670 Industrielle und handwerkliche Fertigung
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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.
The persistent development towards decreasing batch sizes due to an ongoing product individualization, as well as increasingly dynamic market and competitive conditions lead to new changeability requirements in production environments. Since each of the individualized products mgith require different base materials or components and manufacturing resources, the paths of the products giong through the factory as well as the required internal transport and material supply processes are going to differ for every product. Conventional planning and control systems, which rely on predifined processes and central decision-making, are not capable to deal with the arising system's complexity along the dimensions of changing goods, layouts and throughput requirements. The concepts of "self-organization" in combination with "autonomous ocntrol" provide promising solutions to solve these new requirements by using among other things the potential of autonomous, decentralized and target-optimized logistical objects (e.g. smart products, bins and conveyor systems) wich are able to communicate and interact with each other as well as with human wokers. To investigate the potential of automation and human-robot collaboration for intralogistics, a research project for the development of a collaborative tugger train has been started at the ESB Logistics Learning Factory in lin with various student projects in neighboring research areas. This collaboraive tugger train system in combination with other manual (e.g. handcarts) and (semi-) automated conveyoer systems (e.g. automated guided forklift) will be integrated into a dynamic, self-organized scenario with varying production batch sizes to develop a method for target-oriented sefl-organization and autonomous control of intralogistics systems. For a structured investigation of self-organized scenarios a generic intralogistics model as well as a criteria cataloghe has been developed. The ESB Logistics Learning will serve as a practice-oriented research, validation and demonstration environment for these purposes.
After the initiator of the ESB Logistics Learning Factory, Prof. Vera Hummel had made experience in developing and implementing a concept for a Learning Factory for Advanced Industrial Engineering (aIE) at the University of Stuttgart, Institute IFF between 2005 and 2008, she was appointed as a full professor at ESB Business School, a faculty of Reutlingen University in March 2010. Lacking a realistic, hands on learning and teaching environment of industrial scale for its industrial engineering students, first ideas for a Learning Factory that would strongly focus on all aspects of production logistics were drafted in 2012. Already back then, a strong integration of virtual and physical factory was desired: While the Learning Factory itself would be physical, the neighboring partners along the supply chain, such as suppliers or distribution warehouses, could be added in a fully virtual way. Considering implementation of the ESB Logistics Learning Factory a strategic initiative of the university, initial funding was provided by the faculty ESB Business School itself. Following its own creed, to provide future-oriented training for the region, also primarily local suppliers and manufacturers were selected as equipment providers to the new Learning Factory. During the initialization phase, 2014, a total of three researchers and nine students worked approximately four months to set up a first assembly line, storage racks, AGVs, or pick-by-light systems in conjunction with the underlying didactical concept. Since then, several hundred of students have participated in trainings and lectures held in the ESB Logistics Learning Factory, several research projects were carried out, and multiple high-level politicians and industry executives have been touring the shop floor. Also, more than EUR 2 million in research and infrastructure funds could be secured for expansion and upgrade — allowing the ESB Logistics Learning Factory today to represent many core aspects of an Industrie 4.0 production environment.
Increasingly volatile market conditions and manufacturing environments combined with a rising demand for highly personalized products, the emergence of new technologies like cyber-physical systems and additive manufacturing as well as an increasing cross-linking of different entities (Industrie 4.0) will result in fundamental changes of future work and logistics systems. The place of production, the logistical network and the respective production system will underlie the requirements of constant changes and therefore sources and sinks of logistical networks have to obey the versatility of (cyber-physical) production systems. To cope with the arising complexity to control and monitor changeable production and logistics systems, decentralized control systems are the mean of choice since centralized systems are pushed to their limits in this regard. This paradigm shift will affect the overall concept under which production and logistics is planned, managed and controlled and how companies interact and collaborate within the emerging value chains by using dynamic methods to generate and execute the created network and to allocate available resources to fulfill the demand for customized products. In this field of research learning factories, like the ESB Logistics Learning Factory at ESB Business School (Reutlingen University), provide a great potential as a risk free test bed to develop new methods and technical solutions, to investigate new technologies regarding their practical use and to transfer the latest state of knowledge and specific competences into the training of students and professionals. Keeping with these guiding principles ESB Business School is transferring its existing production system into a cyber-physical production system to investigate innovative solutions for the design of human-machine collaboration and technical assistance systems as wells as to develop decentralized control methods for intralogistics systems following the requirements of changeable work systems including the respective design of dynamic inbound and outbound logistic networks.
