weight) were derived. The method will be validated by the conceptualization and setup of several work system demonstrators at Werk150, the factory of ESB Business School on campus of Reutlingen University, to prove the positive ergonomic effect on humans and the supporting process to choose the suitable exoskeleton. The developed method and demonstrators enable the user to experience the positive ergonomic effects of exoskeletal support in lifting, holding and carrying processes in logistics and production. The new work system design method will contribute to the fact that employees can pursue their professional activity longer without substantial injuries or can be used more flexibly at different work stations. Also new work concepts, strategies and scenarios are opened up to reduce the risk of occupational accidents and to promote the compatibility of work for employees. A training module is being developed and evaluated with participants from industry and master students to build up competence.
The early involvement of experiences gained through intelligence and data analysis is becoming increasingly important in order to develop new products, leading to a completely different conception of product creation, development and engineering processes using the advantages that the dedication of the digital twin entails. Introducing a novel stage gate process in order to be holistically anchored in learning factories adopting idea generation and idea screening in an early stage, beta testing of first prototypes, technical implementation in real production scenarios, business analysis, market evaluation, pricing, service models as well as innovative social media portals. Corresponding product modelling in the sense of sustainability, circular economy, and data analytics forecasts the product on the market both before and after market launch with the interlinking of data interpretation nearby in real-time. The digital twin represents the link between the digital model and the digital shadow. Additionally, the connection of the digital twin with the product provides constantly updated operating status and process data as well as mapping of technical properties and real-world behaviours. A future-networking product, by embedded information technology with the ability to initiate and carry out one's own further development, is able to interact with people and environments and thus is relevant to the way of life of future generations. In today's development work for this new product creation approach, on one hand, "Werk150" is the object of the development itself and on the other hand the validation environment. In the next step, new learning modules and scenarios for trainings at master level will be derived from these findings.
Blockchain is a technology for the secure processing and verification of data transactions based on a distributed peer-to-peer network that uses cryptographic processes, consensus algorithms, and backward-linked blocks to make transactions virtually immutable. Within supply chain management, blockchain technology offer potentials in increasing supply chain transparency, visibility, automation, and efficiency. However, its complexity requires future employees to have comprehensive knowledge regarding the functionality of blockchain-based applications in order to be able to apply their benefits to scenarios in supply chain and production. Learning factories represent a suitable environment allowing learners to experience new technologies and to apply them to virtual and physical processes throughout value chains. This paper presents a concept to practically transfer knowledge about the technical functionality of blockchain technology to future engineers and software developers working within supply chains and production operations to sensitize them regarding the advantages of decentralized applications. First, the concept proposes methods to playfully convey immutable backward-linked blocks and the embedment of blockchain smart contracts. Subsequently, the students use this knowledge to develop blockchain-based application scenarios by means of an exemplary product in a learning factory environment. Finally, the developed solutions are implemented with the help of a prototypical decentralized application, which enables a holistic mapping of supply chain events.
Today's logistics systems are characterized by uncertainty and constantly changing requirements. Rising demand for customized products, short product life cycles and a large number of variants increases the complexity of these systems enormously. In particular, intralogistics material flow systems must be able to adapt to changing conditions at short notice, with little effort and at low cost. To fulfil these requirements, the material flow system needs to be flexible in three important parameters, namely layout, throughput and product. While the scope of the flexibility parameters is described in literature, the respective effects on an intralogistics material flow system and the influencing factors are mostly unknown. This paper describes how flexibility parameters of an intralogistics system can be determined using a multi-method simulation. The study was conducted in the learning factory “Werk150” on the campus of Reutlingen University with its different means of transport and processes and validated in terms of practical experiments.
