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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.
Development of an indoor positioning system to create a digital shadow of production plant layouts
(2023)
The objective of this dissertation is to develop an indoor positioning system that allows the creation of a digital shadow of the plant layout in order to continuously represent the actual state of the physical layout in the virtual space. In order to define the requirements for such a system, potential stakeholders who could benefit from a digital shadow in the context of the plant layout were analysed. In order to generate added value for their work, the requirements were derived from their perspective. As the core of an indoor positioning system is the sensory aspect to capture the physical layout parameters, different potential technologies were compared and evaluated in terms of their suitability for this particular application. Derived from this analysis, the selected concept is based on the use of a pan-tilt-zoom (PTZ) camera in combination with fiducial markers. In order to determine specific camera parameters, a series of experiments were conducted which were necessary to develop the measurement method as well as the mathematical calculation method and coordinate transformation for the determination of poses (positions and angular orientations) of the respective facilities in the plant. In addition, an experimental validation was performed to ensure that the limit values for individual parameters determined in the requirements analysis can be met.
Development of an expert system to overpass citizens technological barriers on smart home and living
(2023)
Adopting new technologies can be overwhelming, even for people with experience in the field. For the general public, learning about new implementations, releases, brands, and enhancements can cause them to lose interest. There is a clear need to create point sources and platforms that provide helpful information about the novel and smart technologies, assisting users, technicians, and providers with products and technologies. The purpose of these platforms is twofold, as they can gather and share information on interests common to manufacturers and vendors. This paper presents the ”Finde-Dein-SmartHome” tool. Developed in association with the Smart Home & Living competence center [5] to help users learn about, understand, and purchase available technologies that meet their home automation needs. This tool aims to lower the usability barrier and guide potential customers to clear their doubts about privacy and pricing. Communities can use the information provided by this tool to identify market trends that could eventually lower costs for providers and incentivize access to innovative home technologies and devices supporting long-term care.
Process risks are omnipresent in the corporate world and repeatedly present organizations with the challenge of how to deal with these risks. Efforts in trying to analyze and prevent these risks are costly and require many resources, which do not always bring the desired added value. The goal of this work is to determine how a benefit-oriented resource allocation can be made for risk-oriented process management. For this purpose, the following research question is posed: "How can systematic prioritization decisions regarding risk-oriented process management be made?” To answer it, an evaluation procedure is developed which assesses processes based on their characteristics regarding potential risk disposition as well as entrepreneurial relevance. For this purpose, requirements for such a procedure are first collected and used to define selection criteria for it. After the detailed analysis of known selection and evaluation procedures, one of them is selected and used for further development. Next steps include the definition of relevant criteria for the evaluation of the processes by examining process characteristics regarding their suitability for process evaluation. The focus here lies on characteristics that provide indications of the risk disposition and business relevance of processes. The result of this approach is a scoring model with a criteria catalog consisting of 15 criteria according to which a process is evaluated. The evaluation result is presented both numerically and in a matrix. This enables the comparison of several processes and a derived prioritization of those for a more in-depth risk analysis. The application of this approach will ensure a benefit-oriented allocation of resources in the management of process risks and increased process reliability.
Development of an easy teaching and simulation solution for an autonomous mobile robot system
(2019)
With mass customized production becoming the mainstream, industries are shifting from large-scale manufacturing to flexible and customized production of small batch sizes. Agile manufacturing strategies adopted by SMEs are driving the usage of collaborative robots in today's factories. Major challenges in the adoption of cobots in the industry are the lack of a highly trained workforce to program the robot to perform complex tasks and integration of robot systems to other smart devices in the factory. In addition, the teaching and simulation by non-robotics experts of many industrial collaborative robot systems like the KUKA LBR iiwa is a major challenge, since these systems are designed to be programmed by robot experts and not by shop floor workers or other non-experts. This paper describes the research and development activities done for reducing the barriers in operation and ensure holistic integration of LBR iiwa cobot in the assembly on the example of the ESB Logistics Learning Factory. These include a visual programming solution for the easy teaching of various tasks. Robotic tasts are classified based on common robotics applications and application-specific blocks abstracting specific actions are implemented. A factory worker with no programming competency cour create robot programs by combining these blocks using a Graphical User Interface. In addition, a simulation solution was developed to visualized, analyse, and optimize robotic workflow before deployment. an autonomous mobile robot is integrated with the LBR iiw to improve reconfigurability and thus also the productivity. The system as a whole is controlled using an event-driven distributed control system. Finally, the capabilities of the system are analysed based on the design principles of Industrie 4.0 and potential future research ideas are discussed to further improve the system.
