A framework for implementing Industrie 4.0 in learning factories

Du Plessis, Carl Jan (2017-03)

Thesis (MEng)--Stellenbosch University, 2017.

Thesis

ENGLISH ABSTRACT: Globalisation and resource scarcity have drastically increased the intensity of competitive manufacturing, forcing companies to deliver on higher expectations with less staff and minimal resource usage. This situation has ushered forth a new industrial revolution, Industrie 4.0. This new revolution, analogous to coined phrases such as smart factories and the internet of things, has given way to exponential advances in technologies. The implementation of these technologies, should in theory, enable firms to reduce the negative impact of their operations on their triple bottom line and improve efficiencies. However, whilst the implementation of these technologies provides seeming and logical improvements; how to implement them, with what, and where is still largely unclear and can lead to total abolishment due to the lack of knowledge. A decision support framework is proposed in this thesis for aiding companies, specifically small and medium enterprises (SMEs), and learning factories in their implementation efforts towards Industrie 4.0. Industrie 4.0 is broken down into basic levels corresponding to those found in learning factories and SMEs. These levels are put forward as dimensions of the framework, ranging from objects and technologies to Industrie 4.0 applications in SMEs and competencies taught in learning factories, offering the user a visual representation of the practical implementations needed for Industrie 4.0. This framework can be used in three different ways. The first, is a greenfield design, aimed at new learning factories who wish to develop industry related competencies and skills. In this greenfield design, the framework suggests implementation guidelines for the user based on the targeted competency criteria that the user seeks to develop through an Industrie 4.0 perspective. The second, an Industrie 4.0 greenfield design, is for the case where a user seeks to implement Industrie 4.0 concepts with the purpose of enhancing traditional operations in SMEs or showcasing the possibilities of Industrie 4.0 in learning factories. The third application is for redesigning the current operations within a learning factory or SME with Industrie 4.0 in mind. The Industrie 4.0 redesign is aimed at learning factories and SMEs who wish to implement Industrie 4.0 concepts using the infrastructure and equipment they already have. The decision support framework is implemented in two learning factories, representing the two extreme cases of the framework, namely the Industrie 4.0 redesign and the greenfield design. The framework is applied in a technologically-advanced environment in Germany, and successfully allows for the incorporation of three distinct Industrie 4.0 applications in an already well-established learning factory. For further validation, the framework is applied at the Stellenbosch University learning factory to showcase the case where the complete design of a learning factory is commenced with the aim of incorporating Industrie 4.0 into the desired learning competencies.

AFRIKAANSE OPSOMMING: Globalisering en skaarsheid van hulpbronne het drasties die intensiteit van mededingende vervaardiging laat toeneem, en dwing maatskappye om op ’n ho¨er verwagtinge met minder personeel en minimale gebruik van hulpbronne af te lewer. Hierdie situasie het ingelui tot ‘n nuwe industrile rewolusie, Industrie 4.0. Di´e revolusie, analogies aan frases soos slim fabrieke en die internet van dinge, het vooruitgang gegee tot eksponensi¨ele tegnologiese vordering. Die implementering van hierdie tegnologie, sal in teorie, maatskappye in staat stel om die negatiewe impak van hul bedrywighede op hul “tripple bottom line” te verminder en doeltreffendheid te verbeter. Maar terwyl die implementering van hierdie tegnologie o¨enskynlike en logiese verbeteringe bied; hoe om dit te implementeer, met wat en waar is nog grootliks onduidelik en kan lei tot totale afskaffing as gevolg van die gebrek aan kennis. ‘n Besluit ondersteuning raamwerk word voorgestel in hierdie tesis vir die ondersteuning van maatskappye, spesifiek klein en medium ondernemings (KMOs), en leerfabrieke in hul implementeringspogings teenoor Industrie 4.0. Industrie 4.0 word afgebreek in basiese vlakke wat ooreenstem met di`e wat in die leer van fabrieke en KMO voorkom. Hierdie vlakke is voorgesit as dimensies van die raamwerk, en wissel van voorwerpe en tegnologie tot Industrie 4.0 toepassings in KMO en vaardighede geleer in leerfabrieke, en bied die gebruiker ‘n visuele voorstelling van die praktiese implementering nodig vir Industrie 4.0. Hierdie raamwerk kan op drie verskillende maniere gebruik word. Die eerste is ‘n “greenfield” ontwerp, wat gemik is op nuwe leerfabrieke wat bedryfsverwante bevoegdhede en vaardighede wil ontwikkel. In hierdie “greenfield” ontwerp, dui die raamwerk implementeringsriglyne vir die gebruiker aan, wat gebasseer is op die geteikende bevoegdheid kriteria wat die gebruiker wil ontwikkel deur ‘n Industrie 4.0 perspektief. Die tweede, ’n “Industrie 4.0 greenfield” ontwerp, is vir die geval waar ‘n gebruiker Industrie 4.0 konsepte wil implementeer met die doel van verbetering aan tradisionele bedrywighede in KMOs of vir di`e wat klem wil lˆe op die moontlikhede van Industrie 4.0 in leerfabrieke. Die derde toepassing is vir die herontwerp van die huidige bedrywighede binne ‘n leerfabriek of KMO met Industrie 4.0 as raamwerk. Die Industrie 4.0 herontwerp is gemik op leerfabrieke en KMOs wat Industrie 4.0 konsepte wil implementeer slegs met die infrastruktuur en toerusting waaroor hulle reeds beskik. Die besluit ondersteuning raamwerk is ge¨ımplementeer in twee leerfabrieke, die twee uiterste gevalle van die raamwerk, naamlik die produksie 4.0 herontwerp en die “greenfield” ontwerp. Die raamwerk is toegepas in ‘n tegnologies-gevorderde omgewing in Duitsland, en maak suksesvol voorsiening vir die oprigting van drie afsonderlike Industrie 4.0 toepassings in ‘n reeds gevestigde leerfabriek. Vir verdere bekragtiging, is die raamwerk toegepas op die Universiteit Stellenbosch leerfabriek die geval waar die volledige ontwerp van ‘n leerfabriek in aanvang neem, met die doel om die integrasie van Industrie 4.0 in die gewenste leer vaardighede ten toon te stel.

Please refer to this item in SUNScholar by using the following persistent URL: http://hdl.handle.net/10019.1/101189
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