Fraunhofer Institute for Large Structures in Production Engineering IGP
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© Fraunhofer IGP
© Fraunhofer IGP
© Fraunhofer IGP
© Fraunhofer IGP
© Fraunhofer IGP
Production Organization
Work area
In close cooperation with industrial partners, the Production Organization team at Fraunhofer IGP develops individual solutions for the design of tomorrow’s production.
In the field of factory and logistics planning, the latest methods and tools from the Digital Factory, such as material flow simulation, 3D-layout planning and robot simulation, are applied. Among other things, this supports industrial partners in safeguarding their reorganisation or investment projects.
At shop floor level, the focus is on development and implementation of individual solutions for the smart factory in the context of Industry 4.0. These include IT-based production data capture systems, which are used in combination with the most modern positioning technology to increase the transparency of the production process. At the same time, it is becoming ever more important to ensure that employees are provided with digital information in a fast and flexible manner. In order to achieve these goals, assistance systems such as data spectacles, tablets, and other smart devices are used.
A further field of focus are ergonomic assistance systems. By using intelligent workplace systems and ergonomics simulation, assembly processes can be designed correctly and efficiently in terms of ergonomics. In addition, innovative production concepts based on human-robot collaboration are developed.
Since 2020, Head of Group Dr -Ing. Jan Sender has also been head of the Production Systems and Logistics department, which unites the Production Organisation, Automation Technology and Measuring of Large Structures working groups under one roof.
Project overview
Human-Robot Collaboration
Cobots as an innovative solution
Human-robot collaboration in mechanical joining technology
In the course of digitisation and the safeguarding of competitiveness, there is a high demand for flexible automation solutions which are used for repetitive and stressful handling tasks. Due to increasing demands on flexibility for batch size 1, fully automated robot systems cannot be used economically. Here, human-robot collaborations (‚cobots‘) enable innovative solutions. Intelligent sensor technology eliminates the need for safety fences and this means that adaptive, compact and mobile robot cells can be implemented. The strengths of the human being (cognitive, motor, sensory abilities) are combined with those of the robot (precision, high payloads, long operating times), so that employees are de-burdened and productivity is increased.
Digitisation
Finally realising the full potential
Digitisation in the skilled crafts sector
Despite the enormous importance of adhering to fixed deadlines in trade businesses such as interior fitters, the scheduling is largely analogous. In general, at present, the potential of digitisation is often not fully exploited in the trade sector. In order to exploit the full optimisation potential of this technology, a system
for complete digital assembly planning was developed in cooperation with a staircase manufacturer from Mecklenburg-Western Pomerania. All relevant data originates from defined interfaces to overarching production software systems and on-site digital data capture processes. Consistent data management, system-supported process structures and the application of role models allow for an increase in transparency of the holistic planning process.
Auxiliary systems
Optimally coordinate process steps
Auxiliary systems in batch 1 assembly size
Particularly in the assembly of small batches up to batch size 1, attempts at automation are often uneconomical, so that humans are used due to their flexibility. Aiming for a smooth, fault-free process and a general reduction in throughput time requires auxiliary systems. Various approaches are being pursued and in a funded process innovation, a system for visual support as well as the process-dependent provision of the components to be installed in the control panel has been developed. This is based on the digital linking of the necessary components and work instructions with the respective process steps. The results include a projection for visual support of the process, optimised material supply and holistic process mapping.
Project overview
Projects
Services
Factory Planning and Logistics – Digital Factory
- Productivity and potential studies for production systems
- Digital factory design by means of material flow and kinematic simulation to secure investment decisions
- 3D layout planning in a virtual reality environment for new planning and reorganisation projects
- Optimisation of production and logistics systems on the basis of lean production methods
Production planning and control - industry 4.0
- Design and implementation of intelligent algorithms for production planning and control
- Development of innovative software and hardware solutions for flexible production management (production control centre, fault management, etc.)
- Introduction of digital track and tracing systems based on Auto-ID technologies (RFID, localisation, etc.) for complete traceability of orders
Ergonomics and work design – workers of the future
- Ergonomic analysis at the workplace (including ergonomic simulation)
- Implementation of innovative work systems based on human-robot collaboration
- Development of ergonomic workplace systems and intelligent handling systems for weightless handling of loads
- Implementation of digital employee assistance systems for production, logistics and maintenance
Equipment
Production design
- Plant Simulation (material flow simulation)
- visTable touch VR (collaborative factory planning)
- Process Simulate, Delmia (3D and robot simulation)
- Tool tracking systems
- Production data acquisition system
Ergonomics
- Ergonomic assembly workstations
- Process Simulate Human, Delmia, ICIDO VDP (ergonomics analysis)
- Lightweight robots for human-machine collaboration
Virtual Reality
- Passive one-sided powerwall
- Tracking unit for ergonomics analysis
- Catia V5, Autodesk 3D Studio Max (CAD and 3D visualisation)