ESB Business School Reutlingen / Fraunhofer Austria Research / TU Vienna

Implications for Learning Factories from Industry 4.0

Challenges for the human factor in future production scenarios

Andreas Jäger, MSc, MBA

Prof. Dr. Wilfried Sihn
Fraunhofer Austria Research GmbH
Vienna University of Technology

Fabian Ranz, MSc

Prof. Dr. Vera Hummel
ESB Business School, Reutlingen University
Industry 4.0
The human factor in cooperation with CPPS

Revolution?
Strategy?
Current
Event?
Future?

Science
CIM 2.0?
Industry 4.0 Fiction?

Hype? Myth?

2
Industry 4.0
The human factor in cooperation with CPPS

Revolution?

?
Strategy?
Current
Event?
Future?

Science
CIM 2.0?
Industry 4.0 Fiction?

Hype? Myth?

3
Industry 4.0
The human factor in cooperation with CPPS

Scenario 1 (autonomous automation): Scenario 2 (hybrid collaboration):

Technology guides Human Human guides Technology

Revolution?

?
Strategy?
Current
Event?
Future?

Science
CIM 2.0?
Industry 4.0 Fiction?

Hype? Myth?

4
Industry 4.0
The human factor in cooperation with CPPS

Scenario 1 (autonomous automation): Scenario 2 (hybrid collaboration):

Technology guides Human Human guides Technology
Senses for
perception
Intelligence Revolution?
Strategy? Ability to improve
Learning aptitude Current
Versatility
Creativity
Event?
Future? Experience
Social
Science

Industry 4.0
interaction

CIM 2.0? Fiction?

Hype? Myth?

5
Industry 4.0
Challanges – Qualification and Education

Standardization
Process and Work Organization
Available Products
New Business Models Required competencies
Security / Know-How-Protection and skills?
Available Qualified Employees Future job profiles?
Research
Qualification
Legal Framework

Number of namings

Source: Survey by plattform-i40 (BITKOM, VDA, ZVEI) January 2013, Responses: 284 / Quote 9,2%

6
Industry 4.0
Essential competence requirements

Cyber Space
Virtual Production

Digital Production

Product
Cyber-Physical-Production System

Real Production Global Production & Supplier Collaboration

Physical World

Smart
Design – Integrated Process Ramp Up &
Manufacturing Planning & Layout Production Utilization Recycling
Collaboration Simulation Planning Execution

Automation

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Industry 4.0
Essential competence requirements

Cyber Space
Virtual Production

Digital Production

Product
Cyber-Physical-Production System

Real Production Global Production & Supplier Collaboration

Physical World

Smart
Design – Integrated Process Ramp Up &
Manufacturing Planning & Layout Production Utilization Recycling
Collaboration Simulation Planning Execution

Automation

,Integrated Product and

Process Planning and
Design Competence

8
Industry 4.0
Essential competence requirements

Cyber Space
Virtual Production

Digital Production

Product
Cyber-Physical-Production System

Real Production Global Production & Supplier Collaboration

Physical World

Smart
Design – Integrated Process Ramp Up &
Idea
Manufacturing Planning & Layout Production Utilization Recycling
Engineering
Collaboration Simulation Planning Execution

Innovation Management

Automation

Creativity & Methods ,Integrated Product and

Competence for systematic Process Planning and
Idea & Innovation Mgmt. Design Competence

9
Industry 4.0
Essential competence requirements
Cloud Computing
Cyber Space

Intelligence Virtual Reality Virtual Production

Senses for Data Mining
perception Internet of
Wireless Network Things
Ability to improve Software Tools Digital Production
Learning aptitude

Product
Versatility
Creativity
Interface Cyber-Physical-Production System
Experience
Social RFID Real Production Global Production & Supplier Collaboration
Physical World

Smart
interaction Sensors & Actuators Design – Integrated Process Ramp Up &
Idea
Wearable Computers Manufacturing Planning & Layout Production Utilization Recycling
Engineering
Collaboration Simulation Planning Execution
Smart Devices
Control Center Innovation Management
Embedded
Smart Grid Systems
Social Machines Automation

