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Theory and practice of implementing a successful enterprise IoT strategy in the industry 4.0 era
(2021)
Since the arrival of the internet and affordable access to technologies, digital technologies have occupied a growing place in industries, propelling us towards a 4th industrial revolution: Industry 4.0. In today’s era of digital upheaval, enterprises are increasingly undergoing transformations that are leading to their digitalization. The traditional manufacturing industry is in the throes of a digital transformation that is accelerated by exponentially growing technologies (e.g., intelligent robots, Internet of Things, sensors, 3D printing). Around the world, enterprises are in a frantic race to implement solutions based on IoT to improve their productivity, innovation, and reduce costs and improve their markets on the international scene. Considering the immense transformative potential that IoTs and big data have to bring to the industrial sector, the adoption of IoT in all industrial systems is a challenge to remain competitive and thus transform the industry into a smart factory. This paper presents the description of the innovation and digitalization process, following the Industry 4.0 paradigm to implement a successful enterprise IoT strategy.
Artificial intelligence (AI) technologies, such as machine learning or deep learning, have been predicted to highly impact future organizations and radically change the way how projects are managed. The Project Management Institute (PMI), the network of around 1.1 million certified project managers, ranked AI as one of the top three disruptors of their profession. In an own study on the effect of AI, 37% of the project management processes can be executed by machine learning and other AI technologies. In addition, Gartner recently postulated that 80% of the work of today's project managers may be eliminated by AI in 2030.
This editorial aims to outline today's project and portfolio management in context of pharmaceutical research and development (R&D), followed by an AI-vision and a more tangible mission, and illustrate what the consequences of an AI-enabled project and portfolio management could be for pharmaceutical R&D.
This paper covers test and verification of a forecast-based Monte Carlo algorithm for an optimized, demand-oriented operation of combined heat and power (CHP) units using the hardware-in-the-loop approach. For this purpose, the optimization algorithm was implemented at a test bench at Reutlingen University for controlling a CHP unit in combination with a thermal energy storage, both in real hardware. In detail, the hardware-in-the-loop tests are intended to reveal the effects of demand forecasting accuracy, the impact of thermal energy storage capacity and the influence of load profiles on demand-oriented operation of CHP units. In addition, the paper focuses on the evaluation of the content of energy in the thermal energy storage under practical conditions. It is shown that a 5-layer model allows to determine the energy stored quite accurately, which is verified by experimental results. The hardware-in-the-loop tests disclose that demand forecasting accuracies, especially electricity demand forecasting, as well as load profiles strongly impact the potential for CHP electricity utilization on-site in demand-oriented mode. Moreover, it is shown that a larger effective capacity of the thermal energy storage positively affects demand-oriented operation. In the hardware-in-the-loop tests, the fraction of electricity generated by the CHP unit utilized on-site could thus be increased by a maximum of 27% compared to heat-led operation, which is still the most common modus operandi of small-scale CHP plants. Hence, the hardware-in-the-loop tests were adequate to prove the significant impact of the proposed algorithm for optimization of demand-oriented operation of CHP units.
The technologies of digital transformation, such as the Internet-of-Things (IoT), artificial intelligence or predictive maintenance enable significant efficiency gains in industry and are becoming increasingly important as a competitive factor. However, their successful implementation and creative, future application requires the broad acceptance and knowledge of non-IT-related groups, such as production management students, engineers or skilled workers, which is still lacking today. This paper presents a low-threshold training concept bringing IoT-technologies and applications into manufacturing related higher education and employee training. The concept addresses the relevant topics starting from IoT-basics to predictive maintenance using mobile low-cost hardware and infrastructure.
We analyze economics PhDs’ collaborations in peer-reviewed journals from 1990 to 2014 and investigate such collaborations’ quality in relation to each co-author’s research quality, field and specialization. We find that a greater overlap between co-authors’ previous research fields is significantly related to a greater publication success of co-authors’ joint work and this is robust to alternative specifications. Co-authors that engage in a distant collaboration are significantly more likely to have a large research overlap, but this significance is lost when co-authors’ social networks are accounted for. High quality collaboration is more likely to emerge as a result of an interaction between specialists and generalists with overlapping fields of expertise. Regarding interactions across subfields of economics (interdisciplinarity), it is more likely conducted by co- authors who already have interdisciplinary portfolios, than by co-authors who are specialized or starred in different subfields.
