Efficient factories

Research and Development at the Production Technology Center Berlin

FUTUR Vision Innovation Realization

Efficient Factories

Everything Ship-shape in One Place Scenario Methods

Reverse Engineering Centers for Factories

Future-proof Technology Concepts

INSTITUTE FOR MACHINE TOOLS A N D FA C T O RY M A N A G E M E N T T E C H N I S C H E U N I V E R S I TĂ„T B E R L I N

Content Imprint FUTUR 1-3/2013 ISSN 1438-1125 Publisher Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann

04

Berlin-Brandenburg Takes up the Turbo Challenge

06

Under Close Observation – More Safety for Machine Engineering

07

Everything Ship-shape in One Place – Reverse Engineering Centers for Factories

Fraunhofer Institute for Production Systems and Design Technology IPK

10

Water Power – High-pressure Cleaning of Turbines

Institute for Machine Tools and Factory Management (IWF), TU Berlin

12

With an Eye on Everything – Sustainable Management of Projects and Resources

14

It Pays to Set Your Standards High – Quality Management for Added-value

16

Information in Tomorrow's World – New Knowledge through Information Technology

18

Scenario Methods – Future-proof Technology Concepts

20

Sustainable Sanitation Systems – Ecological Fertilizers through Local Recycling of Nutrients

22

A Smart Decision – Using IT for Sustainable Product Design

24

Mastering Digital Materiality – VISION Advanced Infrastructure for Research (VISIONAIR)

25

Cutting Costs on the Last Mile – The BentoBox Carries the Day

26

Interview: Markus Robin, SEC Consult

28

Company Portrait: Meyer & Meyer

29

Lab Portrait: A New Robotics Complex at PTZ

30

Events and Dates

Co-Publisher Prof. Dr.-Ing. Roland Jochem Prof. Dr.-Ing. Erwin Keeve Prof. Dr.-Ing. Holger Kohl Prof. Dr.-Ing. Jörg Krüger Prof. Dr.-Ing. Michael Rethmeier Prof. Dr.-Ing. Günther Seliger Prof. Dr.-Ing. Rainer Stark

Editor-in-chief Steffen Pospischil

Compilation, Layout and Production Claudia Engel, Alina Goldberg Contact Fraunhofer Institute for Production Systems and Design Technology IPK Director Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann Pascalstrasse 8-9 10587 Berlin Phone +49 30 39006-140 Fax +49 30 39006-392 info@ipk.fraunhofer.de http://www.ipk.fraunhofer.de Printed by Heenemann Druck GmbH

Photos BMW AG: 1 Kai Dräger: 33 Fotolia / Werner Weber: 6 Fraunhofer IPK / Steffen Pospischil: 15, 30 Fraunhofer IPK / Gerhard Schreck: 31 bottom Fraunhofer IPK / Katharina Strohmeier: 10 Meyer & Meyer: 28 Siemens AG: 4 TU Berlin / Ulrich Dahl: 34 TU Berlin / SFB 1026: 19

© Fraunhofer IPK Reprint, also in extracts, only with complete references and after consultation with the editors.

Please forward a copy.

FUTUR 1-3/2013

Editorial

Dear Readers,

Did you know that the Berlin-Brandenburg region hosts the highest concentration of manufacturers of turbomachinery in the whole of Europe? In our new Fraunhofer Innovation Cluster »Life Cycle Engineering for Turbomachines« we have been work-

Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann

ing together with many of them since the beginning of this year on optimizing mate-

at our XIV Production Technology Collo-

rials and technologies for these high invest-

quium held in September in Berlin – directly

ment goods whose real dividends come only

following the 11th Global Conference on

in the long term. Yet such real positive long-

Sustainable Manufacturing (GCSM). Some

term effects depend on reliable functional-

of the novel ideas for handling knowledge,

ity, and a major part of the company budget

tools and methods were presented here,

goes on maintenance, repairs and overhaul

including scenarios for everyday handling

to ensure it. So by making processes and

of information in tomorrow’s world and

technologies in the fields of design, produc-

sustainable technology concepts for coun-

tion, operations, MRO and recycling both

tries with different levels of development.

energy and resource-efficient, real costs

Whether it is developing a minifactory for

savings can be achieved.

production of cocoa paste in Sierra Leone or designing digital factories in the context of

You can read about the new solutions we

Industry 4.0 – at Fraunhofer IPK we always

have come up with for this in the latest edi-

place resource-efficient production across

tion of our FUTUR magazine. We present

the whole value-added chain at the very

our concept for Reverse Engineering Centers

center of our research.

in factories, and show you ways to make automation work in inspection and reengi-

Learn more about our work in this latest

neering processes. Effective maintenance is

issue of FUTUR. With best wishes for enjoy-

only possible, if the machines and equip-

able reading,

ment have been properly cleaned beforehand. We have found that cleaning with the high pressure water jet method is particularly effective in this respect, and are now engaged on ways of making this method even more efficient for our customers.

How can we continue to successfully develop and manufacture global and regional products in the future as well?

What resources will we need? How can we ensure sustainable added value? Answers to these and other pressing questions were given by experts from industry and science

3

4

Research and Development Life Cycle Engineering

Berlin-Brandenburg Takes up the Turbo Challenge Following the success of the MRO Fraunhofer Innovation Cluster, the go-ahead

a reduction in emissions but an increase in

was given for the new Fraunhofer Innovation Cluster »Life Cycle Engineering

the quality, affordability, efficiency, safety

for Turbo Machines« in January 2013. This innovation cluster will take a

and security of air transport systems. To

holistic view of materials and technologies for turbomachinery in the avia-

meet these challenges, industry and science

tion and energy generation industries in which the Berlin-Brandenburg cluster

have come together in the Fraunhofer Inno-

region plays a leading role.

vation Cluster »Life Cycle Engineering for Turbo Machines«.

►► Industrial solutions for a proven concept Turbomachinery manufacturers in the avia-

sions together with increased use of renew-

Life Cycle Engineering (LCE) is an estab-

able energies. This latter priority calls for

lished concept that takes a holistic view of

greater flexibility in load changes in fossil

the whole life cycle of a product: it consid-

tion and energy generation industries must

fuel driven power plants, and thus also in

ers economic impacts, ecological impacts

meet future challenges in terms of con-

their turbomachinery. On top of this, the

and technical boundary conditions not just

serving resources, keeping costs down and

increasing scarcity of resources in terms of

in terms of construction, production and

ensuring aviation safety. Climate change

materials and fuels is another major chal-

use, but also in terms of recycling and reuse

means that the energy policy framework

lenge. The aviation programs ACARE 2020

of raw materials. This comprehensive life-

must prioritize a reduction of CO2 emis-

and FLIGHTPATH 2050 are targeting not just

cycle approach is of particular value when it comes to products with a high investment volume and long service life like turbomachines, as it can meet the requirements for higher efficiency and lower costs while also improving environmental compatibility.

►►LCE for turbomachines The aim of the new Fraunhofer LCE innovation cluster is to apply the Life Cycle Engineering concept to turbomachines, engineering energy and resource-efficient technologies for all life cycles of turbomachinery. The double focus here is on jet engines in the aviation industry and gas turbines in the energy generating sector.

►►The Berlin-Brandenburg cluster region Providing over 8000 jobs including in supplier industries and with an annual turnover of € 1.8 billion, the turbomachine industry is a major driver of the economy of BerlinBrandenburg. The region boasts the highest density of turbomachine manufacturers in the whole of Europe which makes it particularly suitable for the successful rollout of the Life Cycle Engineering concept.

Maintenance, Repair and Overhaul at Siemens (© Siemens AG)

ignfe Cycle Monitorin Pro s e Li chining Te g

perception of the Berlin-Brandenburg region at the executive level of the turbomachine

RO

industry. And not least of all, the network evolved by the MRO innovation cluster will be leveraged to identify and address common

lin

g

focal points of research across the product

&

yc

M

Rec

Pro ces s o M d l e lin ta i g g Di

Product Strategies

es gi agement an

chn a o d M format n ion lo In a d M an

n ctio du

D

FUTUR 1-3/2013

ti a r e Op

life cycle. Participation in the cluster initia-

on

The four fields of innovation are cross-sectional and address a variety of phases.

tive is still open. Please address your inquires to the central office of the LCE Fraunhofer innovation cluster.

The Fraunhofer Innovation Cluster Ressourceneffizenz »Life Cycle Engineering for TurbomaSimulationstechnik chines« (LCE)

Companies hosted by the region cover

duction and operations & MRO phases, while

Mission: Development and optimization

the whole life cycle from evolution of the

Production Strategies has its main impact on

of materials and technologies for energy

first draft designs and production technol-

operations, even though it also deals with

and resource-efficient turbomachines.

ogy to roll-out. Leading companies in the

other life cycle phases. The Digital Model-

branch like Siemens Energy, Rolls-Royce,

ing and Information Management innova-

Innovation Fields: Product Strategies, Mikrofräsen Digital Modeling and Information Manage-

MAN Diesel & Turbo, Alstom Power Ser-

tion field addresses problems and solutions

vice and MTU Maintenance have an estab-

through digital support in product develop-

ment, Process and Processing Technologies Mikrofräsbearbeitung and Life Cycle Monitoring.

lished presence here with production facil-

ment, the digital factory and model-based

Duration: January 2013 to December 2015

ities, service and maintenance operations

maintenance planning and implementation.

Partners: 6 research institutes,

and assembly works.

Life Cycle Monitoring applies to the whole

25 companies

product life cycle as it includes both status

Funding: Fraunhofer-Gesellschaft,

►► Four innovation fields in one profile

monitoring and diagnosis and testing during

industry, federal states of Berlin and

Given the need for further research and

the actual production process.

Brandenburg Budget: € 17.3 million

development projects, the new cluster All fields of innovation are linked by interfaces

Coordination: Fraunhofer IPK

predecessor, the MRO Fraunhofer innova-

so they can be tailored to meet specific cus-

Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann

tion cluster, with its new focus on Life Cycle

tomer requirements. As the turbomachine

initiative will pick up on the success of its

Engineering for turbomachines. The cluster is

industry is a wide field that covers both the

subdivided into four phases – design, produc-

aviation and the energy generating industries,

www.innovationscluster-lce.de

tion, operations & MRO and recycling – from

its interests cannot be served by one single

which four cross sectional cross-phase inno-

complex of themes alone – as the MRO inno-

Your contact

vation fields are derived: Product Strategies;

vation cluster has demonstrated. Accordingly,

Dr.-Ing. Martin Bilz

Digital Modeling and Information Manage-

the LCE innovation cluster brings together

Phone: +49 30 39006-147 martin.bilz@ipk.fraunhofer.de

ment; Process and Processing Technologies

a host of regional core competencies and

and; Life Cycle Monitoring.

synergies under one roof.

The Process and Processing Technologies

The actors are also interested in bilateral R&D

Phone: +49 30 39006-351

innovation field is mainly concerned with pro-

projects and will seek to inculcate a better

jeannette.baumgarten@ipk.fraunhofer.de

Jeanette Baumgarten M.A.

5

6

Research and Development Condition Monitoring

Under Close Observation More Safety for Machine Systems

Identifying the best time for maintenance can be quite a headache. To do

Selected methods and algorithms are used

so, you need a means of detecting the current status of your machines and

in three design phases – signal preprocess-

equipment and their mechatronic components. And this can only be done by

ing, feature extraction and feature classifi-

continuous monitoring of all your systems. This is where Condition Monitoring

cation – to enable statements to be made

systems step in. These systems aim at providing early warning of changes

about the actual condition of the machinery.

through automated status detection and evaluation. Fraunhofer IPK develops

These statements are based on the analysis

solutions for the diagnosis and forecasting of faults.

and evaluation of measuring data captured by sensors and/or internal control systems as well as single events presented as reports. This data is also considered in combination with other constraining factors such as ambient conditions, user profiles, the type of stress or strain etc. to extrapolate a forecast of the development of the component under observation. This can then be replaced before it has time to fail.