Creativity & Methods ,Integrated Product and

Systems and Interface
Competence for systematic Process Planning and
Competence
Idea & Innovation Mgmt. Design Competence

10
Industry 4.0
Job profiles (excerpt) for a cyber-physical working environment

Development & Integration & Configuration & Integration & Development &
Testing Implementation Optimization Implementation Testing

Specialisation Informatics Electrical Engineer Industrial Mechanic

Technology Specialist
Automation Technician Manufacturing Engineer
Robot Programmer
Processes SPS Programmer Production Technician
Software Engineer
Inter- Electronics Technican Mechanical Engineer
Industrial Engineer
disciplinary for Industrial Systems

System of Systems Engineer

System-Design Electronics Robotics Automation Equipment Engineering

Digital System Design Embedded Systems Cybernetics Kinematics

IT Digital Signal Processing Industrial Controllers Kinetics Material Science

Information & Communication Cyber Physical Systems Real Production

Technology

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ESB Logistics-Learning-Factory
Holistic Approach from Product to Factory System realization and
ramp-up

Assembly and intralogistics systems,

Jigs & Fixtures
Design & Realization
Process
Design & Validation
Customization of
adaptable product
(high variance)

© redorbit

,Integrated
Creativity & Methods
Product and Process Systems and Interface
Competence for systematic
Planning and Design Competence
Idea & Innovation Mgmt.
Competence

Education Training Research Industry Projects

12
ESB Logistics-Learning-Factory
Integrative tie-in of virtual factory and physical system
Customer Customer
requirements orders
CAS / CAD / PDM Order Data
Operations Cockpit
Engineering &

Production Program

Configuration of Process- and work station

production system Simulation
design

Manufacturing Execution

Quick Adaption Transparency

to Turbulences & Traceability
Learning Factory
Physical System

Exemplary Smart, low-cost

aspects of solutions for
Industry 4.0 SME
requirements

Spring Spring Nov 2014

2013 2014 2014 July 2014 Oct 2014 First Industry 4.0 SS 2015 2015
Hardware Software workshop for 2015
New team & First system First trainings with System Regular
installation installation external New building
suppliers run students expansion operation

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ESB Logistics-Learning-Factory
Industry 4.0– Flexible conveyor system
Forerunner-Follower-Identification

Automated
topology
feedback

Touch-screen
control and
monitoring
Unlimited layout
opportunities with minimized
changeover times
Plug-and-play
for goods,
power & Autonomous
information routing with no
flow Start IP: 192.0…
dead-locks

Integrated
Systems and
Pictures courtesy of: Product and Process
Interface
Planning and Design Destination
Competence IP: 192.1…
Competence

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ESB Logistics-Learning-Factory
Industry 4.0– Flexible conveyor system Use Case
Flexible conveyor for changing logistical requirements

Initial order scenario Realization of ideal Turbulences affecting the Result: adapted
(quantity, variants, dates) plant layout scenario production system

Demand change
Supply outage
Equipment defect
Technological change
…

E Short-cyclical re-design of logistical systems,

Aspects for Education,
Research and Industry

including planning as well as technical realization Systems and Interface

,Integrated Competence
Product and Process R Automated planning of multimodal intralogistics
Planning and Design systems (e.g. with unsteady conveyor)
Competence
I Development of use applications for the industry

15
ESB Logistics-Learning-Factory
Industry 4.0– Technical Assistance System
Technical assistance with collaborative robots

Conventional robots Fit for the future robots Use Case ESB Logistics Learning Factory

Creativity & Methods Open-source ROS Systems and

Competence for for creative
Interface
systematic Idea & solutions &
Innovation Mgmt. innovation sharing
Competence

© v-quadrat. © Kawada Industries.