Supply chains have become increasingly complex, making it difficult to ensure transparency throughout the whole supply chain. In this context, first approaches came up, adopting the immutable, decentralised, and secure characteristics of the blockchain technology to increase the transparency, security, authenticity, and auditability of assets in supply chains. This paper investigates recent publications combining the blockchain technology and supply chain management and classifies them regarding the complexity to be mapped on the blockchain. As a result, the increase of supply chain transparency is identified as the main objective of recent blockchain projects in supply chain management. Thereby, most of the recent publications deal with simple supply chains and products. The few approaches dealing with complex parts only map sub-areas of supply chains. Currently no example exists which has the aim of increasing the transparency of complex manufacturing supply chains, and which enables the mapping of complex assembly processes, an efficient auditability of all assets, and an implementation of dynamic adjustments.
Comparative analysis of the R&D efficiency of 14 leading pharmaceutical companies for the years 1999–2018 shows that there is a close positive correlation between R&D spending and the two investigated R&D output parameters, approved NMEs and the cumulative impact factor of their publications. In other words, higher R&D investments (input) were associated with higher R&D output. Second, our analyses indicate that there are "economies of scale" (size) in pharmaceutical R&D.
Employing diffuse reflection ultraviolet visible (UV–Vis) spectroscopy we developed an approach that is capable to quantitatively determine flux residues on a technical copper surface. The technical copper surface was soldered with a no-clean flux system of organic acids. By a post-solder cleaning step with different cleaning parameters, various levels of residues were produced. The surface was quantitatively and qualitatively characterized using X-ray photoelectron spectroscopy (XPS), Auger electron spectroscopy (AES), Fourier transform infrared spectroscopy (FTIR) and diffuse reflection UV–Vis spectroscopy. With the use of a multivariate analysis (MVA) we examined the UV–Vis data to create a correlation to the carbon content on the surface. The UV–Vis data could be discriminated for all groups by their level of organic residues. Combined with XPS the data were evaluated by a partial least squares (PLS) regression to establish a model. Based on this predictive model, the carbon content was calculated with an absolute error of 2.7 at.%. Due to the high correlation of predictive model, the easy-to-use measurement and the evaluation by multivariate analysis the developed method seems suitable for an online monitoring system. With this system, flux residues can be detected in a manufacturing cleaning process of technical surfaces after soldering.
Preliminary results of homomorphic deconvolution application to surface EMG signals during walking
(2021)
Homomorphic deconvolution is applied to sEMG signals recorded during walking. Gastrocnemius lateralis and tibialis anterior signals were acquired according to SENIAM recommendation. MUAP parameters like amplitude and scale were estimated, whilst the MUAP shape parameter was fixed. This features a useful time-frequency representation of sEMG signal. Estimation of scale MUAP parameter was verified extracting the mean frequency of filtered EMG signal, extracted from the scale parameter estimated with two different MUAP shape values.
A systematic study using a central composite design of experiments (DoE) was performed on the oxygen plasma surface modifications of two different polymers—Pellethane 2363-55DE, which is a polyurethane, and vinyltrimethoxysilane-grafted ethylene-propylene (EPR-g-VTMS), a cross-linked ethylene-propylene rubber. The impacts of four parameters—gas pressure, generator power, treatment duration, and process temperature—were assessed, with static contact angles and calculated surface free energies (SFEs) as the main responses in the DoE. The plasma effects on the surface roughness and chemistry were determined using scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS). Through the sufficiently accurate DoE model evaluation, oxygen gas pressure was established as the most impactful factor, with the surface energy and polarity rising with falling oxygen pressure. Both polymers, though different in composition, exhibited similar modification trends in surface energy rise in the studied system. The SEM images showed a rougher surface topography after low pressure plasma treatments. XPS and subsequent multivariate data analysis of the spectra established that higher oxidized species were formed with plasma treatments at low oxygen pressures of 0.2 mbar.
Conventional production systems are evolving through cyber-physical systems and application-oriented approaches of AI, more and more into "smart" production systems, which are characterized among other things by a high level of communication and integration of the individual components. The exchange of information between the systems is usually only oriented towards the data content, where semantics is usually only implicitly considered. The adaptability required by external and internal influences requires the integration of new or the redesign of existing components. Through an open application-oriented ontology the information and communication exchange are extended by explicit semantic information. This enables a better integration of new and an easier reconfiguration of existing components. The developed ontology, the derived application and use of the semantic information will be evaluated by means of a practical use case.
Respiratory diseases are leading causes of death and disability in the world. The recent COVID-19 pandemic is also affecting the respiratory system. Detecting and diagnosing respiratory diseases requires both medical professionals and the clinical environment. Most of the techniques used up to date were also invasive or expensive.
Some research groups are developing hardware devices and techniques to make possible a non-invasive or even remote respiratory sound acquisition. These sounds are then processed and analysed for clinical, scientific, or educational purposes.
We present the literature review of non-invasive sound acquisition devices and techniques.
The results are about a huge number of digital tools, like microphones, wearables, or Internet of Thing devices, that can be used in this scope.
