Research project NeWiP

1. Demonstrator for the application scenario ZF Friedrichshafen AG

problem:

Defective products are reworked after quality control in a repair area. Individual workstations are available for the repair, the repair itself is mainly carried out manually. Due to the complexity of the product, the variety of variants and increasing customer requirements, the following problems arise:

– Insufficient control and documentation of repair processes carried out

– Training and qualification of new staff is very time-consuming and extensive

In the application scenario and in the demonstrator, solutions were therefore developed to implement process control for the critical processes (FMEA) on the one hand and to assist the employee in the process on the other.

Advantages of the solution:

The use of on-the-job assistance and training for the employee enables the continuous training and qualification of employees. A flexible creation of the work plan, with simultaneously variant-dependent process sequences, can also be guaranteed. In addition, there are advantages in customer documentation, as the various systems used enable control and documentation of repair processes.

2. Demonstrator for the application scenario Woll Maschinenbau GmbH

problem:

Analog technical drawings are used for the production of customer-specific solutions in special machine construction, according to whose specifications individual parts, assemblies and ultimately the system are manufactured and assembled. The use of analog technical drawings is not a problem in itself, but this creates difficulties when there are changes to components and assemblies in production. These are usually noted on the technical drawings by hand, which can lead to loss of information, unrecognisable comments or repeated errors if changes are recorded too late or not at all in the construction as a result of the paper-bound transfer. In addition, there is the problem of traceability and labelling of materials and components or assemblies in special machine construction.

Advantages of the solution:

The solution developed in the specific application scenario enables the digital and timely documentation and communication of changes and, on the other hand, maintains the analog technical drawing in the production or construction site environment. The solution is mobile (tablet, smart phone, etc.) and can therefore be used in production environments as well as on construction sites, etc. In addition to various functions for the documentation of a change, additional information such as the digital technical drawing can also be retrieved.

Technologies used / development:

The demonstrator shows on the one hand the developed application for the documentation of changes and on the other hand various possibilities for the labelling of materials. The developed application for documenting changes is a mobile solution and can be used, for example, on a tablet. For the design department, software plugins were developed with the help of which an Auto ID code (QR or DMC) is applied to the technical drawing either in the CAD program or when converting drawing files to PDF. This allows a clear identification of the technical drawing. When documenting a change, the Auto-ID code is scanned and the technical drawing information is digitally loaded. The application provides the employee with several functions for the documentation of a change to the component and technical drawing. On the one hand, the change can be made via tablet pen directly in the digital version, on the other hand, photos of the facts can be taken and commented on. An ‘intelligent’ pen is also available in the demonstrator, which allows the employee to continue to mark changes manually on the technical drawing, but which are recorded via an integrated camera and also digitised directly.

3. Demonstrator for the Imperial application scenario – a Miele Group company

problem:

In the Imperial application scenario of the research project, the topic of transparency in production was in the foreground. The production of steam cookers at the Bünde site was examined. At the plant, the various steam cooker families and their variants are produced in a very high depth of added value. Apart from some specific points in production (e.g. Examination) in which an automated feedback of the products and test results takes place, the planners and team leaders in day-to-day operations are often dependent on manual feedback. Particularly in the case of unplanned events, personnel-intensive coordination rounds are required in order to assess the current status and to make a decision to continue production. In the scenario, therefore, the topics of MES, machine connection and intelligent material trolleys were followed and solutions developed. The demonstrator available at ZeMA includes the two intelligent material trolleys developed in the project.

Advantages of the solution:

The material trolleys are equipped with various sensors that make it possible to identify the material trolley, locate it, get information and feedback, as well as to monitor the individual slots of the material trolley. Overall, the material trolley offers the possibility to continuously send feedback on the current status, whereby details of the location and material stock can be visualized in the MES. The use of robust ‘industrial sensors’ enables the use of the material trolleys in the production and assembly environment. However, today's sensor prices stand in the way of widespread use.

Technologies used/development:

Different sensors were installed in the demonstrator and the two intelligent material trolleys in order to create a technology carrier for further tests during development. For example, the material trolleys have redundant systems for inventory recording (manual recording to fully automatic recording). The material trolleys are equipped with beacons for identification and localization using the RSSI value. E-ink displays enable the visualization of loaded material and assigned order directly on the material trolley. On the one hand, radio sensors and UHF RFID technology are used to record the inventories in the material trolley. The use of UHF RFID technology in combination with LED also enables the implementation of employee guidance during the feeding or removal of material. Thus, the individual slots can be equipped with LED and a pick-to-light can be realized. A control program was developed for the material trolleys in order to link the different technologies together and pass the data on to the XETICS MES system used in the scenario. The material trolleys are connected to the MES via a REST API interface.

4. Demonstrator for the application scenario XENON Automatisierungstechnik GmbH

problem:

In the XENON application scenario, the focus was on the development of tools for networking experts in production plant construction. XENON develops and produces production systems according to customer specifications. Coordination with the customer is an important part of project management at all times as well as the internal handling of project-relevant data and information. The availability of up-to-date data and the assessment of effects resulting from short-term changes are crucial for the phases of quotation, plant development and service. The project therefore developed tools to support planners and developers during the plant development phase and to make the work with the customer more transparent; For the service phase, a service platform was developed to implement customer inquiries and service activities faster and more efficiently in coordination with the customer.

Advantages of the solution:

The developed solutions and tools support the employees, primarily in the field of planning and development as well as in service. Due to the platform and networking nature of the solutions, the internal coordination between individual people and teams can be improved as well as external experts of the customer can be involved. Other prototypical tools support employees, for example, in the revision of specifications, the reconciliation of changes or the description of data records for more efficient searches.

