330 Wirtschaft
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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.
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.
Increasing flexibility, greater transparency and faster adaptability play a key role in the development of future intralogistics. Ever-changing environmental conditions require easy extensibility and modifiability of existing bin systems. This research project explores approaches to transfer the Internet of Things (IoT) paradigm to intralogistics. This allows a synchronization of the material and information flow. The bin is enabled by the implementation of adequate hardware and software components to capture, store, process and forward data to selected system subscribers. Monitoring the processes in the intralogistics by means of the smart bin system ensures the implementation of appropriate actions in case of defined deviations. By using explorative expert interviews with representatives from the automotive and pharmaceutical industries, seven practical application scenarios were defined. On this basis, the requirements of smart bin systems were examined. For each individual case of application, a system model was created in order to obtain an overview of the system components and thus reveal similarities and differences. Based on the similarities of the system models, a general requirement profile was derived. After the hardware components of the bin system had been determined, a utility analysis was carried out to find the adequate IoT software. The utility analysis was conducted with a focus on data acquisition and data transfer, data storage, data analysis, data presentation as well as authorization management and data security. The results show that there is great interest in easily expandable and modifiable bin systems, as in all cases, the necessary information flow in the existing bin system has to be improved by means of new IoT hardware and software components.
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 level of automation in intralogistics has steadily increased over recent years. For small and medium-sized enterprises (SMEs), however, the associated digital change is a major challenge. Since most SMEs are facing increasing sales volumes (e.g. due to e-commerce and good overall economy) in combination with decreasing lot sizes due to the market demand for individualized products, SMEs have to find innovative solutions to cope with these challenges in production as well as in logistics. Innovative technologies, like 3D printing technologies for the production for small lot sizes and future-oriented intralogistics technologies can serve as enablers in logistics to realize flexible logistic processes for increasing market requiremments. Considering that, this paper examines innovative and future-oriented technologies for intralogistics such as smart containers, driverless forklift systems, data glasses, smart shelves and smart pallets regarding their potential for SMEs. This explorative research paper shows that digital technologies are already suitable and available for SMEs.However, challenges are still seen in areas like the identification and digitalization potential and the financing of these new projects. The primary reason escpecially for SMEs for this is that they have to make investments based on an economically feasible payback period and less based on prestigious reasons like digitalization flagship projecs done by large corporations. In addition, the identification of feasible starting points for digitalization within intralogistic systems embedded in specific factory processes is a major challenge not only for SMEs.