►►The applications The new methods and algorithms are also easy to integrate. Realization of a specific application is an iterative process using the appropriate methods and algorithms in each of the three design stages. This means that

Power plants need effective Condition Monitoring.

users do not have to adhere to a particular input sequence on the user interface but

►►Condition Monitoring

systems whose applications for fault detec-

can freely switch between the design stages

The heavy strain placed on machines and

tion and diagnosis enable systematic deci-

to effect any necessary changes. The fully

equipment changes the material structure

sions to be made about necessary mainte-

developed application comes as an autono-

of their components which results in aging,

nance measures. This helps to increase the

mous MATLAB M-File.

fatigue, corrosion and wear-out. Such

availability and safety of your machinery.

changes can seriously impede the function-

Unlike standard preventive maintenance,

The toolbox of methods was evaluated and

ality of machines and in extreme cases lead

this condition-based approach brings a sub-

validated by a series of tests on a test rig

to their breakdown. Every effort should be

stantial reduction in the time and costs of

for ball bearings. Scientists used a spark-

taken to avoid such operational constraints.

maintenance work.

erosion machine to etch the ball bearings at

One such means is Condition Monitoring

various places with different types of dam-

►►The Toolbox of methods Your contact

age. At the same time as Fraunhofer IPK was

The Fraunhofer MRO innovation cluster has

developing the toolbox of methods, as its

developed a toolbox of methods for monitor-

contribution to the project Fraunhofer IZM

Dipl.-Ing. Eckhard Hohwieler

ing the condition of equipment and compo-

developed a hardware toolbox featuring a

Phone: +49 30 39006-121

nents which supports users in the design and

miniaturized smart sensor system. Taken

realization of Condition Monitoring applica-

together, these toolboxes enable the design

tions. These are applications for the detection

of applications for specific use cases of Con-

Dipl.-Ing. Abdelhakim Laghmouchi

of worn parts in mechatronic applications –

dition Monitoring.

Phone: +49 30 39006-129

such as applications for the monitoring of the

abdelhakim.Laghmouchi@ipk.fraunhofer.de

degree of wear in a wind turbine power train.

eckhard.hohwieler@ipk.fraunhofer.de

Research and Development

FUTUR 1-3/2013

MRO Planning and Digital Support

Everything Ship-shape in One Place Reverse Engineering Centers for Factories

How can repairs be carried out when the technical documents have gone missing or when the person who used to be responsible has now left the company? Or when the manufacturer is no longer producing the spare parts? The alternatives here are either to produce your own parts or resort to reengineering. Only that calls for 3D models of products. Which means that the processes for capturing such data need to be standardized. The solution comes in the form of the Reverse Engineering Center for Factories.

►►Missing 3D product data and documentation Long-life capital goods like steam turbines and jet engines with a lifespan of over 30 years are often maintained and repaired by different service teams. These include product manufacturers, users and service companies. For maintenance, inspection, and reengineering interventions, they all require technical documentation which often enough is only held by the manufacturer who refuses to release it for reasons of confidentiality. This means that all too often product users and service companies have to fall back on their own know-how. Problems are bound to occur, particularly when experienced members of staff quit the company.

And even when the know-how is there,

A reconstructed impeller using surface reconstruction and parameterization of 3D scan data

there’s still the danger that production of spare parts will be discontinued because it’s no long profitable enough which effectively

cessing chain involves a great number of

The measurement data generated enable

ends replacement of defective components

manual – and thus extremely time-consum-

automatic recognition of component parts

and repair and maintenance of machinery.

ing – interventions.

and product structures and their inclusion

a great number of spare parts with the

►►The Reverse Engineering Center

report is then produced based on an auto-

purchase of the machine. The alternative

The Reverse Engineering Center offers

mated comparison between the data and

approaches – producing your own spare

an innovative solution that in future will

the product target status and product his-

parts or using reengineering for modern-

address problems of data and documenta-

tory from which the appropriate mainte-

ization purposes – both require production

tion acquisition and supply. Factories will

nance strategy can be derived.

of 3D models.

be equipped with fixed reverse engineer-

in a product data management system. A

This is why it’s common practice to order

ing cells or mobile solutions for automated

One decisive advantage here is that even

This explains why there has been such a

3D data acquisition. A combination of 3D

less skilled operators can execute complex

surge in the use and development of 3D

imaging lasers, structured light and X-ray

work stages as a workflow system gen-

scanning systems. Yet up to now there has

based measurement techniques keeps the

erates a clear and easily understandable

been no standardization of relevant reverse

time and costs for disassembly to a bare

sequence of steps. This workflow system

engineering processes while the data pro-

minimum.

and the knowledge base to which it is linked

7

8

Research and Development MRO Planning and Digital Support

Original

Digitization by 3D scanning

Segmentation and identification of single parts

Reconstruction of CAD product structure

Recognition of product structure for PDM integration

Automatic generation of components models and identification of product structure using a test data of an automobile generator

provide all the requisite data and administer

now working on an automated technique

niques still under development, a computer

the operator’s input.

for using the retrieved CAD parts to build

tomography identifies and extracts relevant

component models in order to generate

structures such as component parts, pins,

Not the least of advantages is that the 3D

a parameterized data set of the scanned

vias and conducting paths. As their course

geometric data allow for support by aug-

geometry.

is tracked, a net list can be compiled which

mented reality systems: they visualize the

in the next stage can be compared with an

actual product status and superpose pro-

The component model serves as input for a

cedural instructions into the immediate real

self-developed Product Structure Generator

electrically generated net list.

context. Use of 3D data and generative pro-

which evaluates the relations of neighboring

The aim is to minimize errors. Components

duction technologies is a fast way to replace

single parts within a component and stores

are identified in a comparison of geometries,

obsolete components.

a product structure for reference structure

selected according to their circuit layout

comparisons on a product data manage-

symbols and imaged on the circuit board

►►Solutions

ment system.

To optimize reengineering und inspection

pages. Autorouting also connects them to the conducting paths.

processes, experts at Fraunhofer IPK have

►►Extension with optical techniques

developed a data processing chain covering

To enable the repair of electronic compo-

all stages from 3D acquisition to definition

nents, a process chain for the automatic

of parameters for component models and

generation of circuit layouts for PCBs has

the associated product structure. Solutions

been designed and tested in a feasibility

for sub-processes were implemented as

study. Previous electrical techniques involved

prototypes while 3D scans with structured

use of flying probe testers which carry out

light, lasers and computer tomography were

connectivity testing through pin contacts.

used, and possible combinations and data formats were investigated, to identify the

The aim here is to compile a net list that

optimal 3D scanning technology and mea-

can serve as the basis for the design of the

surement strategy.

circuit layout. Yet impedance of pin contact

A segmentation technique was used to iden-

tion by component parts render this tech-

tify and separate single parts in the compo-

nique highly error prone which often makes

nent scan. A trawl of a standard parts library

its results unusable for practical purposes.

using a geometric similarity search enabled

This is why a process based on optical tech-

retrieval of related CAD parts and their tech-

niques has now been developed as a com-

nical descriptions. In addition, scientists are

plement. Employing segmentation tech-

due to protective coatings and obstrucThe impeller in a micro gas turbine – the task is to replace the present nickel-based alloy impeller with a ceramic impeller to increase the level of efficiency. First of all, the impeller is scanned, then the 3D model for fabrication of a ceramic version is revised and amended to allow for optimal distribution of stress.

FUTUR 1-3/2013

Your contact Dipl.-Ing. Hendrik Grosser Phone: +49 30 39006-295 hendrik.grosser@ipk.fraunhofer.de

Dipl.-Ing. Sebastian Adolphy Phone: +49 30 39006-216 sebastian.adolphy@ipk.fraunhofer.de

9

10

Research and Development Cleaning Technology

Water Power

High-pressure Cleaning of Turbines The blades of a turbine need to be free of deposits of dirt, grime and functional coatings, if any defects in them are to be detected before they become really serious. Yet cleaning always comes with the risk of damaging the base material.

The high pressure water jet method is particularly adept at meeting this challenge, as recent experiments at the Institute for Machine Tools and Factory Management (IWF) at the Technical University of Berlin have shown.

Reliable discovery of defective turbine blades is only possible when the blades are clean.

►►Detecting defects

►►How it works

Cleaning turbine blades and components

Scientists at the Production Technology

In the high pressure water jet method

is a critical part of the MRO process chain

Center (PTZ) have analyzed and evaluated

a pump compresses water by subject-

as all the follow-on stages – and especially

a variety of jet methods to ascertain their

ing it to a pressure of several thousand

inspection for faults and defects and their

cleaning potential. Of all the methods ana-

bars. The compressed water is then pro-

remedy – depend on the results it delivers.

lyzed, the high pressure water jet method

pelled through a fine nozzle (mainly made

This is why both operational impurities

was one of the most outstanding, deliv-

of sapphire) with an internal diameter

like rust or accumulated deposits, and

ering highly promising results in terms of

of between 0.2 and 0.4 millimeter. The

functional coatings like ceramics or adhe-

residue-free removal of light and heavy

ensuing water jet has a speed of up to

sive layers need to be removed safely

impurities – without damage to the base

900 meters per second. This enables sep-

and reliably in order to reveal all pos-

material.

aration of entire components and targeted

sible defects in the underlying part.

cleaning of their surfaces.

FUTUR 1-3/2013

Base Material Contamination

Embedding Compound

Handling a steam turbine blade with an adjusted set of parameters. Strip width of 25 mm – note the minor damage on the surface of the component revealed after cleaning.

The main challenge in the cleaning of

An SEM scan of deposits of impurities on the cross- section of a steam turbine blade

First of all the unwanted layers were ana- great advantage, for example, are the low

components is correct adjustment of

lyzed using SEM scans and EDX analysis

diameters of the water nozzles and the

the parameters as on the one hand the

which showed that they were mainly

option of using complex curved types of

unwanted layers have to be safely and reli-

composed of oxide with a thickness in

nozzles without abnormal wear and tear

ably removed while on the other the base

the range of 0 to approx.100 µm. These

which allows for cleaning of areas of lim-

material must be left in as pristine a state

results served as the basis for an exten- ited accessibility. Use of a pure water jet

as possible. And this is especially problem-

sive set of technological investigations

also eliminates introduction of foreign

atic when the coating is harder than the

on cleaning impact. Close attention was

substances into the turbine and prevents

base material itself.

paid to the parameters for pressure, feed, the build-up of cleaning agents in the

Even though the water jet is extremely fine,

their influence on the cleaning outcome.

simultaneous use of multiple jets can make

The high pressure water jet was directed

for economic cleaning even of large scale

in a meandering movement over the com- The multiple advantages it offers make the

working distance and angle of impact, and

workpiece.

►►Areas of use high pressure water jet method ideal for

components. The unwanted layers to be

ponent to treat a flat surface area. The

removed can vary considerable from case

follow-up evaluation identified the sig- use in a broad variety of situations. Apart

to case in terms of their thickness, hard-

nificant parameters and derived a set of

from the turbomachine industry, it can also

ness and chemical composition. Thus the

parameters from them suitable for the

be deployed on ships hulls in the shipping

parameters of each cleaning process need

cleaning of turbine blades.

industry, on machine components in the production technology, for cleaning con-

to be individually adjusted to take account of the unique combination of unwanted

►►On-wing processing

crete and for the removal of hard to dis-

layers and base material in each use case.

A large part of the costs and time involved

lodge deposits in heat exchangers, pipes,

in the maintenance of turbomachines is

conduits and high-pressure vessels.