The process for the production of customized bras is really challenging. Although the need is very clear, the lingerie industry is currently facing a lack of data, knowledge and expertise for the realization of an automated process chain. Different studies and surveys have shown, that the majority of women wear the incorrect bra size. In addition to aesthetic problems, health risks such as headaches, back problems or digestive problems of the wearers can result from this. An important prerequisite for improvements is the basic knowledge about the female breast, both in terms of body measurements and different breast shapes. The current size systematic for bras only defines a bra size by the relation between bust girth and underbust girth and standardized cup forms do not justice to the high variability of the human body. As the bra type shapes the female breast, basic knowledge about the relation of measurements and shapes from the clothed and the unclothed breast is missing.
In the present project, studies are conducted to explore the female breast and to derive new breast-specific body measurements, different breast shapes and deformation knowledge using existing bras.
Furthermore, an innovative process is being developed that leads from 3D scanning to individual and interactive pattern construction, which allows an automatic pattern creation based on individual body measurements and the influence of different material parameters.
In the course of the presentation, the current project status will be shown and the future developments and project steps will be introduced.
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.
Recent advances in artificial intelligence have enabled promising applications in neurosurgery that can enhance patient outcomes and minimize risks. This paper presents a novel system that utilizes AI to aid neurosurgeons in precisely identifying and localizing brain tumors. The system was trained on a dataset of brain MRI scans and utilized deep learning algorithms for segmentation and classification. Evaluation of the system on a separate set of brain MRI scans demonstrated an average Dice similarity coefficient of 0.87. The system was also evaluated through a user experience test involving the Department of Neurosurgery at the University Hospital Ulm, with results showing significant improvements in accuracy, efficiency, and reduced cognitive load and stress levels. Additionally, the system has demonstrated adaptability to various surgical scenarios and provides personalized guidance to users. These findings indicate the potential for AI to enhance the quality of neurosurgical interventions and improve patient outcomes. Future work will explore integrating this system with robotic surgical tools for minimally invasive surgeries.
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.
Due to constantly changing conditions, demand, and technologies, companies increasingly seek flexibility. Productivity results from automation, improved working conditions and the focus of people in production in interaction with machines. Unfortunately, the human factor is often not considered to increase flexibility and productivity with new concepts. This work aims to develop a hybrid assistance system that allows a dynamic configuration of cyber-physical production systems considering the current order situation and available resources utilizing simulation. The system also considers human factors in addition to economic factors, which contributes to the extended economic appraisal.
The increasing urban population growth leads to challenges in cities in many aspects: Urbanisation problems such as excessive environmental pollution or increasing urban traffic demand new and innovative solutions. In this context, the concept of smart cities is discussed. An enabling element of the smart city concept is applying information technology (IT) to improve administrative efficiency and quality of life while reducing costs and resource consumption and ensuring greater citizen participation in administrative and urban development issues. While these smart city services are technologically studied and implemented, government officials, citizens or businesses are often unaware of the large variety of smart city service solutions. Therefore, this work deals with developing a smart city services catalogue that documents best practice services to create a platform that brings citizens, city government, and businesses together. Although the concept of IT service catalogues is not new and guidelines and recommendations for the design and development of service catalogues already exist in the corporate context, there is little work on smart city service catalogues. Therefore, approaches from agile software development and pattern research were adapted to develop the smart city service catalogue platform in this work.
The Circular Economy aims to reintroduce the value of products back into the economic cycle at the same value chain level. While the activities of the Circular Economy are already well-defined, there exists a gap in how returned products are treated by the industry. This study aims to examine how a process should be designed to handle returned products in the context of the Circular Economy. To achieve this, a machine learning-based algorithm is used to classify data and extract relevant information throughout the product life cycle. The focus of this research is limited to land transportation systems within the Sharing Economy sector.
