Classification of a Hybrid Production Infrastructure in a ... · PDF fileClassification of a...

© WZL/Fraunhofer IPT

Classification of a Hybrid Production

Infrastructure in a Learning Factory

Morphology

Sven Cremer, M.Sc.

Scientific Research Assistant

WZL at RWTH Aachen University

7th CIRP Learning Factory Conference

Darmstadt, April 5th 2017

Seite 2© WZL/Fraunhofer IPT

Summary and Discussion4

Hybrid Production in the Context of Learning Factory Morphology3

Hybrid Production Infrastructure in the Aachen Demonstration Factory2

Learning Factories in Disruptive Times1

Agenda






Agenda


The components of VUCA describe an environment that confronts companies with new

huge challenges.

We live in a VUCA world

CComplexity

Development of

derivatives in

automotive industry

1982 1994 2006 2015

Fluctuation and level of volatility index

VDAX-New in the past three years

17,703VVolatility Sep

´15

Nov

´15

Jan

´16

Mar

´16

May

´16

Remain

59%

Leave

41%

Prognosis of the bookmakers for

the Brexit vote (June 14, 2016)

UUncertainty

Source: Bennett/ Lemoine (2014); Bennett/ Lemoine (2014); Onvista.de (2016)

AAmbiguity


In a disruptive time changeability is not sufficient anymore.

The need for companies to learn and adapt agility increases.

Today we manage the challenges of a VUCA world with flexibility

and changeability of our production systems

Agility:

Real-time capability

Heuristic decision-making ability

Adaptability

Agility cannot be planned,

it has to be learnedFlexibility Changeability Agility

stable dynamic disruptive

Req

uir

em

en

ts

t

Historical chart DAX 30 from 1967 to 2016

Source: Finanzen.net (2016)


The ability for structural learning is a key element to achieve agility

Structural learning becomes core competence

Learning faster means winning the game

Learning Factories provide an Environment for Structural Learning

Learning Factories…

implement new ways for

building competencies and for

lifelong learning to adapt to

the VUCA environment 1, 2, 3

enable new production

technologies to be put on trial

provide an environment of

limited risk of failure or major

cost pressure 4

serve as an advantageous

surrounding for testing new

work processes, new machinery

and production of prototypes 4

promise a setting for agile

learning and thereby support a

company‘s long term success

in the future 5

Sources: [1] BMBF, Zukunftsprojekte der Hightech-Strategie (2012) [2] ElMaraghy et. al. (2009) [3] Adolph et. al. (2014) [4] Abele et. al. (2015) [5] Bender et. al. (2015)

IMAGE REMOVED






Agenda


The Aachen Demonstration Factory Provides a Learning Experience

in an Actual Production Setting

Aachen Demonstration FactoryHybrid Production Infrastructure 1

Science and Academia- Research

- Education

- Training

Industry- Real production

- Factory

- Marketable products

[1] Concerning the hybrid concept also refer to the keynote by Dr. Thomas Gartzen in the session “Learning factory concepts” at 14:00 today


IMAGE OF

SHOP FLOOR

REMOVED

Shop Floor Management

The Production Value Stream simultaneously serves as an

Educational Setting with Various Use Cases

Area 2: Smart Warehouse Area 3: Production Area 5: Performance ManagementArea 4: Kart AssemblyArea 1: Supply Chain Lab

3

24

1

KPI Visualization

Shop Floor Management

via Data Evaluation and

Display

Warehouse

Production Monitoring

Assembly

Pick-by-Voice System

Equipment-Assisted

Commissioning

Real Time Locating

System (RTLS)

Collect Production Time

and Location Data

3D-CAD

Instruction

Fast Assembly

and Learning

Support






Agenda


Classification of the Aachen Demonstration Factory

in a Learning Factory Morphology

The Aachen Demonstration Factory is to be classified in the Learning Factory

Morphology by Abele et. al. *

Business

ModelPurpose Process

Product Didactics MetricsSetting

Abele, Metternich, Tisch, Chryssolouris, Sihn, ElMaraghy, Hummel, Ranz. Learning Factories for research, education and training; The 5th Conference on Learning Factories, 2015.