The production environment experiences copious challenges, but likewise discovers many new potential opportunities. To meet the new requirements, caused by the developments towards mass-customization, human-robot-cooperation (HRC) was identified as a key piece of technology and is becoming more and more important. HRC combines the strengths of robots, such as reliability, endurance and repeatability, with the strengths of humans, for instance flexibility and decision-making skills. Notwithstanding the high potential of HRC applications, the technology has not achieved a breakthrough in production so far. Studies have shown that one of the biggest obstacles for implementing HRC is the allocation of tasks. Another key technology that offers various opportunities to improve the production environment is Artificial Intelligence (AI). Therefore, this paper describes an AI supported method to improve the work organization in HRC in regards to the task-allocation. The aim of this method is to build a dynamic, semi-autonomous group work environment which keeps not just employee motivation at a high level, but also the product quality due to a decreased failure rate. The AI helps to detect the perfect condition in which the employee delivers the best performance and also supports at identifying the time when the worker leaves this optimal state. As soon as the employee reaches this trigger event, the allocation of the tasks adapts based on the identified stress. This adaptation aims to return the employee to the state of the optimal performance. In order to realize such a dynamic allocation, this method describes the creation of a pool with various interaction scenarios, as well as the AI supported recognition of the defined trigger event.
Manufacturing companies are confronted with external (e.g. short-term change of product configuration by the customer) and internal (e.g. production process deviations) turbulences which are affecting the performance of production. Predefined, centrally controlled logistics processes are limiting the possibilities of production to initiate countermeasures to react in an optimized way to these turbulences. The autonomous control of intralogistics offers a great potential to cope with these turbulences by using the respective flexibility corridors of production systems and applying intelligent logistic objects with decentralized decision and process execution capabilities to maintain a target-optimized production. A method for AI-based storage-location- and material-handling-optimization to achieve performance-optimized intralogistics system through continuous monitoring of performance-relevant parameters and influencing factors by using AI (e.g. for pattern recognition) has been developed. To provide the basis to investigate and demonstrate the potentials of autonomously controlled intralogistics in connection with turbulences of production and in combination with AI, an intelligent warehouse involving an indoor localization system, smart bins, manual, semi-automated/collaborative and autonomous transport systems has been developed and implemented at Werk150, the factory on campus of ESB Business School (Reutlingen University). This scenario, which has been integrated into graduate training modules, allows the analysis and demonstration of different measures of intralogistics to cope with turbulences in production involving amongst others storage and material provision processes. The target fulfilment of the applied intralogistics measures to master arising turbulences is assessed based on the overall performance of production considering lead times and adherence to delivery dates. By applying artificial intelligence (AI) algorithms the intelligent logistical objects (smart bin, transport systems, etc.) as well as the entire logistics system should be enabled to improve their decision and process execution capabilities to master short-term turbulences in the production system autonomously.
Teaching at assembly workstations in production in SMEs (small and medium sized companies) often does not take place at all or only insufficiently. In addition to the lack of technical content, there are also aggravatingly incorrect movement sequences from an ergonomic point of view, which "untrained" people usually automatically acquire. An AI based approach is used to analyze a definite workflow for a specific assembly scope regarding the behavior of several employees. Based on these different behaviors, the AI gives feedback at which points in time, work steps and movement’s particularly dangerous incorrect postures occur. Motion capturing and digital human model simulation in combination with the results of the AI define the optimized workflow. Individual employees can be trained directly due to the fact that AI identifies their most serious incorrect postures and provide them with a direct analogy of their “wrong” posture and “easy on the joints posture”. With the assistance of various test persons, the AI can conduct a study in which the most frequently occurring incorrect postures can be identified. This could be realized in general or tailored to specific groups of people (e.g. "People over 1.90m tall must be particularly careful not to make the following mistake...). The approach will be tested and validated at the Werk150, the factory of the ESB Business School, on the campus of the Reutlingen University. The new gained knowledge will be used subsequently for training in SMEs.
Learning factories on demand
(2021)
Learning Factories are research and learning environments that demonstrate new concepts and technologies for the industry in a practical environment. The interaction between physical and virtual components is a central aspect. The mediation and presentation usually occur directly in the learning factory and are thus limited in time and concerning the user group. A learning factory- on-demand- can be provided by dividing and virtualizing the individual components via containers and microservices. This enables both local operation and operation hybrid cloud or cloud systems. Physical components can be mapped either through standardized interfaces or suitable emulators. Using the example of the Learning Factory at Reutlingen University (Werk150), it will be shown how different use cases can be made available utilizing software-based orchestration, thus promoting broader and more independent teaching.