Developing a learning factory to increase resource efficiency in composite manufacturing processes

Learning factories serve as platforms to ensure research findings are disseminated into industrial practice. A critical success factor for an effective technology transfer via a platform is the definition of a representative process chain. Due to the increasing demand for lightweight components in automotive industry, established materials like steel are partially substituted by composites materials. Hence the Green Factory Bavaria was established as learning factory to demonstrate energy efficient manufacturing processes for composites. This paper contains the process and workpiece definition necessary to ensure a wide transferability of research results into various industries. Using the developed methodologies of flexible measurement concepts and machine upgrading, suitable efficiency measures are integrated in a learning concept The obtained energy savings are discussed for selected process steps like cutting, cleaning and assembly technologies.