►► Parameter studies

due to the dis-assembly and re-assembly

Scientists at the Production Technology

of turbine components, operations which

Center (PTZ) have conducted a series

used to be indispensable for maintenance.

of parameter studies to investigate the

Handling machinery in its assembled

cleaning effects of a pure water jet on

or partly dismounted state represents a

industrially soiled turbine blades. The

huge potential for saving costs and time.

range of blades studied included blades

The qualities offered by the high pres-

from airplane jet engines in the aviation

sure water jet as described above make

industry and blades from gas turbines and

it a truly excellent medium for cleaning

Your contact

steam turbines from the energy sector.

turbo­machinery in its assembled state. Of

Dipl.-Ing. Fabian Faltin Phone: +49 30 314-23624 faltin@iwf.tu-berlin.de

11

12

Research and Development Project Controlling

With an Eye on Everything Sustainable Management of Projects and Resources The costs, schedules and performance of investment projects all require precise

in high investment volumes, an integrated

monitoring. Yet traditional methods of project controlling fall way short of the

form of project controlling is crucial for fac-

mark. They frequently show a lack of objectivity in the assessment of project

tory planning projects. This must not only

progress, are unable to offer quality projections, and fail to offer proper support

be able to detect any straying from project

for evaluation of controlling measures. Together with PSIPENTA Software Systems,

targets but must also facilitate cause-effect

Fraunhofer IPK has now developed a controlling system that goes a long way

analyses and selection of remedial measures.

to redressing these shortcomings. The Project Master Control (Projektleitwarte) enables integrated evaluation of the progression of costs, deadlines and results, and thus places the spotlight squarely on monitoring project goals and performance results.

►►Strategic and Operative Project Control In day to day operations both project controlling and strategic multi-project management

►►Project Master Control

and continuous project assessment. This

Sustainable project and resources man-

means that projects must be considered

products, generally MS-Office applications.

agement is the aim of the PROLEIT collab-

in relation to relevant company processes

The scalable Project Master Control devel-

orative project funded by the European

and various other alternative project pro-

oped by Fraunhofer IPK and PSIPENTA is a

Union and the federal state of Berlin which

jections. A great deal of electronic data

holistic integrated project management sys-

began work in September 2010 and ended

is needed for such a complex evaluation

tem that closes this gap. It provides func-

in August 2013. In this project Fraunhofer

process. Only then is sustainable project

tionalities for operative and strategic project

researchers and experts from PSIPENTA

management possible.

control in a system environment. Standard

worked on the development of methods,

deploy a broad spectrum of heterogeneous

integration of the PSIprofessional project

algorithms and business processes for a

►►Factory Planning

management system and the ERP PSIpenta

scalable Project Master Control. Built on

Controlling the progress of factory planning

system and an open import interface are

PSIPENTA’s PSIprofessional project manage-

projects through objective criteria requires

unique characteristics of the unit which pro-

ment software, the Project Master Control

not just analysis of schedule and cost targets

vide a warranty for the extreme sophistication of the evaluation functions it offers.

is an independent unit in its own right that

but also close comparison of target results

further extends the company’s range of

with the planning results actually achieved.

products. With it users can ascertain the

Given the interdependencies between the

►►The Indicator Matrix

status of an on-going project at a glance

time, costs and work results control param-

The core of these functionalities is mapped by

but can also flexibly select a series of indica-

eters, the high complexity of the processes

the indictor matrix. The lines of the indicator

tors for evaluation of project progress. The

of factory planning and the risks involved

matrix are for project processes covered by

prototype of the Project Master Control is now being tested for applications in the fields of mechanical and plant engineering and factory planning.

►►Mechanical and Plant Engineering

System architecture of the new Project Master Control

Client

Application Server

DB Server

Companies in the mechanical and plant engineering sector produce their products in single or multi-model series or in

MS Project Client

small batches. Thus each customer order represents a project which, if improperly executed, carries serious economic risks for the company. To minimize such risks, companies need methods and tools for powerful project and resource controlling

PLS Client

MS Project (MSP) Server

PP-DB

Java Application Server

FP-DB

Project Master Control Server

JDBC

C-DB

FUTUR 1-3/2013

Process / Control Station

Planning Result / Weighting

1:n Process 1 . . . .

Process n

Planning Result 1 . . . .

Planning Result n

Indicators / Weighting

1:n

1:n

Results Indicators

1:n

Cost Indicators

1:n

Schedule Indicators

1:n

Calculation and Aggregation Rules

13

Functional Parameters

f1, Target . . fn, Target Target and Actual Values

1:n

f1, Actual . . fn, Actual

1:n

The indicator matrix of the new Project Master Control

the project planning system. Its columns are

can be accessed via the planning results. The

PSIPENTA Software Systems GmbH:

for target planning results, and results, costs

actual and target values of the indicators can

PSIPENTA offers manufacturing compa-

and schedules indicators with their compu-

be replicated at any time – a vital prerequisite

nies in mechanical and plant engineering,

tation and data capture instructions, func-

for objective evaluation criteria. Alternatively,

automotive engineering and aeronautics a

tional parameters and parametric values. The

the target and actual values of the evalua-

complete portfolio of software for efficient

indictor matrix offers maximum flexibility in

tion indicators can be intuitively estimated

added-value processes in the areas of pro-

the definition of enterprise or project-spe-

by experts. The retrospective and prospec-

duction planning (ERP), detailed planning

cific indicator systems for the evaluation of

tive degree of project progress is then arrived

(MES) and maintenance. Its Planning, Execu-

project progress. Even though standard con-

at by evaluation of the indicator system and

tion and Control (PEC) solution packages are

trolling methods and tools are all predicated

use of the aggregation rules stored for single

addressed to companies seeking a system

on the existence of objective criteria for ascer-

indicator values.

for more efficient production and/or main-

taining the degree of production, they offer no help whatsoever in the definition of such criteria. Nor do they offer any help in the definition of target work results. The Project

tenance processes in an already existing IT

►►Testing the Methods and the Prototype

landscape. PSIPENTA is a 100% subsidiary of PSI AG founded in 1969 and market-listed

The methods and the prototype developed

since 1998. As Germany’s third largest soft-

Master Control largely remedies these short-

by the project are now being tested by the

ware producer, PSI is a market leader in a

comings. With it at least one planning result

project partners and a group of selected

wide range of market segments. PSI solu-

has to be defined for each project task and

customers. And it is already apparent that –

tions are renowned across the world for their

each planning result must be assigned at least

unlike traditional controlling methods – these

contribution to optimal safety in production

one results indicator. If several results indi-

new methods do indeed offer an objective

and logistics and safety and efficiency in the

cators are assigned, each of these must be

and automatic means of evaluating the prog-

energy supply

weighted according to the importance of its

ress made by investment projects. What’s

role in defining the progress of results. Cost

more, one of the hallmark qualities of this

Your contact

and schedule indicators are directly assigned

new approach is the high reliability of the

Dr. Christina Kaltwasser

to a project task. If the matrix assigns sev-

forecasts it generates. It also offers the pos-

PSIPENTA Software Systems GmbH

eral cost or schedule indicators to one task,

sibility of assessing the impact of controlling

Phone: +49 30 2801- 2415

these are weighted in the same way as results

measures on project goals, while with it plan-

ckaltwasser@psi.de

indicators.

ning omissions and errors can be detected at a much earlier stage, thus giving project

Each indicator is given precise instructions for

managers greater time to take countermea-

the computation of target values. The vari-

sures.

ables and parameters used in the computation instructions are deposited in the indicator

Your contact

matrix. For computation of the actual values

Dr.-Ing. Thomas Knothe

of the indicators, the indicator matrix comes

Phone: +49 30 39006-195

with a set of data capture instructions which

thomas.knothe@ipk.fraunhofer.de

Author: Dr.-Ing. Sven Glinitzki

Research and Development Management and Organization

It Pays to Set Your Standards High Quality Management for Added Value How does quality management (QM) contribute to a company’s added value?

makes no direct value-adding contribution to

What are the key factors on which an efficient QM system should be based?

a company’s success, and should thus be allo-

Without answers to these two questions, managers have no solid base for

cated only a minimum of resources. On the

making decisions when it comes to the optimal allocation of resources in the field

other side, empirical studies show that there

of quality. Scientists at Fraunhofer IPK and the Institute for Machine Tools and

is indeed a positive relation between a com-

Factory Management (IWF) at the Technical University of Berlin are developing

pany’s success and its deployment of a quality

innovative concepts, methods and organizational approaches for the consistent

management system. Yet how can the eco-

integrated evaluation and design of quality processes and QM systems. Their

nomic value of a company’s quality-related

aim is to ensure a sustainable, excellent company-wide quality level that gives

activities be assessed? This is where it pays

companies tangible added value.

to take a closer look at company internal and external effects and the causal links between added value and quality management.

Recent years have seen tremendous changes

no longer realize cost advantages solely over

both in customer expectations in products and

economies of scale, but must increasingly

►►ExternalVorgang Company /Effects

services and the competitive marketplace for

focus on what are the key factors of a com-

Many ofSteuerungsstelle the activities and approaches used Gewichtu

enterprise. Customer expectations in products,

pany’s success. And this, in turn, puts the spot-

in quality management aim at excellence in

Planungserge

processes and services are evolving ever more

light not just on the quality of company prod-

product quality. High quality products are

rapidly, while many companies feel the impact

ucts alone, but also – and critically – on the

of changing market conditions in terms of

quality of company processes and structures.

the foundations on which high customer satPlanungsergeb 1:n isfaction and customer loyalty are built and . . . .

Planungsergeb in general promote the quality image and

stiffer competition, increased product complexity and ever greater diversification of their

►►More positive than expected

product portfolios. Industrial companies can

Critics always argue that quality management

Quality management for added value

market position of the manufacturer. SatisVorgang 1 fied customers are loyal customers who also . . . . generate vital Vorgang multiplyingneffects by their regu-

1:n

lar purchases of products of the same brand and their recommendations to other potential buyers. Recommendations are now increasingly being passed on by simple rating mecha-

Economic Variables

1:n

nisms on the internet whose importance as

Economic Success

a channel of communication should not be underestimated. Such recommendations are

Ensuring a Company‘s Survival

generally seen as credible and trustworthy and

Client

e.g.: Product Quality Brand Management Reduction of Price Elasticity Overcoming Market Barriers External Effects Building a Quality Image Staff Participation

Continuous Improvement

Application

can play a valuable role in the acquisition of

new customers. What’s more, high customer

Market Shares Revenue Cost Reduction Growth

Pre-economic Variables

14

satisfaction is an effective way of MS-Project preempting (MSP) MS-Project negativeClient trends in the wake of price adjustServer

e.g.: Time to Market Preventive Error Avoidance Efficient Production of Goods and Services Reduction of Error Allocations Internal Effects

Process Orientation Customer Focus

QUALITY MANAGEMENT

Communication Compliance with Law and Standards

ments so that lower demand or loss of market Java Application shares become less likely.

Server

►► Internal PLS Company EffectsProjektleitstand (PL Server With its Client process-oriented and cross-departmental approach, quality management exerts an influence on a company’s operational efficiency. Process-orientation and efficient interdisciplinary communication are particularly effective in helping to minimize interface

FUTUR 1-3/2013

Performance indicators and key performance indicator systems are early warning systems.

problems. Quality programs ensure consistent

nal market, companies must often prove

the step-by-step introduction of the performance indicator system to the company.

improvement and implementation of best

that their products comply with particular

practice solutions throughout the company

EU regulations. Standards-compliant QM

and thus have a direct influence on efficiency

systems allow manufacturers to furnish such

Future R&D work by the scientists will be

and overall performance. Cost sinking effects

proof of conformity and thus enable them

directed to improving the efficiency of the

enable companies to amortize needed invest-

to overcome market barriers and open up

methods and the consistency of the quality

ment and serve various market price seg-

new markets.

tools deployed across business processes.

ments targeted by their business strategy.

The great leaps forward which are now been

►►Quality Controlling

made in the development of quality-related

At the same time, focus on processes and

Admittedly, effective quality management

software solutions will also help to keep the

consistent enhancement of processes also

also means that a company needs to put

efforts needed for operational work with quality tools to a minimum.

generates higher potential for protection

greater efforts into its organization and

against product plagiarism. The better the

operations. Such efforts must be profitable.

processes are controlled, the more difficult

Direct evidence of the profitability of quality-

Bottom line for companies: targeted invest-

it is for competitors to copy them. And in

related activities in a company can hardly be

ment in the field of quality brings positive

the light of exploding costs for the rectifi-

had without the support of appropriate key

sustainable returns. The extend to which

cation of defects, effective quality manage-

performance indicators and performance

quality management contributes to a compa-

ment also pays off in terms of preemptive

indicator systems. These can serve as an early

ny’s economic success depends both on the

avoidance of faults. At the same time, it also

warning system to ensure that the quality

requirements of particular market segments

reduces the risk of cost intensive maldistribu-

of products and processes never falls below

and the manner in which quality manage-

tion of resources and the risk of damage or

set target levels.

ment is embedded in the company. Those

This is why the QM experts at Fraunhofer

apply quality measures across the whole of

also benefit from robust quality assurance

IPK and the TU Berlin consider controlling

their organization are the ones with the most

and consistent customer orientation: opti-

to be an essential and integral part of qual-

promising outlook.

companies which consistently and rigorously

breakdown incidents on the customer side.

