Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Learning process planning for special machinery assembly

2018 , Menn, Jan-Philipp , Sieckmann, Felix , Kohl, Holger , Seliger, Günther

Special machinery manufacturers provide customer specific solutions. These specific solutions create tremendous challenges for employees during first assembly, erection at the customer site and future service activities. Especially in serial production, Learning Factories proved to be an effective solution to convey competencies for employees on how to improve production related processes. In special machinery, product specific competencies like working principle and built up of machines are additionally important. Therefore, to utilize the advantages of Learning Factories in special machinery it is necessary to shift the focus from processes to products. This results also in additional requirements regarding versatility of the technical infrastructure. A learning process planning approach which addresses requirements of special machinery assembly, has been designed. It was exemplarily applied for the knowledge transfer regarding the assembly process of an integrally geared compressor. As every product in special machinery is unique, learning process steps have to be adapted for each product. Therefore, a shorter assembly learning process is necessary to cope with continuing product innovations and customer requirements. Around a basic compressor casing that represents the least common denominator regarding product variety, specific interchangeable sub-assemblies for product variants are implemented that utilize digital content. This allows a fast adaption to different product variants.

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Learning Factory for Industry 4.0 to provide future skills beyond technical training

2018 , Schallock, Burkhard , Rybski, Christoffer , Jochem, Roland , Kohl, Holger

The paper will describe the design of a learning factory for Industry 4.0 that addresses the growing demand for future skills of production staff. Existing learning factories often focus on the technical skills whereas this learning factory also trains decision making, group work and performance monitoring skills. The paper refers to the existing categorizes of learning factories and unveils its numerous features. The conceptual design includes theoretical and practical parts, which prove to be successful in a German learning factory that was realized by the authors. Especially, for the industry 4.0 environment, the layout consists of three stages of a production system, from manual to automatized manufacturing. The practical tasks cover the introduction of smart devices, connection of information flows as well as monitoring of performance. The didactical design of the training program provides a sustainable approach by not only realizing training courses but also includes preparation with management, mid-term coaching and success monitoring after the training. The learning factory is a part of a whole research institute for intelligent manufacturing in China including consultancy and application support. One of the underlying goals of the learning factory is to enable production staff for change management, decision making and innovation.

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