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The manufacturing industry has to exploit trends like “Industrie 4.0” and digitization not only to design production more efficiently, but also to create and develop new and innovative business models. New business models ensure that even SMEs are able to open up new markets and canvass new customers. This means that in order to stay competitive, SMEs must transform their existing business models.
The creation of new business models require smart products. The required data base for new business models cannot be provided by SMEs alone, whereas smart products are able to provide a foundation, given the creation of smart data and smart services they enable. These services then expand functions and functionality of smart products and define new business models.
However, the development of smart products by small and medium-sized enterprises is still lined with obstacles. Regarding the product development process the inclusion of smart products means that new and SME-unknown domains diffuse during the process. Although there are many models regarding this process there appears to be a substantial lack of taking into account the competencies enabled by the implementation of digital technologies. Hence, several SME-supporting approaches fail to address the two major challenges these enterprises are faced with. This paper generally describes valid objectives containing relevant stakeholders and their allocation to the phases of the product life cycle.
Within each objective the potential benefit for customers and producers is analyzed. The model given in this paper helps SMEs in defining the initiation of a product development project more precisely and hence also eases project scoping and targeting for the smartification of an already existing product.
Smartification and digital refinement of products to enable the design of smart ones is a pivotal challenge in the manufacturing industry. Companies fail to design smart products due to missing knowledge of digital technologies and their integral part in product development processes. This paper presents a methodology that enables the derivation of digital functions for smart products through selected cases in manufacturing usage. We develop a morphology that consists of digital functions for smartification. In this context, we explained and derived characteristics by a set of examples regarding smart products in the manufacturing industry. Our methodology reduces the time spent initiating a development project with the focus on smartification.
The number of available technologies is constantly rising. Be it additive manufacturing, artificial intelligence (AI) or distributed ledger technologies. The choice of the right technologies may decide the fate of a company. Due to the overwhelming amount of information sources, regular technology market research becomes increasingly challenging, especially for SMEs. In order to assist the technology management process, the authors will introduce the architecture of an automated, AI-based technology radar. The architecture will automatically collect data from relevant sources, assess the relevance of the respective technology (i.e. their maturity level) and then visualize it on the radar map.
Manufacturing companies face the challenge of selecting digitalization measures that fit their strategy. Measures that are initiated and not aligned with the company’s strategy carry the risk of failing due to lack of relevance. This leads to an ineffective use of scarce human and financial resources. This paper presents a target system to help companies select relevant digitalization measures compliant with their strategy for IT-OT-integration projects. The target system was developed based on literature research and expert interviews, and later validated in two use cases. The target system considers the goals of production companies and combines them with digitalization measures. The measures are classified by different maturity levels required for their realization. Thus, the target system enables manufacturing companies to evaluate digitalization measures with regards to their strategic relevance and the required Industrie 4.0 maturity level for their realization. This ensures an effective use of resources.
Digitalization and Industry 4.0 continue to shape our industrial environment and collaboration. For many enterprises, a key challenge in moving forward in this matter is the integration of their shop-floor systems (hard- and software) with their office-floor systems to harvest the full potential of industry 4.0.
A multitude of different technologies and respective use-cases available on the market leave many companies startled. This paper presents a set of use-cases for IT-OT-Integration to bring transparency into a company’s digital transformation.
Additionally, a technical requirements profile for integrating IT- and OT-Systems based on the use cases is presented. Both, use-cases and their requirements, guide companies in selecting the digitalization measures that fit their current situation and help in identifying technical challenges that need to be addressed in the transformation process.
The digital transformation is changing the way companies think and design their manufacturing environment. Both due to the increasing number of connections between IoT-Devices, tooling machines, and production lines and the phenomenon of the convergence of IT and OT, systems are becoming more complex than years ago. Organizational and cultural changes within manufacturing companies strengthen this trend and form Industry 4.0 environments and cyber-physical production systems (CPPS). As these systems do not longer stay alone but are connected to each other and the company’s outside, the size of the potential attack surface is increasing as well. Besides that, manufacturing companies, small and medium-sized in particular, are facing complex challenges based on lack of knowledge, budget, and time to understand as well as to interpret their current situation and risk level and therefore to derive necessary counter-measures. Efficient as well as pragmatic tools and methods for these companies do not exist. This paper shows a research approach in which the company-specific set-up of Industry 4.0 environment and CPPS is characterized by its potential vulnerabilities. This enables companies to evaluate their risk potential before setting up this kind of environments and to undJo,erstand the potential consequences more precisely. By doing so, companies can derive and prioritize important counter-measures and so to strengthen their level of cyber-security efficiently. This will decrease the number of cyber-security attacks and increase the company’s competitiveness.