Company product development processes

mized distribution of resources keeps costs

ity management. And they have developed

to a minimum, while improved time to mar-

a compact target and quality-oriented con-

ket brings with it greater sales benefits.

cept for key performance indicators which addresses critical factors and bottlenecks in

Consistent application of quality assurance

a company along the value chain. This per-

measures also makes it easier for companies

formance indicator pyramid gives an over-

on the legal front in terms of product or

view of defined key performance indicators

manufacturer liability as it enables them to

– from the executive level to individual busi-

Your contact

offer solid evidence that they have indeed

ness units. Classification of each key per-

Prof. Dr.-Ing. Roland Jochem

fulfilled their organizational obligations. In

formance indicator in relation to the time

Phone: +49 30 39006-118

an increasingly harmonized European inter-

and costs of its implementation allows for

roland.jochem@ipk.fraunhofer.de

15

16

Research and Development Information Technology

Information in Tomorrow's World New Knowledge through Information Technology Germany’s transformation from a center for industry to a hub for science has brought about fundamental changes in the world of work. Availability, networking and use of transdisciplinary knowledge both inside and outside a company are now seen as key success factors, particularly in terms of product development.

The scenarios outlined below show the importance of knowledge and tools will gain in future and how they enable engineers to interact intuitively with dynamic complex databases and make purposeful use of them in the development process.

►►The W³ Model

in systems engineering. The new professional

If we take the W³ model, two different

systems engineer works with a broad variety

►►Scenario 2: Shaping today what’s important for tomorrow

directions can be distinguished. If we con-

of development artifacts such as specifica-

To a very large extent, the characteristics dis-

sider the model in a clockwise direction,

tions, systems elements and simulation mod-

played by a product across its whole lifecycle

IT tools can be used to turn a new insight

els which are all connected for interoperability,

are specified in an early stage of product

(Eureka!) into more added value. New

while semiautomatic assistance systems offer

development. In future simulation models

knowledge about materials, for instance,

further support. This is the basis on which

will combine multiple criteria-based opti-

means that better simulations of models in

models are built, connected with one another

mization of sustainability dimensions over

IT systems can be built which in turn makes

by semantic rules. This means, for instance,

the product’s value creation network with

for more efficient product design and cre-

that a systems engineer can use intelligent

system optimization.

ates greater digital added value.

models to generate proposals for the modularization of a system structure – and have

Simulation models allow development engi-

Considered in the anticlockwise direction,

the system adjust the module structure in

neers to see the economic, ecological and

in strategic terms a company must always

line with any changes in product specifica-

social impact of their decision-making and

remain competitive. In the digital added

tions or functionalities.The module structure

allow them to weigh up different product

value chain, this can be achieved through

is also opened up for downstream develop-

alternatives – without losing sight of the

use of efficient and effective IT tools to

ment activities.

generate knowledge. Such new knowledge

product’s technical functionality. The engineer is then given processed-based support

then makes for greater added value.

The following scenarios show the interplay

Interactions of knowledge, tools and value creation in user experience of a virtual simulation

between knowledge, tools and value creation, and demonstrate how the W³ model can be understood in a clockwise (scenarios 1 and 2) or anticlockwise (scenarios 3 and 4) direction.

Linking Know-how

Added Value

-Intelligent Models -Expert Knowledge -Experience

-Risk Protection -Modular Design and -Further Use

through

through

►►Scenario 1: Intelligent systems engineering The increasing functionality of modern products has brought about an increase in the

Tool for Experiencable Product Verification e.g. Virtual Model of a Back Door with Haptic Interactive Device to Experience Opening and Closing of Back Door

complexity, interdependencies and numbers of digital models used to describe systems in the development process. This has led to the much wider use of model-based approaches

CAE MKS Simulation, 3D Visualization, Interaction Algorithms, Real-time Interface

FUTUR 1-3/2013

17

Feedback, (e.g. Back Door Does Not Open Easily, Cannot Be Handled Well)

Charlotte Laurenceau

Shashank Mehrota

Simulation Expert

Projekt Manager

Coffee Shop in Paris

Test Center in Bangalore

Connected via Video Conference Aim:

Project Manager Decides about Concept

Connected via Video Conference

Running Simulation, Changing Parameters on the Fly

Experiencable Testing of Various Concepts

Preparation: Building of Simulation Model; Start of Simulation

Feedback to Development Team

Future use of knowledge and tools in a global network of value creation

in the construction phase as a warranty for

sitting in a café in Paris while at the other

a cross-domain basis with their colleagues

assured high quality. To this end, previously

end the project manager in Bangalore evalu-

in MES technology, plant automation and

used methods of quality assurance are mir-

ates the system using an interactive device

logistics planning. On-going feedback of

rored in the virtual development process.

composed of a virtual simulation and labo-

geometry, the functional behavior of the

Digital mapping of a product – which ideally

ratory hardware. Video conferencing sends

control program and factory electrical sys-

should be complete and exhaustive – creates

feedback to the developer who can adjust

tems into a database will enable them to

new advantages in terms of key performance

parameters on the fly so that the project

keep the time spent on information procurement and meetings to the bare minimum.

indicator systems and the early comparison

manager can again experience and assess

of interfaces and development solutions.

the changed system.

►►Scenario 3: Verification through

►►Scenario 4: The real world factory

user experience from any point in the world

in digital planning Today’s generation of factory planners have

Verification of technical systems plays a key

their work cut out for them. The huge efforts

role in the product development process.

involved in procuring information and coor-

User studies in an early development phase

dinating it with other areas means that they

can reduce the need for subsequent cost

only spend half their time doing what they

intensive changes. However, if user studies

are actually supposed to do – planning for

are to yield truly representative results, veri-

processes, layouts and logistics. Consistent

fication must be designed to take account

factory data management and holistic map-

of actual user experience with consideration

ping of the real factory in digital models will

Your contact

of a variety of dimensions including sym-

help factory planners of the future not just

Prof. Dr.-Ing. Rainer Stark

bolic aspects, emotionality, aesthetic aspects,

to use existing processes, production facili-

Phone: +49 30 39006-243

correct functionality and, last but not least,

ties or even whole plants as the basis for

rainer.stark@ipk.fraunhofer.de

usability. Enactment of verification need not

their planning, but will also enable them to

be tied to any particular site so that, for

factor in operational process optimization.

Dipl.-Ing. Kai Lindow

example, a simulation expert could initiate

They will also be able to discuss and develop

Phone: +49 30 39006-214

and control a simulation of tailgates when

various alternatives for the digital model on

kai.lindow@ipk.fraunhofer.de

18

Research and Development Sustainable Manufacturing

Scenario Methods Future-proof Technology Concepts The world population is now seven billion people. Of these less than one billion live in so-called early industrialized nations which enjoy a level of prosperity that other countries now wish to emulate. However, if all these other countries used the same technology currently used by industrialized countries, global consumption of resources would be stretched far beyond any acceptable ecological, economic and social limits. Use of sustainable technologies for achieving a balance between quality of life and consumption of resources is the mission of the Collaborative Research Center 1026 »Sustainable Manufacturing – Shaping Global Value Creation«. For the very first time, scientists have now presented a scenario-based method that supports development of sustainable technology systems for countries with different development levels.

►►One technology, two approaches

develop a path to the objective that takes

nology that addresses problems of growth in

Based on a specific start-out situation and

into account and deals with possible impedi-

threshold regions of the world. Their work

observable developments, scenario methods

ments. The technology-induced approach,

covers the fields of mobility, energy and man-

are used to make projections of the future.

on the other hand, starts out with a specific

ufacturing. On the one hand, these methods

The method facilitates development of inno-

technology for which meaningful fields of

enable them to identify the potential for sus-

vative and sustainable solutions to meet both

application are to be found. The final result

tainable technology and transfer it into use-

present challenges and those the future may

of both methods is delivery of a future-proof

ful applications in procedures which reflect

bring. Two distinct approaches are possible

technology concept.

the technology-induced approach of sce-

for scenario development, depending on the

nario methods. On the other hand, how-

specific start-out situation and the particular

►►Scenarios for sustainability

ever, the work of this research group also

set of problems to be addressed. The starting

In the Collaborative Research Center 1026

considers the needs of the people affected

point for a problem-induced approach – as

»Sustainable Manufacturing – Shaping

and strives to find sustainable ways of meet-

the name suggests – is a particular prob-

Global Value Creation«, researchers apply

ing them. This mirrors the problem-induced

lem that needs solving. The aim here is to

these scenario methods for developing tech-

approach.

Cocoa minifactory

1

Roll Crusher (to crush cocoa beans)

2

Ascending Sifter (to sort peels)

3

Roaster

7

6 2 1

3

4

5 4

Stone Mill (to pre-grind the nibs)

5

Ball Mill (fine grinding)

6

Stirring Tank

7

Diesel Fuel Tank and Power Unit

FUTUR 1-3/2013

The first results can be illustrated by reference to the bicycle mobility in Berlin and

►► Production Scenarios for Sierra Leone

production scenarios for Sierra Leone

Sierra Leone was taken as a case study for a

projects. They exemplify two distinct phases

manufacturing scenario of generally applica-

of the problem-induced path. The starting

bility to a region of low development. Cocoa

point for both are scenarios which map out

is one of the main export goods of this West

the variety of possible futures and which are

African country. Yet the anticipated frame-

used as the basis for developing technol-

work conditions needed for the processing

ogy solutions enabling derivation of robust

of the cocoa bean to cocoa paste are pre­

future-proof technology systems.

carious: lack of a proper electricity supply,

►►Bicycle Mobility in Berlin

tion all make Sierra Leone a challengingly

Researchers in CRC 1026 are investigating

problematic place for production.

Scenario 1 – Pedal Power for the Berlin Economy.

bad roads, and an unstable political situa-

the bicycle as a hypothetical solution for sustainable mobility. Motivations prompt-

Against this backdrop, the concept for a

ing people to use the bicycle range from

simple to realize minifactory for the produc-

very pragmatic reasons to questions of life-

tion of cocoa paste has been evolved that

style. Yet the widespread popularity of the

gives local people a tangible opportunity to

bicycle as a means of mobility in many coun-

improve their quality of life. All the requisite

tries of different development levels makes

equipment can be housed in a single 40 foot

it a highly rewarding topic of research. Its

container. Once delivered, the container only

development must be geared to the needs of

needs slight modification such as installa-

people which can vary considerably accord-

tion of windows and a roof to become an

ing to their particular development situa-

operational factory.

Scenario 2 – The Wild East.

tion. This means that efforts to identify or develop sustainable technologies must pay

The minifactories are designed to process

close attention not just to present sets of

relatively small amounts of cocoa and can

circumstances, but to those anticipated for

be run by local communities. This concept

the future as well – because future capabil-

factors in rural village structures and enables

ity is an essential part of the sustainability

small farmers to participate in the value

paradigm.

creation objective. As these farmers plant cocoa in a mixed form of cultivation, the

Three scenarios have been evolved for bicycle

concept also helps to promote retention of

mobility in Berlin in the year 2025. They vary

biodiversity.

Scenario 3 – Business as usual.

in terms of the parameters they use, which include such factors as development of Berlin’s infrastructure, service models, motivations to use the bicycle, networking with other means of transport, as well as more general factors such as economic growth and environmental awareness. These three scenarios form the basis on which appro­

Your contact

priate bicycle concepts will be built.

