The Industry 4.0 belongs to the most important future projects of Germanys government. One of the goals it has in the industry is to raise the efficiency of the production technology through smart IT networking. Additionally the project Industry 4.0 is supposed to secure the sustainability of the German industrial position. For the cologne AutoID experts of PANMOBIL it is definite that to successfully convert this project not only the technology needs to be optimized. MES systems, which follow the Industry 4.0 idea have to also integrate the “man in the middle” which is the “Werker 4.0” next to the thin and intelligent machine processes in order to achieve all of the objectives.
Flexible production of high-quality goods instead of mass production
With the concept “ Industry 4.0” the production facilities are supposed to become smart factories which not only assimilate to technical and logistical challenges, but also benefit from all existing resources. The integration of the staff member comes to the fore to be able to have full control of the production processes at any time. The definition of “Cyber physical systems” should be carried out, so that real life in the fabrics melt together with the virtual world. Sensors, communication interfaces and systems with embedded software transfer production information into the internet or to the own company administration software and make all the production processes transparent. Therefore a decentralized controlling of the production processes are possible. This advantage becomes more important for the German companies. No matter if in a local company or via the internet the networking of all production units and their abilities to seamlessly work together it’s a necessary requirement of the German industry.
The magic word for it is “Production on demand”. Summarized and brought to a point : to create high quality products in the shortest time, with small production units and remunerative costs. The requirement for such a production speed is the ability of all the involved production units to own an integrated intelligence. An employee needs to be able to solve a problem fast and independently and not wait for his supervisor to tell him what to do. The “Production on Demand” concept depends additionally on stopping ongoing large-scale production if need, so that a production of a small-scale is possible. Hereby it is necessary to expand the standard production chain of all employees and machineries, so that the special assignment can be done effectively. Such a special slalom between ongoing production and special assignment is only possible with flexible employees, who adapt in a flash to the changed production processes.
The “Werker 4.0” concept offers an effective “Production on Demand”
The employees are the most important connection between the machinery and the virtual production process. Their seamless integration into the modern production process is the requirement to use the “Production of Demand” efficiently. This is possible with PANMOBILs “Werker 4.0” concept. The goal: to integrate the individual staff member to the machines in the slim industry 4.0 process. Currently two PANMOBIL research projects together with the MES-specialists and SAP partner “SALT Solutions” as well as the Fraunhofer Institute develop on methods and technologies, which makes the data structure and the application scenarios in the MES environment specially for small middle class companies more efficient and easier to integrate.
Smart networking leads to high production success
What does the “Werker 4.0” concept look like in detail? The worker is equipped with his mobile AutoID tool which fulfills all requirement concerning the 4.0- environment. PANMOBIL uses mobile and hybrid AutoID data devices, which enables the worker to integrate himself into the production process 100%. Due to the RTLS (Real Time Locating) he can be located via WiFi and GPS and communicates via all possible connection paths like WiFi, GPRS, Bluetooth or also with 433 MHz with the MES-system which makes him flexible and can be called to the necessary workstation as soon as possible. In the management system, his expertise has been saved like if he is a master, foreman or a machine operator. When the worker approaches the production machine he reads the RFID tag with his AutoID scanner. This information will be transferred to the MES-server and the production machine releases the authorization due to the stored personal data and eligibility. Hereby operating errors can be avoided since only the responsible coworker can repair or operate who has the necessary requirements. There are several other information about the Worker which the production machine learns, besides the authorization to provide a secure and ergonomic operating. The physical characteristics of the worker like height can be adjusted, which provides a secure and productive working.
Networking all Industry 4.0 components we come up with so many advantages
- High flexibility
- Timely availability of production materials
- Timely access to manufacturing machines
- Timely availability of manpower
-Provision of transport resources
-Targeted utilization of testing and quality assurance capacities
Conclusion
The interactive information exchange between the “Werker 4.0” and the “Industry 4.0” based on the MES-system, provides an optimal use of all production processes for all involved machine and human resources. The secured timely availability of production materials is secured through the targeted assignment of the “Werker 4.0”. This results in a positive impact on the investment in material resources lets say tied up financial resources. Through the integration of the “Werker 4.0”- concepts into the planned, slim and accelerated working process the production factor human will be integrated in the working process and enables therefore the planned target “Production of Demand”. The main goal is the timely manufacturing in shorter production periods and with the associated backup of the production location Germany which will be reached via the application of intelligent capturing units which are tailored to the needs and understanding of the “Werker 4.0” in the MES environment.
