Implementation of the MIALinx integration concept for future manufacturing environments to enable retrofitting of machines

Lücke, Dominik; Einberger, Peter; Schel, Daniel; Luckert, Michael; Schneider, M.; Cuk, Emir; Bauernhansl, Thomas; Wieland, Matthias; Steimle, Frank; Mitschang, Bernhard

doi:10.1016/j.procir.2019.02.084

Cited by 11 publications

(3 citation statements)

References 5 publications

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“…Different authors provide different definitions of retrofitting based on the objectives of their studies. For instance, Lucke et al [108] define retrofitting as a method of enhancing existing machinery in order to gather information about its status. Lins and Oliveira [47] on the other hand, describe retrofitting as the transformation of industrial equipment into a cyber-physical production system (CPPS).…”

Section: Different Understandings Of Retrofittingmentioning

confidence: 99%

Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

2022

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Industry 4.0 technologies and digitalised processes are essential for implementing smart manufacturing within vertically and horizontally integrated production environments. These technologies offer new ways to generate revenue from data-driven services and enable predictive maintenance based on real-time data analytics. They also provide autonomous manufacturing scheduling and resource allocation facilitated by cloud computing technologies and the industrial Internet of Things (IoT). Although the fourth industrial revolution has been underway for more than a decade, the manufacturing sector is still grappling with the process of upgrading manufacturing systems and processes to Industry 4.0-conforming technologies and standards. Small and medium enterprises (SMEs) in particular, cannot always afford to replace their legacy systems with state-of-the-art machines but must look for financially viable alternatives. One such alternative is retrofitting, whereby old manufacturing systems are upgraded with sensors and IoT components to integrate them into a digital workflows across an enterprise. Unfortunately, to date, the scope and systematic process of legacy system retrofitting, and integration are not well understood and currently represent a large gap in the literature. In this article, the authors present an in-depth systematic review of case studies and available literature on legacy system retrofitting. A total of 32 papers met the selection criteria and were particularly relevant to the topic. Three digital retrofitting approaches are identified and compared. The results include insights common technologies used in retrofitting, hardware and software components typically required, and suitable communication protocols for establishing interoperability across the enterprise. These form an initial basis for a theoretical decision-making framework and associated retrofitting guide tool to be developed.

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Section: Different Understandings Of Retrofittingmentioning

confidence: 99%

Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

2022

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“…Lucke et al [21] applied machine retrofitting in a real-world scenario based on the needs of SMEs to improve production on the shop floor and to lower the barriers for SMEs to enter the paradigm of Industry 4.0. Epple et al [22] presented retrofitting for small stationary machines through which safety was guaranteed; the processes improved in terms of reproducibility and accuracy and the times required to perform the operations decreased.…”

Section: Criteria For Assessing the Sustainability Of Production Syst...mentioning

confidence: 99%

Machine Tool Transition from Industry 3.0 to 4.0: A Comparison between Old Machine Retrofitting and the Purchase of New Machines from a Triple Bottom Line Perspective

2021

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The emerging scenario designed by digital technologies connected to Industry 4.0 is pushing towards increasingly sustainable companies. Access to the multiple benefits of digitalization (such as increased productivity, flexibility, efficiency, quality, lower consumption of resources, and the improvement of worker safety) is possible by purchasing new-generation machinery. However, thanks to smart retrofitting processes, companies can extend the shelf life of machinery without replacing it entirely. This work aims to present a framework to assess the sustainability of implementing a smart retrofitting process in old machines as an alternative to replacement from a triple bottom line (economic, environmental, and social) perspective. Due to the multidimensional and multidisciplinary variables that the proposed framework must consider, a multicriteria decision-making process is developed to identify the best transition solution from Industry 3.0 to 4.0. Then, we analyze a case study in which, thanks to the previously proposed methodology, two types of smart retrofitting on a column drill are compared with three replacement options for the same machine tool. In conclusion, the case study shows that retrofitting in the context of Industry 4.0 (or smart retrofitting), despite its high acquisition cost, is the best solution in terms of sustainability, and that this is because the smart retrofitting solution not only positively influences all parameters of digitization but also has a strong impact on the safety criterion.

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“…The key element of the Industry 4.0 strategy [ 4 ] is step-by-step development. Smart retrofitting is defined as a process of enhancing existing machinery to provide current information about its status [ 5 ] as it is the key element of digital transformation, especially in the case of small and medium-sized enterprises (SMEs) [ 6 ]. With smart retrofitting, SMEs can transfer the aspects of Industry 4.0 visions to machines or processes effectively with regard to cost and time [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

Demonstration Laboratory of Industry 4.0 Retrofitting and Operator 4.0 Solutions: Education towards Industry 5.0

Ruppert

Darányi

Medvegy

et al. 2022

Sensors

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One of the main challenges of Industry 4.0 is how advanced sensors and sensing technologies can be applied through the Internet of Things layers of existing manufacturing. This is the so-called Brownfield Industry 4.0, where the different types and ages of machines and processes need to be digitalized. Smart retrofitting is the umbrella term for solutions to show how we can digitalize manufacturing machines. This problem is critical in the case of solutions to support human workers. The Operator 4.0 concept shows how we can efficiently support workers on the shop floor. The key indicator is the readiness level of a company, and the main bottleneck is the technical knowledge of the employees. This study proposes an education framework and a related Operator 4.0 laboratory that prepares students for the development and application of Industry 5.0 technologies. The concept of intelligent space is proposed as a basis of the educational framework, which can solve the problem of monitoring the stochastic nature of operators in production processes. The components of the intelligent space are detailed through the layers of the IoT in the form of a case study conducted at the laboratory. The applicability of indoor positioning systems is described with the integration of machine-, operator- and environment-based sensor data to obtain real-time information from the shop floor. The digital twin of the laboratory is developed in a discrete event simulator, which integrates the data from the shop floor and can control the production based on the simulation results. The presented framework can be utilized to design education for the generation of Industry 5.0.

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Implementation of the MIALinx integration concept for future manufacturing environments to enable retrofitting of machines

Cited by 11 publications

References 5 publications

Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

Machine Tool Transition from Industry 3.0 to 4.0: A Comparison between Old Machine Retrofitting and the Purchase of New Machines from a Triple Bottom Line Perspective

Demonstration Laboratory of Industry 4.0 Retrofitting and Operator 4.0 Solutions: Education towards Industry 5.0

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