Dipl.-Wirt.-Ing. Pia Gausemeier Phone: +49 30 314-27094 gausemeier@mf.tu-berlin.de

19

20

Research and Development Sustainable Manufacturing

Sustainable Sanitation Systems Ecological Fertilizer Production through Local Recycling of Nutrients With their pipes, sewers and sewage works, sanitation infrastructures are highly complex systems which offer enormous potential for improved economic and ecological efficiency. In this respect, the way they are embedded in the natural nutrient cycle and their local context plays a paramount role. The department for Assembly Technology and Factory Management at the Institute for Machine Tools and Factory Management (IWF) of the Technical University of Berlin develops sustainable production technologies and strategies. Researchers in the department have now turned their attention to sustainable sanitary systems.

Figures from the United Nations show that some 2.5 billion people in the world have no access to basic sanitation services. This results in the spread of sanitation-related diseases such as diarrhea. Yet regions in which water-based sanitation systems are common have to contend with a different set of problems. In Germany, for instance, each person uses on average 35 liters of drinking water per day to flush away anything from one to one and a half kilos of urine and feces. In other words, 35 times more water is used to dispose of the excreta than the actual amount it constitutes.

Not only is there high water consumption but the development and maintenance, overhaul and repair of the whole infrastructure from pipes and sewers to sewage plants is highly resource-intensive and the main cost driver in water and waste water management. A further complicating factor is that systematic disposal of human excreta other than by returning them to the ground soil breaks

The Sanitation System Cycle – from food to fertile soil

the nutrient cycle. The result is impoverishment of the soil which leads to erosion and

â–şâ–şTerra Preta Sanitation Systems

a greater need for fertilizers.

One such highly promising alternative is

hygiene reduces adverse health effects,

offered by the Terra Preta Sanitation Sys-

while at the same time a fertilizer is pro-

On the one hand the sanitation systems now

tem (TPS) which is based on the separation

duced in a natural and ecologically friendly

in use are not fit for purpose in developing

of solid and liquid excreta and multi-stage

way. Yet even though the principles on

countries, while on the other their imple-

treatment of excreta including anaerobic fer-

which the system is based have already

mentations in early industrialized countries

mentation and composting. These sanitation

been roughly implemented in prototype

are ecologically inefficient. Thus there is a

systems enable excreta to be collected and

models, there is still no fully comprehensive

pressing need for more ecologically and eco-

returned to the earth in the form of nutrient-

market-ready solution in sight for wide-

nomically effective alternatives.

rich fertilizers and thus create a closed cycle.

spread application. To change this outlook,

They offer two main advantages: better

FUTUR 1-3/2013

the organizers of the annual Global Conference on Sustainable Manufacturing (GCSM) have launched a competition for the »Blue Responsibility Award: Manufacturing for a Sustainable Terra Preta Sanitation System«.

The specific requirements involved in the development of a Terra Preta Sanitation System exemplify the general challenges involved in sustainable production. Promotion of local value creation, for instance, is a decisive factor in the development of a

The CubeFactory – an integrated production system

system for regions with an poorly developed

small scale production that are capable of

pendent. Applied to waste disposal sys-

infrastructure. To address such issues, the

creating added value with whatever local

tems and sanitation systems in particular,

department for Assembly Technology and

resources are available. Minifactories are one

this means providing access to the needed

Factory Management at IWF follows a two

example of such a system. These are com-

knowledge and production technology for

track approach of spreading knowledge on

pact systems of production of a kind that

all the systems elements of the production

the global level and implementing modular

can be housed, for instance, in a standard

process »from food to fertile soil«.

production on the local level.

►►Worldwide Knowledge Dissemination

ISO container. Minifactories can be moved from one strategically advantageous site to

Online-based collaboration platforms for

the next, generating local revenue streams

cooperative open development are a good

through local value creation and thus help-

way of providing solutions. They encourage

An approach based on open source product

ing to promote regional development. This

local initiative as they allow for continuous

development gives local communities access

concept does not involve transport of the

product improvement that factors in unique

to the knowledge they need to pursue eco-

product from a centralized production site to

local conditions. With such access to global

nomic activities. Internet-based open source

the place where it is needed; rather it is the

knowledge, sustainable and fit for purpose

product development facilitates high-speed

production site itself which can be moved

local sanitation systems can be developed

innovation and use of the latest technolo-

to where ever it can generate local income.

and produced, while at the same time local

uct-related knowledge. On top of this, it

Another example of a modular production

Local communities are also empowered to

also promotes continuous product develop-

system is the CubeFactory, a largely autono-

fulfill their needs by leveraging available local

ment which leads to more sophisticated and

mous, mobile production system about one

resources.

gies as it removes access barriers to prod-

health and fertilizer production is enhanced.

mature design – in line with the credo of the

square meter in size that consists of four

open source movement that »given enough

essential modules: production (3D printer),

eyeballs all bugs are shallow«. Yet another

closed circle material disposal (recycler for

advantage of open source product devel-

plastics), power supply (photovoltaic plates

opment is that it leads to designs that are

and storage batteries) and knowledge trans-

much more closely tailored to the individual

fer (touch-PC with enabling learning and

needs of users, precisely because users have

control unit).

been able to voice their needs and expec-

Your contact

►►Applicability to Sanitation Systems

Johannes Seidel, M.Sc.

Open source knowledge and local produc-

Phone: +49 30 314-75835

►►Local Production

tion capacity will overcome the barriers to

seidel@mf.tu-berlin.de

Regions with poorly developed infrastruc-

value creation in emerging economies and

tures need production systems adapted for

make local populations economically inde-

tations during the development process.

21

22

Research and Development Sustainable Manufacturing

A Smart Decision – Using IT for Sustainable Product Design Development of an IT-based assistance system is the job of the project »Virtual Product Development in Sustainable Value Creation Networks«, which is part of the Collaborative Research Center 1026 »Sustainable Manufacturing – Shaping Global Value Creation«. Its target is to improve the sustainability of product design by lending greater transparency to the decisions development engineers must make during the product creation process. Such transparency can only come about when there is maximum availability of all relevant information.

►►Conflicting Aims in Product Creation

frequently stands in contradiction to other

the various dimensions of sustainability is

requirements such as functionality and costs.

now so high that it can hardly be addressed

Climate change and dwindling natural

This is why the legislative framework has

by traditional methods and approaches to

resources in concert with steady demo-

introduced incentives for the development

product creation.

graphic growth pose major challenges to

of sustainable products. At the same time

modern industrial production. To make our

customer expectations about ecologically

►►360 Degree Decision-Making

present economic system fit for the future,

friendly products are also changing, and

The Collaborative Research Center 1026

what we need are innovative sustain­

many companies with a strong customer-

investigates the impact of sustainability on

able solutions that turn threats into real

orientation have already readjusted their

production methods and their technolo-

opportunities.

strategies to take note of them. Social

gies across various scientific levels. The

aspects such as the ergonomics of assem-

project »Virtual Product Creation in Sus-

bly procedures also lead to new require-

tainable Value Creation Networks« aims

special role. Only by consistent avoidance

ments which must be reflected in product

to apply the principles of Life Cycle Think-

of negative environmental impact during

design. More often than not, implementa-

ing to product development in an effort to

the development process can the ultimate

tion of this wide array of generally vague

create forward-looking development that is

goal of sustainable production be achieved

demands is left to developers alone. Yet the

mindful of all the phases of a product’s life

in the long term. Even so, environmentally

level of complexity generated by the inter-

cycle. The general focus is very much on the

friendly, socially acceptable product design

dependencies and conflicting aims between

early stages of product creation, because it

This is where product creation can play a

is here that developers have the greatest influence on shaping the product’s charac1. Development of a New Concept 8. Optimization of EOL Scenario

teristics. The specific focus is on development 2. Chosing Materials with Low Environmental Impact

of an IT-based assistance system which supports developers in their decision-making on sustainability of design by bringing together all the data they need to make informed decisions. Embedded in current engineering

7. Optimizazion of Utilization Phase

3. Material Savings

tools, the assistance system will put forward methodological proposals for improving and assessing sustainability. Such an approach will promote, for instance, use of renewable

6. Reducing Environmental Impacts in Utilization Phase

4. Optimizing Production Technologies 5. Efficient Distribution

Selecting product concepts with the LiDS Wheel

materials to make products more ecologically friendly, higher social compatibility through early consideration of ergonomic aspects, and more rapid adaption to different conditions of life across the globe through use of

FUTUR 1-3/2013

Energy Production

Energy Recovery

Integrated System with Motor and Generator »Charge when Parking«

Braking Energy Recuperation

Ergonomics Intelligent Sitting Position with Loadoptimized Driver's Cab

Light Construction Weight-optimized Plexiglas Cover in Sandwich Structure

Draft design of a sustainable pedelec

modular-based structures. To this end, inter-

and through integration of databases. This

dependencies between the various elements

significantly simplifies and streamlines the

points from which a product can be consid-

of construction and the influence they exert

process of data acquisition.

ered, and thus lead to a high quality technical

on the various dimensions of sustainability across all product life cycle phases must be identified.

►►The Concept of the Assistance System

of the tool increase the diversity of vantage

solution with low impact on the sustainability

►►Latest Results

dimensions. In the case of the turbocharger,

Drawing on the exemplary development of

one of the ways this diversity was reflected

a pedelec (pedal electric cycle) and a turbo­

was in the mix of quantitative (CO2-footprint)

machine, development of the DDSA followed

and qualitative (ease of disassembly) speci-

a bottom-up approach. First of all, methods

fications in the analysis of the basic prod-

Basically, the Design Decision Support Assis-

of sustainable product development were

uct. After various enhancement concepts

tant (DDSA) uses existing methods of sus-

collected in a database and systemized. Then

had been considered, such as regulation

tainable product development. From simple

the functionality of the system was simu-

of the loading pressure by variable turbine

checklists like the Ten Golden Rules of Eco­

lated using the exemplary redesign for a

geometry, the best approach was methodi-

design and assessment procedures like the

Garret GT2860R turbocharger. Scientists

cally selected from the sustainability van-

ERPA-Matrix to complex analytic methods

then made a systematic selection of nine

tage point. With the help of these selected

like Life Cycle Assessment, the past few years

methods which they applied to three differ-

methods, further improvement measures

have seen the evolution of a large number

ent points in the product creation process.

for the product concept – such as weight

of new approaches. Take, for instance, the

In the third stage the development process

reduction – were then identified during the

Life Cycle Design Strategy Wheel or LiDS-

was analyzed with particular attention being

design process.

Wheel, which is a tool for the selection of

paid to the information input and output

various product concepts through com-

triggered by use of the methods. The final

parison of their sets of environmentally

stage involved examination of processes

friendly features. Development engineers

and data input and output. This provided

select, combine and use these methods in

the basis on which the technical data for

line with their set objectives, needs, require-

implementation could be prepared and from

ments and capabilities. The data on which

which insights into the practicability of the

they base their selection is supplied by the

methods could be derived.

assistance system. Users experience such

Your contact Tom Buchert, M. Sc.

support as a step-by-step workflow which

This approach that draws on existing methods

Phone: +49 30 39006-294 tom.buchert@ipk.fraunhofer.de

links methods on the activity level within a

and recombines them afresh for each use

process sequence. Data needed for appli-

case has proven to be highly promising. The

cation of the methods is supplied by users

particular advantages and special abilities

23

24

Research and Development Virtual Product Creation

Mastering Digital Materiality VISION Advanced Infrastructure for Research (VISIONAIR) »VISION Advanced Infrastructure for Research (VISIONAIR)« is a European high end visualization network which is being built in a EU project of the same name.

More than twenty institutes are involved which have opened up their own visualization infrastructures to a wide range of disciplines in the research community to create new opportunities for the interactive visualization of their data and research results. Fraunhofer IPK is also participating in the project with its Virtual Reality Solution Center (VRSC) in which four transnational access projects have already been realized.

and bookcases modeled around them. The fourth approach involved creation of new physical modeling tools which only allow certain trajectories of movement and thus help guide modeling.