Flexible production of high-quality goods instead of mass production
With the concept “ Industry 4.0” the production facilities are supposed to become smart factories which not only assimilate to technical and logistical challenges, but also benefit from all existing resources. The integration of the staff member comes to the fore to be able to have full control of the production processes at any time. The definition of “Cyber physical systems” should be carried out, so that real life in the fabrics melt together with the virtual world. Sensors, communication interfaces and systems with embedded software transfer production information into the internet or to the own company administration software and make all the production processes transparent. Therefore a decentralized controlling of the production processes are possible. This advantage becomes more important for the German companies. No matter if in a local company or via the internet the networking of all production units and their abilities to seamlessly work together it’s a necessary requirement of the German industry.
The magic word for it is “Production on demand”. Summarized and brought to a point : to create high quality products in the shortest time, with small production units and remunerative costs. The requirement for such a production speed is the ability of all the involved production units to own an integrated intelligence. An employee needs to be able to solve a problem fast and independently and not wait for his supervisor to tell him what to do. The “Production on Demand” concept depends additionally on stopping ongoing large-scale production if need, so that a production of a small-scale is possible. Hereby it is necessary to expand the standard production chain of all employees and machineries, so that the special assignment can be done effectively. Such a special slalom between ongoing production and special assignment is only possible with flexible employees, who adapt in a flash to the changed production processes.
The “Werker 4.0” concept offers an effective “Production on Demand”
The employees are the most important connection between the machinery and the virtual production process. Their seamless integration into the modern production process is the requirement to use the “Production of Demand” efficiently. This is possible with PANMOBILs “Werker 4.0” concept. The goal: to integrate the individual staff member to the machines in the slim industry 4.0 process. Currently two PANMOBIL research projects together with the MES-specialists and SAP partner “SALT Solutions” as well as the Fraunhofer Institute develop on methods and technologies, which makes the data structure and the application scenarios in the MES environment specially for small middle class companies more efficient and easier to integrate.
Smart networking leads to high production success
What does the “Werker 4.0” concept look like in detail? The worker is equipped with his mobile AutoID tool which fulfills all requirement concerning the 4.0- environment. PANMOBIL uses mobile and hybrid AutoID data devices, which enables the worker to integrate himself into the production process 100%. Due to the RTLS (Real Time Locating) he can be located via WiFi and GPS and communicates via all possible connection paths like WiFi, GPRS, Bluetooth or also with 433 MHz with the MES-system which makes him flexible and can be called to the necessary workstation as soon as possible. In the management system, his expertise has been saved like if he is a master, foreman or a machine operator. When the worker approaches the production machine he reads the RFID tag with his AutoID scanner. This information will be transferred to the MES-server and the production machine releases the authorization due to the stored personal data and eligibility. Hereby operating errors can be avoided since only the responsible coworker can repair or operate who has the necessary requirements. There are several other information about the Worker which the production machine learns, besides the authorization to provide a secure and ergonomic operating. The physical characteristics of the worker like height can be adjusted, which provides a secure and productive working.
Networking all Industry 4.0 components we come up with so many advantages
- High flexibility
- Timely availability of production materials
- Timely access to manufacturing machines
- Timely availability of manpower
-Provision of transport resources
-Targeted utilization of testing and quality assurance capacities
Conclusion
The interactive information exchange between the “Werker 4.0” and the “Industry 4.0” based on the MES-system, provides an optimal use of all production processes for all involved machine and human resources. The secured timely availability of production materials is secured through the targeted assignment of the “Werker 4.0”. This results in a positive impact on the investment in material resources lets say tied up financial resources. Through the integration of the “Werker 4.0”- concepts into the planned, slim and accelerated working process the production factor human will be integrated in the working process and enables therefore the planned target “Production of Demand”. The main goal is the timely manufacturing in shorter production periods and with the associated backup of the production location Germany which will be reached via the application of intelligent capturing units which are tailored to the needs and understanding of the “Werker 4.0” in the MES environment.
