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Rapidly changing market conditions and global competition are leading to an increasing complexity of logistics systems and require innovative approaches with respect to the organisation and control of these systems. In scientific research, concepts of autonomously controlled logistics systems show a promising approach to meet the increasing requirements for flexible and efficient order processing. In this context, this work aims to introduce a system that is able to adjust order processing dynamically, and optimise intralogistics transportation regarding various generic intralogistics target criteria. The logistics system under consideration consists of various means of transport for autonomous decision-making and fulfilment of transport orders with defined source-sink relationships. The context of this work is set by introducing the Learning Factory Werk 150 with its existing hardware and software infrastructure and its defined target figures to measure the performance of the system. Specifically, the important target figures cost and performance are considered for the transportation system. The core idea of the system’s logic is to solve the problem of order allocation to specific means of transport by linking a Genetic Algorithm with a Multi-Agent System. The implementation of the developed system is described in an application scenario at the learning factory.
Planning of available resources considering ergonomics under deterministic highly variable demand
(2020)
In this paper, a method for hybrid short- to long-term planning of available resources for operations is presented, which is based on a known or deterministically forecasted but highly variable demand. The method considers quantitative measures such as the performance and the availability of resources, ergonomically relevant KPI and ultimately process costs in order to serve as a pragmatic planning tool for operations managers in SMEs. Specifically, the method enables exploiting the ergonomic advantages of available flexible automation technology (e.g. AGVs or picking robots), while assuring that these do not represent a capacity bottleneck. After presenting the method along with the necessary assumptions, mainly concerning the availability of data for the calculations, we report a case study that quantifies the impact of throughput variability on the selection of different process alternatives, where different teams of resources are used.
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.
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.
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.
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.
Production planning and control are characterized by unplanned events or so-called turbulences. Turbulences can be external, originating outside the company (e.g., delayed delivery by a supplier), or internal, originating within the company (e.g., failures of production and intralogistics resources). Turbulences can have far reaching consequences for companies and their customers, such as delivery delays due to process delays. For target-optimized handling of turbulences in production, forecasting methods incorporating process data in combination with the use of existing flexibility corridors of flexible production systems offer great potential. Probabilistic, data-driven forecasting methods allow determining the corresponding probabilities of potential turbulences. However, a parallel application of different forecasting methods is required to identify an appropriate one for the specific application. This requires a large database, which often is unavailable and, therefore, must be created first. A simulation-based approach to generate synthetic data is used and validated to create the necessary database of input parameters for the prediction of internal turbulences. To this end, a minimal system for conducting simulation experiments on turbulence scenarios was developed and implemented. A multi-method simulation of the minimal system synthetically generates the required process data, using agent-based modeling for the autonomously controlled system elements and event-based modeling for the stochastic turbulence events. Based on this generated synthetic data and the variation of the input parameters in the forecast, a comparative study of data-driven probabilistic forecasting methods was conducted using a data analytics tool. Forecasting methods of different types (including regression, Bayesian models, nonlinear models, decision trees, ensemble, deep learning) were analyzed in terms of prediction quality, standard deviation, and computation time. This resulted in the identification ofappropriate forecasting methods, and required input parameters for the considered turbulences.
Smart factories, driven by the integration of automation and digital technologies, have revolutionized industrial production by enhancing efficiency, productivity, and flexibility. However, the optimization and continuous improvement of these complex systems present numerous challenges, especially when real-world data collection is time-consuming, expensive, or limited. In this paper, we propose a novel method for semi-automated improvement of smart factories using synthetic data and cause-effect-relations, while incorporating the aspect of self-organization. The method leverages the power of synthetic data generation techniques to create representative datasets that mimic the behaviour of real-world manufacturing systems. These synthetic datasets serve together with the cause-and-effect relationships as a valuable resource for factory optimization, as they enable extensive experimentation and analysis without the constraints of limited or costly real-world data. Furthermore, the method embraces the concept of self organization within smart factories. By allowing the system to adapt and optimize itself based on feedback from the synthetic data, cause-effect-relationships, the factory can dynamically reconfigure and adjust its processes. To facilitate the improvement process, the method integrates the synthetic data with advanced analytics and machine learning algorithms as well as and the cause-and-effect relationships. This synergy between human expertise and technological advancements represents a compelling path towards a truly optimized smart factory of the future.