The results of the project show that designers in virtual environments can indeed find a rich range of opportunities to master the challenges of digital materiality and meet their professional needs and standards in a design medium. Furthermore, over the

Participants sketching in the virtual environment

course of time it is highly probable that they will develop skills in working in virtual space

►►Mastering Digital Materiality

In the course of the two week project,

that have the same level of professionalism

In July 2012 one of the first VISIONAIR-TNA

which used the »SketchApp« immersive

as those acquired in working with physical

projects was carried out at Fraunhofer IPK’s

modeling system developed by Fraunhofer

materials. Similarly, it can be confidently

Virtual Reality Solution Center in partnership

IPK, the project members developed four

expected that the range of available immer-

with Laurence Mauderli, Laurent Greslin and

ways to master digital materiality. These

sive modeling tools will increase over time

students of the École Supérieure d'Art et

approaches used different ways to compen-

and bring forth new and more convenient

de Design in Reims, France. The aim of the

sate the lack of physical materiality. One of

methods of modeling.

project was to work together with the

the approaches, for instance, worked with

designers to find ways of modeling in vir-

physical constraints to develop a pendulum

tual space in which physical materiality can-

from whose movements virtual spiral mod-

not be experienced – in other words, no

els could be generated. Researchers later

objects can be picked up and no surfaces

added these models to container and basket

can be touched.

models and printed them as 3D models.

Two further approaches used additional vir-

Your contact

tual models as visual constraints and guides

Dr.-Ing. Johann Habakuk Israel

for the modeling process. After completion

Phone: +49 30 39006-168

of the modeling process, these models were

johann.habakuk.israel@ipk.fraunhofer.de

removed so that only the models they had constrained remained in virtual space. For instance, books were loaded in virtual space

Research and Development

FUTUR 1-3/2013

Traffic Management

Cutting Costs on the Last Mile The BentoBox Carries the Day The »BentoBox« is a novel solution for urban collection and delivery systems that enables traffic-reduced low emission packet delivery, particularly in densely populated areas. With it, courier express packet (CEP) service providers can improve their delivery efficiency, service quality, and the sustainability of their transport systems.

one addressee to the next can be replaced by a single process – exchange of the empty container for a full one.

►►All-round Benefits First and foremost the object is to reduce handling costs, in other words the time spent by the courier in the shopping mall.

Another advantage for service providers and customers is the flexibilized delivery times it offers as containers can be exchanged outside of shop opening hours. Low traffic volume also cuts journey times which in turn Both CEP service provider staff and end customers can operate the BentoBox. (© CityLog)

means lower gas consumption and fewer CO2 emissions – an important consideration

►►The Prototype

The courier only has direct contact with the

The BentoBox is the prototype of a joint

goods when handing them over to the end

not just for urban traffic policymaking.

development by Fraunhofer IPK and Logis-

customer. To facilitate placement of goods

In future the BentoBox shall be configured

tic Network Consultants (LNC) in the EU

at the depot or even to automate placement,

as an open multi-client system which will

»Citylog« project. It has already been put

the BentoBox comes with a large door on

enable a variety of CEP service providers

through its paces in field tests in Berlin,

its rear side which offers access to all the

to use their own roller containers and the

Lyon and Turin. In Berlin it served as a con-

compartments.

BentoBox as common meeting and distri-

solidation hub for the local courier service

bution hub instead of cluttering the city

of Messenger Transport und Logistik GmbH.

While CEP service staff use the BentoBox as

with a plethora of provider-specific con-

In Lyon and Turin it was tested by TNT for

a consolidation hub, receivers have direct

tainer systems. So the benefits offered by

deliveries within shopping malls.

access to the individual compartments.

the Bento­Box are for all parties – municipal

Seamless delivery tracking is a particular

authorities, customers and CEP service pro-

►►The Compartment System

challenge here as unique transfer of respon-

viders.

The special feature of the BentoBox is its

sibility at delivery must be documented. This

compartment system for different sized

is why in future a RFID-based delivery iden-

packages. These can be aggregated to

tification system is planned.

form moveable rolling containers all of the same size which can be completely removed

►►The BentoBox in Shopping Malls

Your contact

from the BentoBox. This means they can be

In Lyon and Turin TNT fills the moveable

Werner Schönewolf

filled at the depot and brought to the deliv-

containers at the depot and transports

Phone: +49 30 39006-145 werner.schoenewolf@ipk.fraunhofer.de

ery area without a single package being

them to the BentoBox hub in a shopping

touched by human hand. This also applies

mall. Thus the courier’s time-consuming

to delivery areas within walking distance.

journeys through the shopping mall from

25

26

Interview

Crash Tests for Software When automobile manufacturers want to test the safety of their new models, they put them through a crash test. Markus Robin, general manager of SEC Consult, would like to see similar security tests for software products. In this interview with FUTUR he explains why.

FUTUR: Mr. Robin, you advise companies on

to be done in order to make companies really

FUTUR: How do you test how secure soft-

information and application security. What

safe, by using the state-of-the-art security

ware is?

kind of challenges are manufacturers and

products which are proofed.

Robin: We carry out crash tests just like

users facing today?

FUTUR: Two years ago you showed that over

they do in the automobile industry. We play

Robin: Information and application security

50 percent of all standard software has criti-

through standardized test cases selected over

might be an issue that is very widely aired

cal vulnerabilities. Have the vendors reacted

a certain period of time. This means that our

at the moment, and it is certainly one that

in the meantime? Have you observed any

experts act in the same way as any criminal

is very present in the media. Even so, com-

tangible changes for the better?

hacker. For instance, they feed characters

panies have very little awareness of how

into the input fields that switch the applica-

important it is. I like to compare it with

Robin: Basically only few things have

tion or the software to another status than

healthcare: you might be very well aware

changed. On the one hand this has cer-

the one originally thought up by the devel-

that you need to see your dentist again, only

tainly to do with the stiff price competition

oper. When they enter certain small software

you keep putting off an appointment. This is

software vendors are exposed to. And on

parts into the amount or name field, these

the same kind of attitude many companies

the other side security is a field that is not

can read the database and retrieve other

have towards software security. They often

so transparent for users. Most of them find

content or passwords with which they can

labor under the false impression that they

it very difficult to estimate which software-

continue to work. Generally speaking, no

themselves are perfectly safe and it is only

package is less or more secure. However, we

user name and no password is going to pro-

the others who get zapped by the theft of

can observe the increasing efforts and invest-

tect you against such attacks. Metaphorically

critical data. Companies in the small and

ments in the field of security from vendors'

speaking – if you have a really secure door,

medium-sized enterprise sector are particu-

side. In this segment our work and our state-

the hacker is going to go straight through

larly prone to thinking that they are not on

ments corroborate with the recent finding

the wall.

the hackers’ radar because they do not have

published by the VDMA (German Engineer-

such a high profile as the big OEMs. But as

ing Federation) that investigated the kind of

FUTUR: You are also involved in research

long a customer who wants one of their

security threats mechanical and plant engi-

and development of secure web applica-

products can find them, it is a safe bet that

neers are exposed to. It is really now high

tions. What are your particular areas of

a hacker interested in their IPs can find them

time that people – especially those in the

interest here?

too. There is really no difference whatsoever.

small and medium-sized enterprise sector –

In other words, what we see as the greatest

take these threats seriously. We believe that

Robin: We have just been working together

threat at the moment is this failure by many

you can only identify vulnerabilities when you

with the German BSI (Federal Office for

companies to take the danger really seriously.

involve a third party, an outside expert to

Information Security) on a code of practice

It is like driving on snow and ice with sum-

analyze just where you stand with your own

for the acquisition of secure web applica-

mer tires without turning on the windscreen

security arrangements. On top of this, the

tions. This is a very important issue, at pres-

wipers: you might feel safe for the first few

new coalition agreement also has a passage

ent this is the best opportunity for defining

meters, but the chances to cause an accident

about product liability for software according

security levels for the purchase and instal-

are significantly increased. Our job is to tell

to which in future manufacturers of machin-

lation of software products and compo-

companies what security risks they have and

ery and plant equipment must make sure

nents. Furthermore, we have been closely

explain to them the kind of havoc a hacker

that their machines and the software they

working with Fraunhofer IPK for many years.

can wreak. That is the diagnosis. But we also

contain are given adequate protection so as

Togehter we have implemented various

offer the right kind of therapy: what needs

not to endanger customers.

projects. In the field of reconstruction, we

FUTUR 1-3/2013

27

About Markus Robin After graduating in computer science at the Technical University of Vienna, Markus Robin began his career as a research engineer at Alcatel-Elin. In 1995 he moved to become Senior Manager at Ernst & Young Unternehmensberatung, later Capgemini Consulting Österreich AG where in 2000 are trying to make the research findings of

our new branch office. It is scheduled to

he was appointed as Vice President. Since

the IPK experts accessible to certain domains

start operations in 2014 and we are already

2005 Markus Robin has been General Man-

and user groups in Austria, too. And we also

very much looking forward to having a pres-

ager of SEC Consult Unternehmensbera-

work together on issues of security for criti-

ence here.

tung GmbH, one of the leading consultancy firms for information and application secu-

cal infrastructure applications. The aim here is to develop mechanisms with whose help

FUTUR: You are looking for IT security spe-

rity. Markus Robin is also a member of the

users can ward off such systematic hacker

cialists for your new company. What type of

advisory board of the Cyber Akademie, an

attacks.

candidates have the best chances?

independent training and skills center for information security and data protection.

FUTUR: You are now setting up a high tech

Robin: Our security analysts – our White

company in Berlin. What kind of services

Hat Hackers as we call them – are always

About SEC Consult:

will you provide?

the kind of people who when they were kids

This vendor-independent company with

would rather take their toys apart than put

branches in Frankfurt, Vienna, Wiener Neu­

Robin: One of the things our Berlin sub­

them together. We are looking for people

stadt, Vilnius, Singapore and Montreal is

sidiary will do is to support companies spe-

who are highly creative and who bring a

a specialist for internal and external secu-

cialized in machine and plant engineering.

real passion for security with them. If you

rity testing, secure software (development),

We want to motivate them to run their

are working in this field, you need a very

security certification (ISO 27001, ÖNORM A

products through actual crash tests so they

great deal of stamina. You need to be highly

7700) and incremental sustainable improve-

can really test how secure they are, and if

focused and also emotionally committed to

ment of the security level. Customers of SEC

necessary work together with us to enhance

know just the right way to coax a system to

Consult include leading companies and

their security. And on the other side we also

reveal its weak points. And to know how

organizations in the services and admin-

want to offer our services to German federal

you can help a company deal with its vul-

istration sectors as well as numerous soft-

agencies and government authorities in the

nerabilities. The candidates have to posses

ware vendors. The SEC Academy founded

Berlin region. We are really committed to

a very analytical mind, and also the sense of

by SEC Consult in 2013 offers its own short

security »made in Germany«, because this is

passion which is very important for us.

courses and training programs on IT security

a field of superb quality in terms of security

for enterprise.

products and services. What’s more, we see Berlin as the ideal nurturing environment for the right kind of highly talented people

Your contact

who can help us optimize security tests and

Markus Robin

security solutions for our customers. We are

Phone: +49 (69) 17537343

now heavily involved in the groundwork for

m.robin@sec-consult.com www.sec-consult.com

28

Company Profile

»From Sheep to Shop« Meyer & Meyer Guarantees Full Shelves in the World of Fashion Well stocked shelves and a rich range of collections and fashionable accessories are the delight of every true shopper. There seems to be no limit to the

►►More Efficiency through Automation

selection of clothes offered by the garment industry as jackets, trousers, shirts

For some years now the fashion special-

and blouses stream into the department stores from a never-ending source.

ists have been investigating ways of auto-

Yet a glance at what goes on behind the scenes soon shows that in fact the

mating labor intensive time consuming

well stocked shelves are the end result of a sophisticated system of logistical

logistics services. In 2007 at its site in Peine,

services. It is a system that the fashion logistics specialists Meyer & Meyer

the company opened a state of the art

have brought to perfection.

logistics center with a fully automatic conveyor system for hanging textiles. In 2008, Meyer & Meyer invested in another automated logistics center for flat-packed textiles in Osnabrück where it has its main office.

►►Meyer & Meyer’s commitment to »Green Logistics« Economic efficiency and concern for the environment are written large in the company’s philosophy. Meyer & Meyer is one of the largest operators of photovoltaic plants in the Osnabrück region, making a vital contribution to climate neutrality. Four plants generate enough power to supMeyer & Meyer’s Hanging Textiles Center in Peine (© Meyer&Meyer)

ply 145 households with »green« energy.

