Here you will find details of our consultancy services with detailed information and contacts.
Virtual, flexible, digitally connected. 365 days a year, 24/7. Smart, intelligent and autonomous. That is the production of the future! That is Industrie 4.0! As pioneers for innovative technologies and rapid processes, the demands of today’s production systems are greater than ever. Companies must grasp the enormous potential and opportunities of the fourth industrial revolution, as well as the complex needs of the market, if they are to optimize existing processes and meet their customers’ needs with confidence.
Production assessment 4.0 is a consultancy product that draws on a comprehensive analysis of information flow and the expanded value stream to identify your company’s level of maturity with respect to lean management and Industrie 4.0. Based on this, we work with you to identify specific recommendations for action in the form of applications and user stories for a connected and digital future. Our maturity assessment helps us to work out the extent to which you have already implemented lean management methods within your company and the points at which the effectiveness and efficiency of your value creation stream could be boosted through Industrie 4.0. The maturity assessment model is embedded in a comprehensive and lean assessment approach in order to systematically gather and analyze the information needed to identify the maturity level. It incorporates visions regarding Industrie 4.0 and yields realistic and personalized development goals.
Phase 1: Pathfinding workshop with information flow and value stream analysis
The first workshop is an opportunity to define the assessment’s strategic framework. Following a kick-off meeting, the situation analysis is carried out with the help of various workshops and a production tour. At this stage, the focus is not just on production processes, but on the entire value creation chain from customer to customer. It ends with the determination of maturity levels regarding lean management and Industrie 4.0.
Phase 2: Outlining of initial Industrie 4.0 potential
In the next phase, we evaluate the situational analysis in detail in order to fix specific fields of action. We then use these to jointly come up with potential Industrie 4.0 applications in the course of further workshops. This allows us to ensure that the fields of action are approached in line with the user’s needs. Applications are then evaluated and prioritized in an initial assessment.
Phase 3: Detailed Industrie 4.0 applications and detailed evaluation
The applications determined in phase 2 are now fleshed out in detail in the form of user stories, and we define the necessary conditions for their implementation. A detailed evaluation examines each individual user story for impact and quantitative and qualitative benefit, before ranking them within the overall context.
Phase 4: Implementation plan
To conclude, we define the target value stream, an implementation roadmap and a potential migration path. We also identify and plan the necessary organizational and process modifications. If desired, we will assist you in choosing a company to help you achieve your vision and will support you as you implement the defined roadmap.
Phone +49 711 970-2071
Phone +49 711 970-2208
Robot safety is an increasingly complex issue:
Applying the involved standards of robot safety places great demands on companies that offer robot systems, be it in the shaping of business processes, product development or quality management. For those who can master these standards, however, there is also the chance to really stand apart in the marketplace. Here, you can draw on our experience: Fraunhofer IPA has been actively involved in the work of the standardization body for robot safety for many years now, and is always up to date on the latest developments.
Fraunhofer IPA supports you in all phases of system development, in the assessment of system safety and in the implementation of the necessary processes.
Phone +49 711 970-1152
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Today we stand at the cusp of the fourth industrial revolution. So far, only a few companies have gained wide-ranging experience with the manufacturing-related applications of Industrie 4.0. Even fewer offer ready-made solutions. In the long term, however, experts expect digitalization to yield an efficiency boost of 30 to 50 percent when averaged across all of a company’s departments. Offering digital value-added services connected to one’s own product is becoming more and more popular – to build new business models, attract new customer groups or generate new sources of income within an existing customer base.
Our “Industrie 4.0 business navigator” allows you to harness the potential of digitalization. We work with you on site to analyze the strengths and weaknesses of your company. The goal is to uncover potential that could be exploited with the help of Industrie 4.0 technologies. Potential applications are evaluated with respect to the cost, time and expertise involved, and the investment balanced against the expected gain. This allows us to develop tailored recommendations for action, which you can use to implement a durable strategy for the digitalization of your company.
In order to develop the best possible recommendations for action, we begin with a review of existing production and IT systems within your company.
Phase 1: Readiness check
Which technologies do you use in production and in your products? This question has a decisive influence on the approach to implementing new applications. The result of this assessment serves as a benchmark for your company.
Phase 2: Analysis of potential
Where can you access potential in your production process and in your products? Our experts visit you on site to come up with a list of potential Industrie 4.0 applications.
Based on the starting situation and assessment of potential, we then evaluate the potential Industrie 4.0 applications.
Phase 3: Roadmap
Which applications should be implemented first in order to achieve quick results or achieve optimal strategic alignment? This decision has to do not only with the optimization potential, but is also significantly influenced by your company’s starting situation and overarching business goals. In this final phase, we develop your personal roadmap, which serves as a recommendation for action in implementing the Industrie 4.0 applications that hold the most promise for your business.