Autonomous routing and

2D-Laser for
Stationary use navigation within the
auto-movement
system
Intuitive teaching:
Complex config High-level programming Job enrichment
for operators

Shoulder-to-Shoulder Tactile sensors and

Fenced operation collaboration cognitive
capabilities

Situative integration
Defined task Flexible deployment into assembly,
logistics, QC…

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ESB Logistics-Learning-Factory
Industry 4.0– Technical Assistance System Use Case
Technical assistance with collaborative robots
Design and planning of MTM-based Task-specific teaching
Work tasks
collaborative ergonomic and deployment of the Result
(required abillity)
Works Systems workload analysis assisting system

Demographic-change ready
workplaces

Technology follows the

worker, not worker the
technology
Situative assistance instead
of human substitution ->
© Onexia, Inc.
standardized CWSM

E Integral workplace optimization and expertise enhancement

Aspects for Education,

[VDI2860] Assembly:
Research and Industry

 Mating (e.g.. Screwing, Plugging,,

Gluing, Clipsing) in the deployment of smart local automation solutions
 Handling (e.g. Picking, Placing)
Systems and Interface
 Checking (e.g.. Measuring) Competence
 Adjusting (e.g. Tuning)
R Development of „ability and attribute based" standardized
 Support Ops (e.g. Cleaning) modules for collaborative workings systems (CWSM)
Functions of handling:
 Store
 Adjust quantity I Cost-benefit evaluation of collaborative assisting systems and
 Move
 Check best-practices of application

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TU Vienna Learning & Innovation Factory
„i-PEP“ (integrative product emergence process)

Process Steps

From Idea to Product

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TU Vienna Learning & Innovation Factory
„i-PEP“ (integrative product emergence process)

Didactic Approach

Lecture for
content
preparation
Hands-on
training

Presentation
with feedback
Independent
learning

Teamwork

Teambuilding

2011 2011 / 2012 April 10th May 2012 2012 / 2013 2013 / 2014 2014 - 2016
April 2013 May 2014
Formation Development 2012 2nd Conference Optimization of Integration of PM Industry 4.0
2nd lecture 3rd lecture
& initiation & installation Pilot Run on LF in Vienna training concept & creative tools use cases

19
TU Wien Learning & Innovation Factory
Proceeding

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TU Wien Learning & Innovation Factory
Proceeding

Funding of physical equipment and

digital infrastracture:
 Austrian Ministry for Science & Research
 3 years, started in January 2014
 300k€ for investments
 170k€ inkind performance

21
TU Wien Learning & Innovation Factory
Proceeding

Funding of physical equipment and PhD College:

digital infrastracture:  Ressources (Students) for
 Austrian Ministry for Science & Research CPPS research
 3 years, started in January 2014  Transfer of use cases into
the Learning Factory
 300k€ for investments
 170k€ inkind performance

22
TU Wien Learning & Innovation Factory
Proceeding

Funding of physical equipment and PhD College:

digital infrastracture:  Ressources (Students) for
 Austrian Ministry for Science & Research CPPS research
 3 years, started in January 2014  Transfer of use cases into
the Learning Factory
 300k€ for investments
 170k€ inkind performance

Endowed Professorship:
 Focus: Production of the Future
 Supervison of I4.0 qualification and
development activities

23
 TU Vienna Learning & Innovation Factory
Expansion of Manufacturing Technologies

NC -turning machine & milling machine External procurement

Initial situation

24
 TU Vienna Learning & Innovation Factory
Expansion of Manufacturing Technologies

NC -turning machine & milling machine External procurement

Initial situation

Laser cutting machine Laser welding system Bending machine Thermoforming machine
Target situation

25
 TU Vienna Learning & Innovation Factory ,Integrated Product and
Process Planning and
Expansion of Manufacturing Technologies Design Competence

NC -turning machine & milling machine External procurement

Initial situation

Preliminary, activity-based costing vs. post calculation with real time data
Comparision of production costs from different manufacturing methods Make-or-buy decision

Laser cutting machine Laser welding system Bending machine Thermoforming machine
Target situation