In this way the company reduces the load of ecologically damaging CO2 emissions by

A family owned and managed business

garment industry with a comprehensive

330 tones a year. By using state of the art

with its head office in Osnabrück, this logis-

range of transport and logistics services.

telematic systems and the latest automotive

tics service provider can look back on over

These span everything from logistics for

technology, Meyer & Meyer gives its fleet of

100 years of tradition. It first began to spe-

raw materials and production, warehouse

transport vehicles maximum environmental-

cialize in fashion logistics back in the 1950s.

logistics, finishing and quality assurance to

friendliness, while the company is constantly

Today the company serves leading national

transport of ready to wear products to the

on the lookout for alternative and yet more

and international names and retailers in the

retail outlets. Meyer & Meyer does not just

efficient drive system technologies. The

provide a broad variety of transport ser-

company is involved in pilot projects for

vices: its portfolio also includes such things

overlong cargo trucks and is testing use of

as professional hand ironing for high quality

the all electric truck in its city logistics. In

Your contact

textiles, attaching security alarms and price

such ways in many sectors of the company

Meyer & Meyer Holding GmbH & Co. KG

labels, inspection of size and fit, and cus-

innovative solutions are being created that

Julia Lehrmann

tomized deliveries. From its headquarters

shorten transport time, lend greater effi-

Hettlicher Masch 15/17

in Osnabrück and through its network of

ciency and speed to processes and motions,

49084 Osnabrück, Germany

branch offices and strategic partners in Ger-

and ensure long-term protection for natural

Phone: +49 541 9585-108

many and abroad, Meyer & Meyer manages

resources.

jlehrmann@meyermeyer.de

the logistics activities of 2000 employees in

www.meyermeyer.de

Europe, Asia and North Africa.

Lab Portrait

FUTUR 1-3/2013

A New Robotics Complex at PTZ As one of the results of the Fraunhofer MRO innovation cluster, a new complex is being built for PTZ’s processing robots in the PTZ experimental test field. Since late 2012 this robotics complex has hosted four KUKA and COMAU 6-axes industrial robots of various

3

4

2

dimensions. The robot stations are equipped with a variety of tool drives, and tool and workpiece mountings for the milling, grinding, polishing and optical measurement

1

of workpieces. Processing is either tool or workpiece-guided depending on size, requirements and technology.

A view of the new robotics complex at the PTZ experimental test field

COMAU robots feature an open control interface which enables integration of PTZ’s own process and control algorithms. One new arrival at PTZ is another robot from KUKA which comes with an application package for milling. It features an electri-

3

cally driven processing spindle, a two-axis4

2

positioner, and a tool magazine. An active force torque control system for operations and processing has also been embedded in the robot. This enables validation of strat-

1

egies for processing with industrial robots in a commercially available experimental set up, testing of new approaches and conduct of industrial feasibility studies.

A CAD model of the new robotics complex at the PTZ experimental test field

Station

Robot

Tools/Technologies

Properties

1

Kuka KR 60 HA

HSD milling spindle, 8 kW, HSK E40, belt grinding in preparation

Kuka ForceTorqueControl, two-axis-positioner, tool magazine with 10 locations

2

Comau NJ 130-2.6

IMT spindle, 15 kW, HSK F-63

active force/momentum control

3

Kuka KR 30

pneumatic spindles for deburring

passive force control using compliant spindles

4

Comau NJ 370-2.7

belt grinding, brushing, polishing, slide grinding machine

active force/torque control, optical 3D measurement

Technical data of the robotics complex

Your contact Dipl.-Ing. Marcel Manthei Phone: +49 30 39006-245 marcel.manthei@ipk.fraunhofer.de

29

30

Events and Dates

The Ethiopian Minister of Science Visits Fraunhofer IPK The IPK received distinguished visitors on 29 January 2013 when a delegation from Ethiopia headed by the country’s Minister of Science and Technology Dessie Dalkie Dukamo paid a call. The delegation was greeted by Prof. Jörg Krüger, head of IPK’s Automation Technology division, whose welcome address outlined the work of Fraunhofer IPK and the research done in his own department. Current research projects in the field of quality management excited much interest as did the tour of the Application Center for Microproduction Technology where the visitors were given insights into the workings of microproduction technology. The visit concluded with a guided tour of the PTZ experimental testing arena. The visit was organized by the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH. Your contact

The Minister of Science Dessie Dalkie Dukamo (on the right) and his delegation at the Application Center for Microproduction Technology AMP

Steffen Pospischil Phone: +49 30 39006-140 steffen.pospischil@ipk.fraunhofer.de

Austria's Minister of Culture Tours the Secure Verification Lab In an unusual visit at an unusual time, on Saturday 9 February 2013, Dr. Claudia Schmied the Austrian Minister for Education, the Arts and Culture visited Fraunhofer IPK. She was particularly fascinated by the field of Virtual Reconstruction and its possible applications in the cultural domain. The Minister was in Berlin for the Berlin Film Festival and was attended on her visit by Dr. Sirikit Amann, a member of her ministry’s cabinet and Dr. Georg Locher, director of the Austrian Cultural Forum in Berlin. The delegation used the opportunity of a tour of the Secure Verification Lab to learn about the possibilities offered by virtual reconstruction whose use in the Stasi Puzzle Project has brought it to widespread public attention.

Your contact Dr.-Ing. Bertram Nickolay Phone: +49 30 39006-201 bertram.nickolay@ipk.fraunhofer.de

Divisional head Dr. Bertram Nickolay explaining the »Stasi-Puzzle« technology

FUTUR 1-3/2013

Brazil in Berlin Fraunhofer IPK Supports Development of Brazil’s Research Landscape On 25 and 26 April, Fraunhofer IPK welcomed a delegation from Brazil’s National Service for Industrial Training (SENAI) on its visit to Berlin. Fraunhofer IPK has been collaborating with SENAI since June 2012 in a partnership which will soon see the opening of 23 new research centers across the whole of Brazil. Last year experts from Fraunhofer IPK and SENAI drew up business plans in the first phase of the project for establishment of eight of these innovation institutes based on examples of global best practice from the field of applied research. During their April visit, the 16 regional and national SENAI delegates were able to gain a better understanding of these plans, to discuss them and bring forward their own proposals for shaping the Brazilian research landscape. Fraunhofer IPK and SENAI are currently involved in developing business plans for a further eleven

Prof. Kohl welcomes SENAI delegates to IPK.

innovation institutes. This second project phase is dedicated to a concept planning project for national-level central administration of the SENAI institutes as well as an evaluation system.

Your contact Prof. Dr.-Ing. Holger Kohl Phone: +49 30 39006-168 holger.kohl@ipk.fraunhofer.de

COBOTS in Industry Hannover Trade Fair 8. – 12. April 2013 Human-centric automation comes into its own at the point where full automation reaches its limits. Cooperative robots (COBOTS) do not imitate human capabilities, they support them. They do the heavy work while leaving operators fully in control. The end result is easy to operate systems of low complexity which enable low-cost all-in-all solutions. Together with eepos GmbH we displayed a manipulator for industrial handling tasks at the Hannover Trade Fair 2013. This gave visitors the chance to see real life-sized cooperative robotics at work – and lay their own hands on our COBOT controls.

Your contact Steffen Pospischil Phone: +49 30 39006-140 steffen.pospischil@ipk.fraunhofer.de

WIR STELLEN AUS: HALLE 17, STAND F14

31

32

Events and Dates

Hands on Your Bicycle!

The International »Do-it-Yourself Bicycle Workshop« at the PTZ The role played by the bicycle as a means of urban transport is steadily

scientists and representatives of do-it-yourself workshops and bicycle

gaining in importance. As a cost effective, space-saving, healthy

networks from Germany, France and Spain. During the workshop

and also environmentally friendly alternative to the car, the bicycle

attendees analyzed the business model of do-it-yourself workshops

is destined to play an even greater role in sustainable urban mobility.

to find out what role they played in terms of local value creation and

Accordingly, a local infrastructure needs to be put in place for the

how their work could be made even more efficient in the future. They

rental, maintenance, repair and recycling of bicycles. Yet at present

agreed on the necessity to develop an open knowledge platform in

there is no such comprehensive coverage. The bicycle workshops we

which know-how about the manufacturing and repair of bicycles

do have are frequently overwhelmed with work, and not everybody

could be pooled and made accessible to the general public. With

has the tools and skills needed to repair their own bike. One solution

the help of such a platform everybody should be able to repair their

to this problem could well be Do-it-Yourself Workshops. These help

own bicycle or even assemble a whole bike from scratch! Another

less technically savvy cyclists to repair their own bicycles by providing

cooperative effort was agreed upon in the field of instruments for

technical support and the right tools and by motivating people to

teaching know-how: so-called »learnstruments« or self-explanatory

»do it themselves«. This helps ensure that cyclists can quickly repair

tools should make it easy for non-professional people to learn how

their own preferred means of transport and are quickly back in the

to repair their bikes. Last but not least, the workshop also saw the

saddle rather than having to buy a complete new bike or resort to

birth of a collective of Do-it-Yourself Bicycle Workshops who now aim

environmentally harmful alternatives like the automobile. In this way

to work together to shape the future of sustainable urban mobility.

such workshops also make a major contribution to sustainability.

This is the background against which the Collaborative Research Center 1026 »Sustainable Manufacturing – Shaping Global Value

Your contact

Creation« organized its workshop on Do-it-Yourself Bicycle Work-

Jérémy Bonvoisin

shops. 16 people came together on 23 May at the Production Tech-

Phone: +49 30 314-25549

nology Center in Berlin, including bicycle designers and manufacturers,

bonvoisin@mf.tu-berlin.de

Particularly in urban traffic, the bicycle represents a space-saving, ecologically friendly alternative to the car.

Your contact Dr. Jérémy Bonvoisin Phone: +49 314-25549 bonvoisin@mf.tu-berlin.de

FUTUR 1-3/2013

Robots in the Machining World Towards Flexible Reliable Manufacturing The 5 April 2013 was a special day at Fraunhofer IPK dedicated to »Flexible Manufacturing with Industrial Robots«. This was the name of a workshop held in the institute under the auspices of the EU’s HEPHESTOS project. The workshop brought together representatives of leading robotics producers, industrial companies, SMEs and research initiatives in robot-assisted manufacturing to present the latest developments in their fields. The closing panel discussion articulated the requirements and proposals of industry in terms of future research. The workshop, which was held in English, also served to promote networking between participants in the HEPHESTOS project coordinated by Fraunhofer IPK. The workshop was followed by the opening of the »Science Encounters Art« exhibition at the AMP co-sponsored by Comau, A² and Easy Rob (see the article below). In this way, the audience of experts had the opportunity first to become acquainted with the latest robotics developments in the fields of science and industry and then to view the technology’s creative side.

For further information, please visit:

www.hephestosproject.eu

»Science Encounters Art« An Exhibition Fuses Art and Robotics »Where does art end and science begin?« This question was the springboard for the »Science Encounters Art« exhibition, a coproduction of the artist Ajit Kai Dräger and Fraunhofer IPK. From 5 April to 8 May the results were on view in the form of sculptures in the lobby of the AMP. The works of art embody Dräger‘s view of his collaborative research with IPK’s Dr. Dragoljub Surdilovic over the past one and a half years. A perfect exemplification of the title of the exhibition, the fascinating centerpiece »Transformation of a Cloud« (pictured on the top right) is partly created with the help of robot technology and partly by the artist’s hand. As Dr. Surdilovic comments, »Robotics is an amazing world that helps artists to liberate form from a block of stone while freeing them of the need for hard physical labor. Our research aims to open up the possibilities of robotics to European sculpture and thus to enrich the world of shapes and forms cast in stone.« Your contact Dr. Dragoljub Surdilovic Phone: +49 30 39006-172 dragoljub.surdilovic@ipk.fraunhofer.de

33

34

Events and Dates

We Mourn the Passing of Professor Günter Spur Who Died on 20 August 2013 at the Age of 84.