Some interesting applications have been found. Some devices make easier the sound acquisition in a clinic environment, but others make possible daily monitoring outside that ambient. We aim to use some of these devices and include the non-invasive recorded respiratory sounds in a Digital Twin system for personalized health.
Nanocoatings based on sol–gel coatings are presented as suitable tool to modify materials based on polymers. The main focus is set onto textiles as the most common polymer materials. It presents which types of functionalization can be reached by modified sol–gel processes. Also a suitable categorization of functions is given and set into relation to common applications. A special focus is set on the functional properties, antimicrobial, UV protective, and flame retardant. The concept of bifunctional coatings is discussed and especially the combination of water-repellent and antistatic is presented.
The isothermal curing of melamine resin is investigated by in-line infrared spectroscopy at different temperatures. The infrared spectra are decomposed into time courses of characteristic spectral patterns using Multivariate Curve Resolution (MCR). It was found that depending on the applied curing temperature, melamine films with different spectral fingerprints and correspondingly different chemical network structures are formed. The network structures of fully cured resin films are specific for the applied curing temperatures used and cannot simply be compensated by changes in the curing time. For industrial curing processes, this means that cure temperature is the main system determining factor at constant M:F ratio. However, different MF resin networks can be specifically obtained from one and the same melamine resin by suitable selection of the curing time and temperatures profiles to design resin functionality. The spectral fingerprints after short curing time as well as after long curing time reflect the fundamental differences in the thermoset networks that can be obtained with industrial short-cycle and multi-daylight presses.
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.
The present work proposes the use of modern ICT technologies such as smartphones, NFCs, internet, and web technologies, to help patients in carrying out their therapies. The implemented system provides a calendar with a reminder of the assumptions, ensures the drug identification through NFC, allows remote assistance from healthcare staff and family members to check and manage the therapy in real-time. The system also provides centralized information on the patient's therapeutic situation, helpful in choosing new compatible therapies.
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.
Business opportunities for energy providers to utilize flexible industrial demand are platform-based, connecting small and medium-sized enterprises (SMEs) to a virtual power plant (VPP) in complex ecosystems. Unlike in other VPPs, the focus is on participation, data, and control sovereignty for the SMEs. An exemplary application for an existing cement mill demonstrates positive margins. Viable VPP business models for small and medium-sized utilities include the “orchestrator,” i.e., adding value by linking services of specialized providers, the “integrator,” i.e., incorporating internal and external processes and resources, as well as the “white label user,” i.e., using a turn-key VPP from an exclusive cooperation partner.
Today, many industrial tasks are not automated and still require human intervention. One of these tasks is the unloading of oversea containers. After the end of transportation to the sorting center, the containers must be unloaded manually for further sending the parcels to the recipients. A robot-based automatic unloading of containers was therefore researched. However, the promising results of the system developed in these projects could not be commercialized due to problems with its reliability. Mechanical, algorithmic or other limitations are possible causes of the observed errors. To analyze errors, it is necessary to evaluate the results of the robot’s work without complicating the existing system by adding new sensors to it. This paper presents a reference system based on machine learning to evaluate the robotics grasps of parcels. It analyzes two states of the container: before and after picking up one box. The states are represented as a point cloud received from a laser scanner. The proposed system evaluates the success of transferring a box from an overseas container to the sorting line by supervised learning using convolutional neural networks (CNN) and manual labeling of the data. The process of obtaining a working model using a hyperband model search with a maximum classification error of 3.9 % is also described.
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.
Normal breathing during sleep is essential for people’s health and well-being. Therefore, it is crucial to diagnose apnoea events at an early stage and apply appropriate therapy. Detection of sleep apnoea is a central goal of the system design described in this article. To develop a correctly functioning system, it is first necessary to define the requirements outlined in this manuscript clearly. Furthermore, the selection of appropriate technology for the measurement of respiration is of great importance. Therefore, after performing initial literature research, we have analysed in detail three different methods and made a selection of a proper one according to determined requirements. After considering all the advantages and disadvantages of the three approaches, we decided to use the impedance measurement-based one. As a next step, an initial conceptual design of the algorithm for detecting apnoea events was created. As a result, we developed an activity diagram on which the main system components and data flows are visually represented.
COVID-19 and educational inequality: How school closures affect low- and high-achieving students
(2021)
In spring 2020, governments around the globe shut down schools to mitigate the spread of the novel coronavirus. We argue that low-achieving students may be particularly affected by the lack of educator support during school closures. We collect detailed time-use information on students before and during the school closures in a survey of 1099 parents in Germany. We find that while students on average reduced their daily learning time of 7.4 h by about half, the reduction was significantly larger for low-achievers (4.1 h) than for high-achievers (3.7 h). Low-achievers disproportionately replaced learning time with detrimental activities such as TV or computer games rather than with activities more conducive to child development. The learning gap was not compensated by parents or schools who provided less support for low-achieving students.