Image Source: DFA



in a Learning Factory MorphologyP

art

1:O

pera

ting M

odel

Operator

trainer

development

Initial funding

Ongoing funding

Funding continuity

Business Model for trainings

professor

own development

internal funds

short term funding (e.g. single funding events)

academic institution

university college BA

non-academic institution

vocational / high school

chamber unionemployers‘ association

industrial network

profit-oriented operator

consultingproducing company

researcher student assistanttechnical expert / int.

specialistconsultant educationalist

external assisted development external development

public funds company funds

internal funds public funds company funds

mid term funding (projects and programs < 3 years)

long term funding (projects and programs > 3 years)

closed models(training program only for single company)

open models

club model course fees

Operating Model

Applies to DFA Addition to Morphology




art

2: P

urp

ose &

Targ

ets

education

test environment / pilot environment

vocational training research

advertisement for production

pupils

employeesstudents

bachelor masterPhD

studentsappren-

ticesskilled worker

semi-sk. worker

un-skilled

managers

lower mgmt middle mgmt top mgmt

entr

e-p

ren.

free-lancer

unem

-plo

yed

open p

ublic

main purpose

secondary purpose

target groups for education and training

group constellation

targeted industry

subject relat. learning contents

role of LF for research

research topics

homogenous

mech. & plant eng.

research object

Heterogeneous (Knowledge level, hierarchy, students + employees, etc.)

automotive logistics transportation FMCG aerospace

chemical industry construction insurance / banking textile industry …electronics

research enabler

production management & organization

production management & organization

resource efficiency lean mgmt automation CPPS work system design HMI design …

resource efficiency lean mgmt automation CPPS change-ability HMI didactics …

industrial production

Purpose and Targets





art

3: P

rocess

product life cycle

factory life cycle

order life cycle

indirect functions

material flow

process type

manufact. organization

degree of automation

manufact. methods

manufact. technology

product planning

manuf.

assem

bly

logis

tic

service

maintenance recycling

picking, packaging shipping

recycling

investm. planning

configuration &order order sequencing product. planning / sched.

prod. development product design rapid prototyping

factory concept process planning ramp-up

SCM sales purchasing HR Finance / controlling QM

continuous production

physical

discrete production

mass production series production small series production on-off production

fixed-site manufacturing work bench manufacturing workshop manufacturing flow production

manual partly automated / hybrid automation fully automated

cutting primary shaping additive manufact. forming joining coating change mater. properties

chemical biological

Process





art

4: S

ettin

g

learning environment

environment scale

work system level

enablers for changeability

changeability dimensions

IT-integration

purely physical (planning + execution)

IT before SOP (CAD, CAM, simulation)

physical value stream of LF extended virtually

purely virtual (planning + execution)

physical LF supported by digital factory (see line “IT-integration”)

scaled down life size

work place work system factory network

mobility modularity compatibility scalability universality

layout & logistics product features product design technology product quantities

IT after SOP (PPS,ERP, MES) IT after production (CRM, PLM…)

Setting





art

5: P

roduct

materiality

product origin

marketability of product

no. of different products

no. of variants

no. of components

further product use

form of product

1 product

immaterial (service)