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TU Vienna Learning & Innovation Factory
Installation of Software – Siemens Teamcenter

Red Bull Racing Team

Creativity & Methods
Integrated Idea Capture Competence for systematic
and Management
Idea & Innovation Mgmt.
Collaborative
Data Management

Project Management

Digital Product Development

,Integrated Product and Real-time

Process Planning and Engineering Collaboration
Design Competence

TU Vienna Slotcar Teams

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TU Vienna Learning & Innovation Factory
Industry 4.0 Use Case – Siemens Process Designer (Tecnomatix)

Production
Design
of Jig

Variant A Assembly of Slotcar incl. Time Measurement

Evaluation

Variant B Assembly of Slotcar incl. Time Measurement of

variants

Variant n Assembly of Slotcar incl. Time Measurement

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TU Vienna Learning & Innovation Factory
Industry 4.0 Use Case – Siemens Process Designer (Tecnomatix)

Production
Design Simulation
of Jig

Variant A
Evaluation

of variants
before
SOP Variant B
with Assembly of Slotcar
MTM
(TiCon tool)

Variant n

,Integrated Product and

Process Planning and
Design Competence

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TU Vienna Learning & Innovation Factory
Industry 4.0 Use Case ,Integrated
Product and Process
Planning and Design
Competence

from virtual to real

Systems and Interface

Competence

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TU Vienna Learning & Innovation Factory
Industry 4.0 Use Case

Physical Automated and Digital / Virtual Production Cell

Slotcar Component: Wheel Rim

Safty Eye

NC-Turning Machine
Articulated Robot
Transport Pallet with RFID Chip

Control Center

Mobile Device with App

Syste
m Transfer Station Systems and Interface
Simulation
Competence
Driverless Transport System
with integrated Roller Conveyor

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 Thank you!
Questions

Andreas Jäger, MSc, MBA Fabian Ranz, MSc

Fraunhofer Austria Research GmbH ESB Business School
Division Production and Logistics Management Hochschule Reutlingen
Logistics Network Planning and Design
Vienna University of Technology
Institute of Management Science
Division for Industrial and Systems Engineering

Theresianumgasse 27 | A-1040 Vienna | Austria Alteburgstraße 150 | 72762 Reutlingen | Germany

Mobil: +43 676 888 616 25 Tel.: +49(0)7121 271 3085
andreas.jaeger@fraunhofer.at Fabian.ranz@reutlingen-university.de

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Industry 4.0
Change of qualification requirements
Know How, Decision‐making competence, Problem‐solving competence

De‐skilling Enrichment of tasks

Increased spectrum of Design of rules for

Lack of process knowledge
responsibilities decision making

Restricted by technical Increased mental work via  Gain of information and

predefined decisions learning by doing communication flow

Working in an „Artificial Participation in planning and Systems overview knowledge

Intelligence Environment“ configuring tasks is required

Elimination of Digitalization and virtualization

manual and tedious work of real objects

Technology as Increased technical

assistance system requirements

Shop Floor  CPPS Planners

33
Applied Research / Mobility Project
Network of Innovative Learning Factories (NIL) Members

 Activities related to Learning Factories:

 Standardization of the „System

Learning-Factory“, including joint
development of learning modules on
Industry 4.0

 Intensification of academic exchange

between the involved institutes on the
level of researchers and students,
including a summer school on
Learning Factories
(start: summer 2015)
Sponsors
 Dissemination of related research
results in a series of papers on
Learning Factories
(start: Summer 2014)

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Applied Research Project
LOPEC
 Human specific addressed aspects of Learning Mgmt. System Self-Assessment Tool
Industry 4.0:

 Initiating of lifelong-learning through

a blended learning approach
-> self studying via an LMS
-> hands-on training in the LF

 Fostering work-life balance by self-

assessment of personal, professional
and business objectives Fraunhofer Austria Lean Assembly

 Sensitizing of demographic change

on shop floor level with the initiation
of knowledge transfer between
different age groups

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