The incudo-malleal joint (IMJ) in the human middle ear is a true diarthrodial joint and it has been known that the flexibility of this joint does not contribute to better middle-ear sound transmission. Previous studies have proposed that a gliding motion between the malleus and the incus at this joint prevents the transmission of large displacements of the malleus to the incus and stapes and thus contributes to the protection of the inner ear as an immediate response against large static pressure changes. However, dynamic behavior of this joint under static pressure changes has not been fully revealed. In this study, effects of the flexibility of the IMJ on middle-ear sound transmission under static pressure difference between the middle-ear cavity and the environment were investigated. Experiments were performed in human cadaveric temporal bones with static pressures in the range of +/- 2 kPa being applied to the ear canal (relative to middle-ear cavity). Vibrational motions of the umbo and the stapes footplate center in response to acoustic stimulation (0.2-8 kHz) were measured using a 3D-Laser Doppler vibrometer for (1) the natural IMJ and (2) the IMJ with experimentally-reduced flexibility. With the natural condition of the IMJ, vibrations of the umbo and the stapes footplate center under static pressure loads were attenuated at low frequencies below the middle-ear resonance frequency as observed in previous studies. After the flexibility of the IMJ was reduced, additional attenuations of vibrational motion were observed for the umbo under positive static pressures in the ear canal (EC) and the stapes footplate center under both positive and negative static EC pressures. The additional attenuation of vibration reached 4~7 dB for the umbo under positive static EC pressures and the stapes footplate center under negative EC pressures, and 7~11 dB for the stapes footplate center under positive EC pressures. The results of this study indicate an adaptive mechanism of the flexible IMJ in the human middle ear to changes of static EC pressure by reducing the attenuation of the middle-ear sound transmission. Such results are expected to be used for diagnosis of the IMJ stiffening and to be applied to design of middle-ear prostheses.
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.
Railway operators are being challenged by increasing complexity and safeguarding the availability of passenger rolling stock, bringing maintenance and especially emerging technologies into the focus. This paper presents a model for selection and implementation of Industry 4.0 technologies in rolling stock maintenance. The model consists of different stages and considers the main components of rolling stock, the related appropriate maintenance strategies and Industry 4.0 technologies considering the maturity level of the railway operators. Relevant criteria and main prerequisites of the technologies were identified. The model proposes relevant activities and was validated by industry experts.
Increasing complexity in manufacturing processes poses new challenges for industrial maintenance. In addition, advanced machine monitoring and lifetime forecasting options expand the tools and maintenance strategies available. Today, maintenance strategy selection is performed sequentially usually based on prioritised machines and components. These selections are optimized locally for each machine isolated, not considering the context of other machines within the value-adding network. To overcome these challenges, this paper presents an approach for an integrated maintenance strategy selection in one-step by an integrated model considering possible machine failures and the context of other machines within the value-adding network in parallel.
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.
Adaptation of the business model canvas template to develop business models for the circular economy
(2021)
The Business Model Canvas as a template for strategic management serves the development of new or the documentation of existing linear business models. However, the change towards a Circular Economy requires new value creation structures and thus changed business models. To develop business models for circular economies, it is necessary to adapt the existing template, since the actors involved along the value chain take on changed roles. In the context of this paper, a template is presented, based on the existing Business Model Canvas, which allows to develop and document business models for a Circular Economy.
Maintenance is an increasingly complex and knowledge-intensive field. In order to address these challenges, assistance systems based on augmented, mixed, or virtual reality can be applied. Therefore, the objective of this paper is to present a framework that can be used to identify, select, and implement an assistance system based on reality technology in the maintenance environment. The development of the framework is based on a systematic literature review and subject matter expert interviews. The framework provides the best technological and economic solution in several steps. The validation of the framework is carried out through a case study.
The maintenance of railway infrastructure remains a challenge. Data acquisition technologies have evolved because of Industry 4.0, expanding the capabilities of predictive maintenance. Despite the advances, the potential of these emerging technologies has not been fully realised. This paper presents a technology selection framework in support of railway infrastructure predictive maintenance, which is based on qualitative methods. It consists of three stages, including the mapping of the infrastructure characteristics with the identified technologies, the evaluation of the most appropriate technologies, and the sourcing thereof. This presents the collective decision support output of the framework.
This paper presents the concept of the system architecture of a flexible cyber-physical factory control system. The system allows the automation of process structures using cyber-physical fractal nodes. These nodes have a functional and independent form and can be clustered to larger structures. This makes it possible to equip the factory with a flexible, freely scalable, modular system. The description of this system architecture and the associated rules and conditions is outlined in the concept.