Final report and publication

Müller, R. et al.: NeWiP – New ways of information-led production. Published in Research Reports Assembly Technology and Organization, Volume 2. ISBN: 978-3-8440-6580-0. Aachen, Shaker-Verlag, 2019.

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Lectures and publications at conferences

2017

Müller, R. et al.: Communication in the plant development process - platform to support communication between customer and plant manufacturer. wt Werkstattstechnik Online Year 107 (2017) H. 9

Müller, R. et al.: Development of a lean information and communication tool to connect and digitize company departments in small and medium-sized enterprises. The thirteenth International Conference on Autonomous Systems, Barcelona, 2017.

Müller, R. et al.: Human-centered information tool for in-house networking. Humans and Computers, Regensburg, 2017.

Müller, R. et al.: Lean information and communication tool to connect shop and top floor in small and medium-sized enterprises. 27th International Conference on Flexible Automation and Intelligent Manufacturing, Modena, 2017.

Müller, R.: Consistent provision of information through cyber-physical systems at an assembly machine manufacturer. 67th CIRP General Assembly, Lugano, 2017

Müller, R. et al.: Worker guidance distributes information. Handling, Issue 1-2, Hg. v. Born, P., WEKA Business Medien GmbH, 2017, pp. 50-51

2018

Müller, R. et al.: Towards an integrated knowledge management system for small and medium-sized enterprises in the field of assembly system engineering. eKNOW 2018 The Tenth International Conference on Information, Process, and Knowledge Management, Rome, 2018.

Müller, R. et al.: Communication and knowledge management platform for concurrent product and assembly system development. 7th International conference on Changeable, Agile, Reconfigurable and Virtual Production (CARV2018), Nantes, 2018.

Müller, R. et al.: Industry 4.0 modular system for the digitization of production processes using the example of a networked material trolley. 27. German Material Flow Congress, Munich, 2018.

Müller, R. et al.: Development of an intelligent material shuttle to digitize and connect production areas with the production process planning department. 51st CIRP Conference on Manufacturing Systems, Stockholm, 2018.

Müller, R. et al.: Information and Data Structure to Create Flexible Work Plans for Worker Assistance System Used at Rework Site Procedia CIRP, Volume 79, ed. v. Teti, R.; D’addona, D.M., CIRP, pp.147-152, Naples, 2018.

Müller, R. et al.: Worker Centered Cognitive Assistance for Dynamically Created Repairing Jobs in Rework Area. Procedia CIRP, Vol. 72, Hg. v. Wang, L., CIRP 2018, pp. 141-146

Möhwald, H. et al.: Industry 4.0 – Engage employees. Case studies from operational practice. Ed. Working Group on Industry 4.0 – Engaging Employees, Leipzig, 2018.

2019

Müller, R. et al.: Simulation-based online production planning. 29th International Conference on Flexible Automation and Intelligent Manufacturing, Limerick, 2019.

Müller, R. et al.: Introduction of cyber-physical systems for online planning/control of production processes at an SME. wt Werkstattstechnik Online Year 109 (2019) H. 4

Müller, R. et al.: Enabling existing plants and machines for cross-company networking. Mittelstand-Digital Magazine ‘Science meets practice’ Issue 12, 2019.

Müller, R. et al.: Networking of top- and shop floor by a lean information communication tool to control and optimise production processes. 52nd CIRP Manufacturing Systems Conference, Ljubljana, 2019.

Müller, R. et al.: Intelligent and flexible worker assistance systems – assembly assistance platform for planning assisted assembly and rework as well as execution of a worker-centered assistance. Proceedings of the 13th International Joint Conference on Computer Vision, Imaging and Computer Graphics Theory and Applications (VISIGRAPP 2018), Vol. 2, Hg. v. Richar, P.; Chessa, M.; Braz, J., Insticc, Funchal, 2019

Müller, R.: Cognitive Worker Assistance for Dynamically Created Repairing Jobs in the Rework Area. 68th CIRP General Assembly, Tokyo, 2019.

Müller, R. et al.: Situational Cognitive Assistance System in Rework Area. 29th International Conference on Flexible Automation and Intelligent Manufacturing, Limerick, 2019.

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Lectures at conferences and industrial working groups

Müller, R.: New ways of information-led production – strategies, approaches, application scenarios. 9. Assembly conference, Saarbrücken, 2017.

Schmitt, K-J.; Burkhard, D.: Human-centered information tool for in-house networking. Industrial working group ‘Future-stable assembly’ Bosch Rexroth. Stuttgart, 2017.

Schmitt, K-J.; Burkhard, D.: Networking of the in-house value chain, a demand- and requirements-oriented digitalization of shop and top floor at an SME. Mittelstandszentrum 4.0, Saarbrücken, 2017.

Four feet, R.; Ahmadi, A.; Burkhard, D.: Agile production systems for online planning and control through the digitalisation of the value chain at Imperial-Werke oHG. VDMA Final Event Collaborative Projects. Frankfurt, 2018

Burkhard, D.: Digitization of existing production plants and machines. Mittelstand 4.0 Competence Center, Saarbrücken, 2018

Burkhard, D.: Increase efficiency through production networking – introduction to production networking in different divisions of the company. Mittelstandszentrum 4.0, Saarwellingen, 2018

Müller, R.: New ways of information-led production – example and application. 11. Assembly conference, Saarbrücken, 2019.