2 products 3-4 products >4 products

acceptance of real orders

flexible, developed by participants

material (physical product)

bulk cargogeneral cargo

own development development by participants external development

available on the marketavailable on the market but

didactically simplifiedfunctional, could be available on

the marketwithout function/application, for

demonstration only

1 variant 2-4 variants 4-20variants …

1 component 2-5 components 6-20 components 21-50 components > 100 components51-100 components

disposalre-use/recycling exhibition/display give-away sale

Product





art

6: D

idactics

learning success evaluation

evaluation levels

type of training

standardization of trainings

type of learn. environment

role of the trainer

communication channel

learn. Scenario strategy

competence classes

theoretical foundation

degree of autonomy

dimensions learn. targets

instructed

feedback of participants learning of participants return on trainings/ ROI

instruction

transfer to the real factory econ. impact of trainings

standardized trainings

prerequisite in advance (en bloc) afterwardsalternating w/ pract. parts based on demand

written knowledge test oral knowledge test written report oral presentation practical exam none

customized trainings

tutorial practical lab course project workseminar workshop

presenter moderator coach instructor

self-guided/ self-regulated self-determined/ Self-organized

onsite learning (in the factory environment) remote connection (to the factory environment)

greenfield (development of factory environment) brownfield (improvement of excising factory environment)

cognitive affective psycho-motorical

technical and methodological competencies

social & communication competencies

personal competenciesactivity and implementation

oriented competencies

demonstration closed scenario open scenario experience / do it yourself

Didactics





< 1 day

Part

7: M

etr

ics

no. of participants per training

no. of standardized trainings

aver. duration of single training

participants per year

capacity utilization

size of LF

FTE in LF

1-5 participants

1 training 2-4 trainings

5-10 participants > 30 participants

5-10 trainings > 10 trainings

1-2 days 3-5 days 5-10 days 10-20 days > 20days

10-15 participants 15-30 participants

< 50 participants 50-200 participants > 1000 participants201-500 participants 501-1000 participants

< 10% 10-20 % 76-100%21-50 % 51-75 %

< 100 sqm

< 1 2-4 > 155-9 10-15

100-300 sqm 300-500 sqm 500-1000 sqm 1000-2000 sqm >2000 sqm

Metrics





6 4

1a 1c

6

4

5a 3b

1a

2 43a

1b 1c

4

21a

1b 1c

4

6

3b1a

1c

Company funds (ext.)

Aca

de

mia

ResearchTrainingTeaching

Op

era

tor

Co

nsu

ltin

gIn

du

str

y

2

5a

5b

3a

Learn

ing E

nvironm

ent

rea

lvirtu

al

2

7

5b

3a

Learn

ing C

hannel

On-s

ite

rem

ote

2 7

3b3a

ServicePhysical, not

on marketPhysical,on market

7

3a

5a5b

Public funds

Internalfunds

6

3b

5a

5b

7

1a1b

1b

1b

1c

7

4Univ. Windsor – Research

Scenario

5a1a Darmstadt – Industrial scenarioMcKinsey –

Training Network

5b1b Darmstadt – Education scenarioMcKinsey –

Virtual learning factory

61c Darmstadt – Research scenarioESB Reutlingen –

demonstration scenario

2 7Vienna – Education scenarioDemonstration Factory Aachen

Hybrid Production Scenario

3b Patras – Lab-to-factory LF in the broader sense

3a Patras – Factory-to-classroom LF in the narrow sense

Operating Model

The Demonstration

Factory in Aachen is

a Learning Factory in

the narrow sense:

On-site learning

Set in a real

environment

Operated by

academic

institutions for

training, research

and production

Manufacturing of

physical marketable

products

Funded publically

and internally alike






Agenda


Summary

Today’s Volatility, Uncertainty, Complexity and Ambiguity Require

Organizational Learning and Underline the Significance and

Importance of Learning Factories

The Aachen Demonstration Factory was Successfully

Classified within the Learning Factory Morphology

Consensus presented by Abele et. al.

Slight Amendments Were Suggested to the Morphology

in Order to Cater for the Hybrid Setting

© WZL/Fraunhofer IPT

Thank You.

Sven Cremer, M.Sc.

Scientific Research Assistant

WZL at RWTH Aachen University

Steinbachstraße 19

D-52074 Aachen

Tel.: +49-241-80-26265

[email protected]

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