Smart Service Prototyping
(2021)
This chapter is dedicated to prototyping, one of the steps of the Smart Service Engineering Cycle. It includes three phases: realizing core functionalities, developing core functionalities, and testing functionalities with customers. In order to realize prototypes successfully, methodical aspects of rapid IoT prototyping are used.
First of all, this chapter explains the motivation behind rapid prototyping and provides an introduction to the approach. The concept of rapid IoT prototyping is based on the idea of developing short-cycle solution variants on the basis of benefit hypotheses or benefit promises and user stories focusing on them. The aim is to achieve data acquisition, aggregation, linkage, processing, and finally visualization by developing it in a vertically integrated manner. Once this is accomplished, the prototype can be evaluated with customers, which also makes it possible to put the benefit hypotheses to the test. Finally, the collected customer feedback can be incorporated more quickly into the development process of new prototype versions, leading to a continuous improvement of the user experience as well as a constant focus on prioritizing the user. Another component of rapid IoT prototyping is working and thinking in terms of minimum viable products (MVP), i.e., solutions that do not meet all of the defined requirements in the first iteration, but are nevertheless already functional. [https://link.springer.com/chapter/10.1007/978-3-030-58182-4_6]
In order to introduce load management in the manufacturing industry, some obstacles need to be pointed out. This paper presents a feasible approach on how to implement load management measures in companies.
To this end, load management and energy management are explained and distinguished in a first step. Subsequently, the implementation method is introduced. Therefore, by means of this paper, companies will be enabled to use load management measures and significantly reduce their energy costs. In the second part of the paper, the introduced approach will be applied.
Hence, a use case of a manufacturing company is described. Alongside energy analyses with consumption data, specific measures are presented.
Low-Level-Code Based Production Model For Improving Material Requirements Planning In ERP Systems
(2021)
Single and small-series production companies face specific challenges, such as variable customer order decoupling points (CODP), decreasing quantities and rising cost pressure. This leads to a increasing production complexity and growing requirements on Production Planning and Control (PPC). Digitalization’s direct links between objects, people, and machines as well as detailed recording of production progresses opens new solutions for PPC. However, volume of data and the required processing times are increasing. Thus, to achieve near-real-time data processing, a decentralization of decision-making systems can be observed. The function Material Requirements Planning (MRP) is PPC’s original need for Enterprise Resource Planning (ERP) systems. Here, PPC’s overall problem (to fulfil primary requirements for products) is divided into subproblems (to fulfil single production orders). Especially companies characterized by an organization in accordance to the workshop principle, high in-house production depth and variable CODP are confronted with high dynamics in their production systems. This ends in significant differences between primary requirements (overall problem) and single production orders (subproblems). Ultimately, these insufficient PPC data result systematically in a non-optimal overall solution despite optimal partial solutions. This publication combines PPC’s fundamentals from existing commonly known models with current implementation concepts of ERP systems. A newly developed Low-Level-Code based Production Model provides explanations for deviations between the overall problem and its subproblems. Furthermore, information flows of PPC can be structured between a periodically actualized vertical and an event driven horizontal information flow. These recognitions lead to an improvement of PPC by ERP systems.
Local implementation projects for sector coupling play an important role in the transformation to a more sustainable energy system. Despite various technical possibilities, there are various barriers to the realisation of local projects. Against this backdrop, we introduce an inter- and transdisciplinary approach to identifying and evaluating different power-to-X paths as well as setting up robust local implementation projects, which account for existing drivers and potential hurdles early on. After developing the approach conceptually, we exemplify our elaborations by applying them to a use case in the German city of Wuppertal. It can be shown that a mix of several interlinked interdisciplinary methods as well as several participatory elements is suitable for triggering a collective, local innovation process. However, the timing and extent of end-user integration remain a balancing act. The paper does not focus on a detailed description of power-to-X (PtX) as a central pillar of the sustainable transformation of the energy system. Rather, it focuses on the innovative methodological approach used to select a suitable use path and design a corresponding business model. The research approach was successfully implemented in the specific case study. However, it also becomes clear that the local-specific consideration entails limitations with regard to the transferability of the research design to other spatial contexts.