Professor emeritus Dr.-Ing. h.c. mult. Dr.-Ing. E.h. mult. Dr.-Ing. Günter Spur was an outstanding scientist and university teacher of national and international repute. His eight honorary doctorates, honorary professorship and numerous affiliations to academies of science bear testimony to the excellence of his work. From 1965 to 1997 he was director of the Institute for Machine Tools and Factory Management at the Technical University of Berlin.

From its founding in 1976 through to 1997, he was also executive director of the Fraunhofer Institute for Production Systems and Design Technology. Over the decades he played a major role in the evolution of production sciences at the national and international level. He was always particularly concerned with developing the bonds between basic research and its applications in industry.

Günter Spur supervised nearly 300 doctoral dissertations and way over 1300 diploma theses. Many of the doctoral candidates he supervised are now professors in their own right at universities in Germany and abroad. He is widely considered as the founding father of a new generation of scientists in production technology, and as the man who laid the foundations for a Berlin school of production technology at the TU Berlin.

Günter Spur was a member of the executive boards of acatech, the German Academy of Science and Engineering, and the BerlinBrandenburg Academy of Sciences and Humanities. The numer-

1965 Günter Spur became director of the Institute for Machine Tools

ous awards and distinctions he received for services to production

and Factory Planning (IWF) of the Technical University of Berlin. With

science include the Helmholtz Medal, honorary membership of

the founding of this institute in 1904, Georg Schlesinger, one of

the Technical University of Berlin and honorary membership of the

the pioneers of scientific factory organization, laid down the basic

Fraunhofer-Gesellschaft. From 1991 to 1996 Günter Spur was the

principles governing practical application of scientific research. This

founding dean of the TU Cottbus, which later became the Bran-

very summer Professor Spur organized a commemoration ceremony

denburg University of Technology Cottbus-Senftenberg. Until the

in remembrance of the persecution and exile of Georg Schlesinger,

end of his life he was an active member of the governing board of

the founder of the Institute for Machine Tools and Factory Planning,

the Society of Friends of the TU Berlin. In 1984 he was awarded the

and his Jewish colleagues by the National Socialists.

Grand Merit Cross of the Order of Merit of the Federal Republic of Germany and in 1988 the Order of Merit of Berlin.

The funeral service was held on 12 September 2013 at the Französische Friedrichstadtkirche on Berlin’s Gendarmenmarkt, followed

From 1948 to 1954 Günter Spur studied mechanical engineering

by a reception at the Berlin-Brandenburg Academy of Sciences

at the Technical College (Hochschule) of Braunschweig where he

and Humanities. An act of remembrance commemorating the life

majored in manufacturing technology. After a short time spent

and achievements of Professor Spur was held by the TU Berlin on

working in industry at Gildemeister, he returned to the TH where in

1 November 2013 in the university’s main auditorium.

1960 he took his doctorate on A Contribution to the Measurement of Cutting Forces in Drilling with Spiral Drills with Consideration of

Your contact

Radial Forces. He then returned to work for Gildemeister where, in

Steffen Pospischil

his capacity as director of construction design, he was responsible

Phone: +49 30 39006-140

for various major technical improvements in lathing machines. In

steffen.pospischil@ipk.fraunhofer.de

FUTUR 1-3/2013

Medica 2013 Technologies for Image-guided Surgery Intraoperative X-ray scanning with the aid of robotics, 3D visualization and instrument navigation – at this year‘s MEDICA, Fraunhofer IPK presented once more technologies for image-guided surgery. Modern imaging and visualization procedures can significantly improve the safety and efficiency of surgical interventions. One good example of this is X-ray diagnostics: During complex operations, surgeons use X-ray images to monitor the results of surgery while it is still in progress. The best results come from 3D images, because they offer precise representation of the inside of the patient’s body. But until now it has been very difficult to generate them during actual surgery.

In the ORBIT project, Fraunhofer IPK is now working to create an open 3D X-ray system that can be better integrated into surgical procedures. ORBIT is a prime example of the large pool of expertise held

Research engineer Felix Fehlhaber (left) explains how ORBIT works.

by IPK in image-guided surgery technologies ranging from robotic systems and the reconstruction and presentation of 3D image data, to instrument navigation. We also collaborate with medical staff from Charité – Universitätsmedizin Berlin to perform clinical evaluations of

Your contact

both prototypes and medical technology products that have already

Prof. Dr.-Ing. Erwin Keeve

received approved. At Charité, our Robotics OR is a unique environ-

Phone: +49 30 39006-120

ment that facilitates such evaluation under real world conditions.

erwin.keeve@ipk.fraunhofer.de

12th Global Conference on Sustainable Manufacturing – Emerging Potentials Johor Bahru, Malaysia, 22nd – 24th September, 2014 The Technische Universität Berlin (TU Berlin), the Universiti Teknologi

sustainable manufacturing. It offers keynote speeches, panel discus-

Malaysia (UTM), the International Academy for Production Engineer-

sions, parallel sessions on sustainability issues and a global student

ing (CIRP) and the Collaborative Research Centre 1026 (CRC 1026)

competition on sustainable sanitation systems. Your participation,

are pleased to announce the 12th Global Conference on Sustain-

through the submission of your abstracts will be appreciated by

able Manufacturing – Emerging Potentials to be held in Johor Bahru,

24th of February 2014. Incidentally, 2014 is the visit Malaysia Year

Malaysia on 22nd – 24th September, 2014.

and numerous events and festivals have been lined up for visitors to Malaysia throughout the year.

The Global Conference on Sustainable Manufacturing (GCSM) is expected to attract representatives from science and industry from all over the world to Johor Bahru, Malaysia from the 22nd to the 24th September 2014. It will be the 12th conference in the GCSM series.

In 2014 it will be hosted by the Universiti Teknologi Malaysia (UTM) addressing the subject of emerging potentials for sustainable devel-

Your contact

opment. The conference serves as a forum for academics, research-

Prof. Dr.-Ing. Günther Seliger

ers and practitioners from international universities and research

Phone: +49 30 314-22014

institutes and industrial companies doing work related to the area of

seliger@mf.tu-berlin.de

35

Profile

Production Technology Center PTZ Berlin The Production Technology Center PTZ Berlin comprises of the Institute for Machine Tools and Factory Management IWF of the Technical University of Berlin and the Fraunhofer Institute for Production Systems and Design Technology IPK. The PTZ develops methods and technologies for management, product development, production processes, and design of industrial manufacturing plants.

Furthermore, we also leverage our proven expertise to engineer novel applications in emerging fields such as security, transport and medical technology.

The PTZ is equally committed to making its own contributions to applicationoriented basic research and to developing new technologies in close collaboration with industry. The PTZ works together with its industry partners to transform basic innovations born in research projects into fully functional applications.

With the methods and techniques we develop or improve, we offer our partners comprehensive end-to-end support from product development and fabrication through to product recycling. This also includes the conception of means of production and its integration in complex production facilities, and innovation of all corporate planning and controlling

Your Contact at the PTZ Berlin Corporate Management Prof. Dr.-Ing. Holger Kohl Phone +49 30 39006-168 holger.kohl@ipk.fraunhofer.de Virtual Product Creation, Industrial Information Technology Prof. Dr.-Ing. Rainer Stark Phone +49 30 39006-243 rainer.stark@ipk.fraunhofer.de Production Systems, Machine Tools and Manufacturing Technology Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann Phone +49 30 39006-101 eckart.uhlmann@ipk.fraunhofer.de

Fraunhofer Alliances AdvanCer High-performance Ceramics Tiago Borsoi Klein M.Sc. Phone +49 30 39006-154 tiago.borsoi.klein@ipk.fraunhofer.de Cleaning Technology Dipl.-Ing. Martin Bilz Phone +49 30 39006-147 martin.bilz@ipk.fraunhofer.de Traffic and Transportation Dipl.-Ing. Werner Schönewolf Phone +49 30 39006-145 werner.schoenewolf@ipk.fraunhofer.de

Working Group

Joining and Coating Technology (IPK) Prof. Dr.-Ing. Michael Rethmeier Phone +49 30 8104-1550 michael.rethmeier@ipk.fraunhofer.de

Tool Coatings and Cutting Materials Fiona Sammler, M.Eng.Sc. Phone +49 30 314-21791 fiona.sammler@iwf.tu-berlin.de

Joining and Coating Technology (IWF) Prof. Dr.-Ing. Rainer Stark (komm.)

Phone +49 30 314-25415 rainer.stark@tu-berlin.de

Ceramics Machining Dipl.-Ing. Florian Heitmüller Phone +49 30 314-23624 heitmueller@iwf.tu-berlin.de

Automation Technology, Industrial Automation Technology Prof. Dr.-Ing. Jörg Krüger Phone +49 30 39006-181 joerg.krueger@ipk.fraunhofer.de

Dry Ice Blasting Dr.-Ing. Martin Bilz Phone +49 30 39006-147 martin.bilz@ipk.fraunhofer.de

Assembly Technology and Factory Management Prof. Dr.-Ing. Günther Seliger Phone +49 30 314-22014 guenther.seliger@mf.tu-berlin.de Quality Management, Quality Science Prof. Dr.-Ing. Roland Jochem Phone +49 30 39006-118 roland.jochem@ipk.fraunhofer.de Medical Technology Prof. Dr.-Ing. Erwin Keeve Phone +49 30 39006-120 erwin.keeve@ipk.fraunhofer.de

processes.

Fraunhofer Innovation Cluster Life Cycle Engineering (LCE) Dr.-Ing. Martin Bilz Phone +49 30 39006-147 martin.bilz@ipk.fraunhofer.de Secure Identity Dipl.-Phys. Thorsten Sy Phone +49 30 39006-282 thorsten.sy@ipk.fraunhofer.de

Microproduction Technology Dr.-Ing. Dirk Oberschmidt Phone +49 30 39006-159 dirk.oberschmidt@ipk.fraunhofer.de Berliner Runde (Machine Tools) Dipl.-Ing. Christoph König Phone +49 30 314-23568 ckoenig@iwf.tu-berlin.de

Competence Centers Application Center Microproduction Technology (AMP) Dr.-Ing. Dirk Oberschmidt Phone +49 30 39006-159 dirk.oberschmidt@ipk.fraunhofer.de Benchmarking Prof. Dr.-Ing. Holger Kohl Phone: +49 30 39006-168 holger.kohl@ipk.fraunhofer.de Electromobility Dipl.-Ing. Werner Schönewolf Phone +49 30 39006-145 werner.schoenewolf@ipk.fraunhofer.de

Advanced Training Claudia Engel Phone +49 30 39006-238 claudia.engel@ipk.fraunhofer.de Methods-Time Measurement Dipl.-Ing. Aleksandra Postawa Phone +49 30 314-26866 postawa@mf.tu-berlin.de PDM/PLM Dr.-Ing. Haygazun Hayka Phone +49 30 39006-221 haygazun.hayka@ipk.fraunhofer.de Process Management Dr.-Ing. Thomas Knothe Phone: +49 30 39006-195 thomas.knothe@ipk.fraunhofer.de Rapid Prototyping Dipl.-Ing. (FH) Kamilla König-Urban Phone +49 30 39006-148 kamilla.koenig-urban@ipk.fraunhofer.de Simulation and Factory Planning Dr.-Ing. Sven Glinitzki Phone: +49 30 39006-165 sven.glinitzki@ipk.fraunhofer.de Self-Organising Production (SOPRO) Dipl.-Ing. Eckhard Hohwieler Phone +49 30 39006-121 eckhard.hohwieler@ipk.fraunhofer.de Virtual Reality Solution Center (VRSC) Dr.-Ing. Johann Habakuk Israel Phone +49 30 39006-109 johann.habakuk.israel@ipk.fraunhofer.de Knowledge Management Dr.-Ing. Dipl.-Psych. Ina Kohl Phone +49 30 39006-264 ina.kohl@ipk.fraunhofer.de Dr.-Ing. Markus Will Phone +49 30 39006-304 markus.will@ipk.fraunhofer.de Center for Innovative Product Creation (ZIP) Dr.-Ing. Haygazun Hayka Phone +49 30 39006-221 haygazun.hayka@ipk.fraunhofer.de