Endogenous electrical fields play an important role in various physiological and pathological events. Yet the effects of electrical cues on processes such as wound healing, tumor development or metastasis are still rarely investigated, though it is known that direct current electrical fields can alter cell migration or proliferation in vitro. Several 2D experimental models for studying cell responses to direct current electrical fields have been presented and characterized but suitable experimental models for electrotaxis studies in 3D are rare. Here we present a novel, easy-to-produce, multi-well-based galvanotactic-chamber for the use in 2D and 3D cell experiments for investigations on the influence of electrical fields on tumor cell migration and tumor spheroid growth. Our presented system allows the simultaneous application of electrical field to cells in four chambers, either cultured on the bottom of the culture-plate (2D) or embedded in hydrogel filled channels(3D). The set-up is also suitable for, live-cell-imaging. Validation tests show stable electrical fields and high cell viabilities inside the channel. Tumor spheroids of various diameters can be exposed to direct current electrical fields up to one week.
The focus of the developed maturity model was set on processes. The concept of the widespread CMM and its practices has been transferred to the perioperative domain and the concept of the new maturity model. Additional optimization goals and technological as well as networking-specific aspects enable a process- and object-focused view of the maturity model in order to ensure broad coverage of different subareas. The evaluation showed that the model is applicable to the perioperative field. Adjustments and extensions of the maturity model are future steps to improve the rating and classification of the new maturity model.
The Industry 4.0 paradigm requires concepts for integrating intelligent/ smart IoT Solutions into manufacturing. Such intelligent solutions are envisioned to increase flexibility and adaptability in smart factories. Especially autonomous cobots capable of adapting to changing conditions are a key enabler for changeable factory concepts. However, identifying the requirements and solution scenarios incorporating intelligent products challenges the manufacturing industry, especially in the SME sector. In pick and place scenarios, changing coordinate systems of workpiece carriers cause placing process errors. Using the IPIDS framework, this paper describes the development of a tool-center-point positioning method to improve the process stability of a collaborative robot in a changeable assembly workstation. Applying the framework identifies the requirement for an intelligent workpiece carrier as a part of the solution. Implementing and evaluating the solution within a changeable factory validates the IPIDS framework.
Future intralogistics systems need to adapt flexibly to changing material flow requirements in line with future versatile factory environments, producing personalized products under the performance and cost conditions of today's mass production. Small batch sized down to a batch size of "1" lead to a high complexity in the design and economical manufacturing of these customized products. Intralogistics systems are integrated into higher-level areas (segment level) as well as into upsteam and downstream performance units (system-wide areas). This includes the logistic activities relevant for the system (organized according to storage, picking, transport) such as transportation or storage tasks of tools, semi-finished products, components, assemblies and containers, and waste. Today's centralized material flow control systems, which work based on predefined processes, are not capable and more specifically not suitable to deal with the arising complexity of changeable intralogistics systems. Autononomous, decentralized material flow control systems distribute the required decision-making and control processes on intelligent logistic entities. A major step for the development of an autonomous control method for hybrid intralogistics systems (manual, semi-automated and automated) is the development of a generic archetype for intralogistics systems regarding the system boundaries, elements and relations resulting in a descriptive model taking into account amongst others the time of demand, availability of resources, economic efficiency and technical performance parameters. The ESB Logistics Learning Factory at ESB Business School (Reutlingen University) serves for this as a close-to-reality development and validation environment.
The global demand for individualized products leading to decreasing production batch sizes requires innovative approaches how to organize production and logistics systems in a dynamic manner. Current material flow systems mainly rely on predefined system structures and processes, which result in a huge increase of complexity and effort for system and process changes to realize an optimized production and material provision of individualized products. Autonomous production and logistics entities in combination with intelligent products or logistic load carriers following the vision of the “Internet of Things” offer a promising solution for mastering this complexity based on autonomous, decentralized and target size-optimized decision making and structure formation without the need for predefined processes and central decision-making bodies. Customer orders are going to prioritize themselves and communicate directly with the required production and logistics resources. Bins containing the required materials are going to communicate with the conveyors or workers of the respective intralogistics system organizing and controlling the material flow to the autonomously selected workstation. A current research project is the development of a collaborative tugger train combing the potential of automation and human-robot collaboration in intralogistics. This tugger train is going to be integrated into a self organized intralogistics scenario involving individualized customer orders (low to high batch sizes). To classify the application of self-organization within intralogistics systems, a criteria catalogue has been developed. The application of this criteria catalogue will be demonstrated on the example of a self-organization scenario involving the collaborative tugger train and an intelligent bin system.