Die zunehmende Durchdringung von cyber-physischen Systemen und deren Vernetzung zu cyberphysischen Produktionssystemen (CPPS) führt zu fundamentalen Veränderungen von zukünftigen Montage-, Fertigungs- und Logistiksystemen, welche innovative Methoden zur Planung, Steuerung und Kontrolle von wandlungsfähigen Produktionssystemen erfordern. Zukünftige logistische Systeme werden dabei den Anforderungen einer hochfrequenten Veränderung und Re-Konfiguration ausgelöst durch wandlungsfähige Produktionssysteme für individualisierte Produkte und kleinen Losgrößen unterliegen. Der Einsatz dezentraler Steuerungssysteme, bei denen die komplexen Planungs-, Steuerungs- und Kontrollprozesse auf zahlreiche Knoten und Entitäten des entstehenden Steuerungssystems verteilt werden, bietet ein großes Potential, den Anforderungen in cyber-physischen Logistiksystemen gerecht zu werden. Eine zentrale Herausforderung ist dabei die echtzeitfähige Steuerung und Re-Konfiguration von sogenannten hybriden Logistiksystemen, welche u.a. durch die Kollaboration von Mensch und Maschine, der Kombination verschiedenartiger Fördermittel sowie verschiedenartiger Steuerungsarchitekturen geprägt sind und darüber hinaus auf hybriden Entscheidungsfindungsprozessen beruhen, welche die Fähigkeiten von Menschen und (cyber-physischen) Systemen synergetisch nutzen.
Lernfabriken, wie die ESB Logistik-Lernfabrik an der ESB Business School (Hochschule Reutlingen), bieten dabei weitreichende Möglichkeiten, diese innovativen Methoden, Systeme und technischen Lösungen in einer industrienahen und risikofreien Fabrikumgebung zu entwickeln sowie in die Ausbildung von Studierenden und Weiterbildung von Teilnehmern aus der Industrie zu transferieren. Um die Forschung, Lehre sowie Aus- und Weiterbildung im Bereich zukünftiger Montage-, Fertigungs- und Logistiksysteme auszuweiten, wird das bestehende Produktionssystem der ESB Logistik-Lernfabrik im Rahmen verschiedenster Forschungs- und Studentenprojekte schrittweise in ein dezentral gesteuertes cyber-physisches Produktionssystem, basierend auf einer ereignisorientierten, cloud-basierten und dezentralen Steuerungsarchitektur, überführt.
The increasing emergence of cyber-physical systems (CPS) and a global crosslinking of these CPS to cyber-physical production systems (CPPS) are leading to fundamental changes of future work and logistic systems requiring innovative methods to plan, control and monitor changeable production systems and new forms of human-machine-collaboration. Particularly logistic systems have to obey the versatility of CPPS and will be transferred to so-called cyber physical logistic systems, since the logistical networks will underlie the requirements of constant changes initiated by changeable production systems. This development is driven and enhanced by increasingly volatile and globalized market and manufacturing environments combined with a high demand for individualized products and services. Also nowadays mainly used centralized control systems are pushed to their limits regarding their abilities to deal with the arising complexity to plan, control and monitor changeable work and logistic systems. Decentralized control systems bear the potential to cope with these challenges by distributing the required operations on various nodes of the resulting decentralized control system.
Learning factories, like the ESB Logistics Learning Factory at ESB Business School (Reutlingen University), provide a wide range of possibilities to develop new methods and innovative technical solutions in a risk-free and close-to-reality factory environment and to transfer knowledge as well as specific competences into the training of students and professionals. To intensify the research and training activities in the field of future work and logistics systems, ESB Business School is transferring its existing production system into a CPPS involving decentralized planning, control and monitoring methods and systems, human-machine-collaboration as well as technical assistance systems for changeable work and logistics systems.
Mastering of complex systems and interfaces, idea and innovation management as well as virtually integrated product and process planning are essential competences to be developed and fostered to cope with the changing role of the workforce in a future industry 4.0 work system. Learning factories, like the Logistics Learning Factory at Reutlingen University, which are equipped with state-of-the-art infrastructure, offer a high potential to decidedly address these competences.
Shorter product life cycles and emerging technologies in the field of industrial equipment are changing the prerequisites and circumstances under which the design of assembly and logistics systems take place. Planners have to adapt the production in accordance with the underlying product at a higher pace, oversee a more complex system and - most importantly - find the ideal solution for functional as well as social interaction between humans and machines in a cyber-physical system. Such collaborative work systems consider the individual capabilities and potentials of humans and machines to combine them in a manner that assists the operator during his daily work routine towards more productive, less burdening work. To be able to design work systems which act on that maxim, specific competences such as the ability of integrated process and product planning as well as systems and interface competence are required. The ESB Logistics Learning Factory trains students as well as professionals to gain such qualification by providing a close-to-reality learning environment based on a didactical concept which covers all relevant methods for ergonomic work system design and a state-of-the-art infrastructure composed of a manual assembly system, service robots, visual assistance systems, sensor-based work load monitoring and logistical resources. Group-based, activity oriented scenarios enable the participants to put the learnings into practice within their professional environments. By this, learning factories have an indirect impact on the transfer of proven best practices to the industry and thereby on the diffusion of the idea of human-centric working environment.
System- und Schnittstellenbeherrschung, Ideen- und Innovationsmanagement sowie die virtuell integrierte Produkt- und Prozessplanung sind zu entwickelnde Kompetenzen, die der veränderten Rolle des Menschen in der Industrie 4.0 Rechnung tragen. Dezidiert adressiert werden können diese in zukunftsweisend ausgerüsteten Lernfabriken.