Phone +49 711 970-1642
Phone +49 711 970-1255
Whether it is product development, design, production or business modeling, additive manufacturing techniques open up whole new creative approaches. However, they also place new demands on the manufacturing process itself. If additive manufacturing is to firmly establish itself in the industry of the future, reliable product quality is an absolute necessity. There is a need to adhere to geometric tolerances as well as to certify products according to exact, quantifiable, physical parameters. Component quality must be sustained and reproducible at all times.
It remains difficult to reliably guarantee the quality of additively manufactured components. To date, additive manufacturing has had no quality standards; a generally accepted quality management system likewise does not exist. With regard to the additive process chain, there are five aspects essential to quality management: the production system, the material, the manufacturing process, the product and the final product processing. It is still a challenge to identify, control or influence the parameters influencing quality. There is an urgent need for a systematic approach, planning and qualification procedure.
Our consultancy is designed to provide you with the basic know-how you need to develop a smart inline quality module for additive manufacturing. This quality module encompasses the following:
Phase 1: Identifying inline defects and errors
In the first phase, we analyze your manufacturing processes using a deductive technique that has been combined with a qualitative top-down error tree analysis. This identifies inline effects, defects and errors, allowing for the definition of parameters and specification of tasks – for future inline quality control and in-situ process optimization and regulation. We also present a ranking technique for weighting effects, defects and errors.
Phase 2: Action plan for inline quality control
The subsidiary objectives of the action plan are as follows:
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As we connect machines using smart information technology, production management becomes more and more flexible. By using new data – from sensors and actuators, for instance – management software can provide an even more precise picture of a production system’s status. Predictive maintenance is just one example, and more and more activities can now be automated. As systems become intelligent, there is a necessary shift in the allocation of labor among humans and machines. Machines are gradually taking on management tasks traditionally completed by humans. And employees are faced with a fundamental shift in the tasks they are expected to complete.
For manufacturing companies, the road to Industry 4.0 is full of challenges and fraught with risk. Experience in the management of smart and connected systems is a must. Strategies to protect oneself against system disruption require comprehensive expertise. Smart factories offer highly flexible production, but rely on the implementation of standardized process modules to enable processing. Humans and smart machines must collaborate to master the process, and that calls for systematic planning and qualification. “Smart Blueprint 4.0” is a planning aid we have developed to help you in this task.
Step 1: Modeling current work processes
The first step is to pick out key work processes affected by digitalization. We then model the current status of these processes – considering the human, production technology and smart software aspects – in a way that is accessible to all.
Step 2: Developing PLAN scenarios
The second step focuses on developing PLAN scenarios that outline the future division of labor between humans and smart machines, with the goal of:
Step 3: Testing system mastery in a virtual environment
In the third step, PLAN work processes are implemented in the virtual environment using interactive avatars. Other possibilities include
Phone +49 711 970-2223
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It is not just communication technologies that are advancing in the course of Industrie 4.0. We also have more and more contact with increasingly diverse communication partners. Agile project management and flexible working are transforming the nature, duration and frequency of meetings.
What remains the same in spite of all the changes, however, is the need for reliable communication in a protected environment. As technology continues to develop, it will become all the more valuable to have communication that appeals to the emotions and encourages creative exchange.
Spontaneous online meetings designed to solve a problem quickly and creatively will become more and more established as a form of communication. As work processes become more complex and more abstract, visualization techniques and collaborative solutions will continue to gain in importance. The latest technology allows for increasingly efficient conversation and moderation in the virtual sphere. In order to use this effectively, however, one needs familiarity with the techniques involved and regular practice.
“Virtual Collaboration 4.0 – Training in vitero” is our virtual training package and offers:
Module 1: The technical options for your virtual meeting
Module 2: Special design elements in the virtual space
Module 3: Transfer to individual work context
Phone +49 711 970-2178
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Industrial production is undergoing rapid technological development. The real and virtual worlds are combining to form the Internet of Things and Services: Industrie 4.0. It is now assumed that the role of people in industrial production will change significantly as a result of cyber-physical systems (CPS) – much as the internet transformed communication. With the introduction of cyberphysical production systems that are closely connected with each other and with the internet, we can expect long-term increases in the productivity and flexibility of manufacturing companies.
Industrie 4.0 is more than a technical topic, as it also affects the skills that employees need. It involves systems in which decision making is shared among humans and machines, with one influencing the other and vice versa. It is a fundamental alteration to the human-machine interface, and how this is managed has significant implications – not least for the skills required of us in the future. That is why special skills development initiatives are so important.
In light of the fundamental technological transformations in information, production and communications technologies, any forward-looking personnel policy must be quick to identify future skills requirements and any potential skills shortages.
Phone +49 711 970-2042
Phone +49 711 970-2027