The approach of self-organized and autonomous controlled systems offers great potential to meet new requirements for the economical production of customized products with small batch sizes based on a distributed, flexible management of dynamics and complexity within the production and intralogistics system. To support the practical application of self-organization for intralogistics systems, a catalogue of criteria for the evaluation of the self-organization of flexible logistics systems has been developed and validated, which enables the classification of logistics systems as well as the identification and evaluation of corresponding potentials that can be achieved by increasing the degree of self-organization.
Supply chains have evolved into dynamic, interconnected supply networks, which increases the complexity of achieving end-to-end traceability of object flows and their experienced events. With its capability to ensure a secure, transparent, and immutable environment without relying on a trusted third party, the emerging blockchain technology shows strong potential to enable end-to-end traceability in such complex multitiered supply networks. However, as the dissertation’s systematic literature review reveals, the currently available blockchain-based traceability solutions lack the ability to map object-related supply chain events holistically, which involves mapping objects’ creation and deletion, aggregation and disaggregation, transformation, and transaction. Therefore, this dissertation proposes a novel blockchain-based traceability architecture that integrates governance and token concepts to overcome the limitations of existing architectures. While the governance concept manages the supply chain structure on an application level, the token concept includes all functions to conduct object-related supply chain events. For this to be possible, this dissertation’s token concept introduces token ‘blueprints’, which allow clients to group tokens into different types, where tokens of the same type are non-fungible. Furthermore, blueprints can include minting conditions, which are, for example, necessary when mapping assembly or delivery processes. In addition, the token concept contains logic for reflecting all conducted object-related events in an integrated token history. This ultimately leads to end-to-end traceability of tokens and their physical or abstract representatives on the blockchain. For validation purposes, this dissertation implements the architecture’s components and their update and request relationships in code and proves its applicability based on the Ethereum blockchain. Finally, this dissertation provides a scenario-based evaluation based on two industrial case studies from a manufacturing and logistics perspective to validate the architecture’s capabilities when applied in real-world industrial settings. The proposed blockchain-based traceability architecture thus covers all object-related supply chain events derived from the two industrial case studies and therefore proves its general-purpose end-to-end traceability capabilities of object flows.
Today's pattern making methods for industrial purposes are including construction principles, which are based on mathematical formula and sizing charts. As a result, there are two-dimensional flats, which can be converted into a three-dimensional garment. Because of their high linearity, those patterns are incapable of recreating the complexity of the human body, which results in insufficient fit. Subsequent changes of the pattern require a high degree of experience and lead to an inefficient product development process. It is known that draping allows the development of more complex and demanding patterns, which corresponds more to the actual body shape. Therefore, this method is used in custom tailoring and haute couture to achieve perfect garment fit but is also associated with time.
So, there is the act of defiance to improve the fit of garments, to speed up production but maintain a good value for money. Reutlingen University is therefore working on the development of 3D-modelled body shapes for 3D draping, considering different layers of clothing, such as jackets or coats. For this purpose, 3D modelling is used to develop 3D-bodies that correspond to the finished dimensions of the garment. By flattening of the modelled body, it is then possible to obtain an optimal 2D Pattern of the body. The comparison of the conventional method and the developed method is done by 3D simulation.
Finally, the optical fit test is demonstrated by the simulated basic cuts, that a significantly better body wrapping through the newly developed methodology could be achieved. Unlike in the basic cuts, which were achieved by classical design principles have been created, only a few adjustments are necessary to obtain an optimized basic cut. Also, when considering the body distance, it is shown that the newly developed basic patterns provide a more even enclosure of the body.