Software Development in Production Research IPH Institut fr

Software Development in Production Research IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H (Institute of Integrated Production Hannover Non-Profit Limited Company)

Agenda ■ What IPH „is“ and „does“ ■ Research Work ■ Discussion Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 2

Facts and figures – The Institut für Integrierte Produktion Hannover g. Gmb. H ■ 1988: Foundation of the CIM factory Hanover g. Gmb. H on the initiative of the professors Doege, Tönshoff and Wiendahl as a connecting link between research and industry ■ 1991: Move to the new institute building at the Marienwerder science park ■ 1993: Renaming to IPH - Institut für Integrierte Produktion Hannover g. Gmb. H ■ 1998: Expansion of the institute building ■ Application-oriented research and development in the field of innovative industrial engineering as well as knowledge and technology transfer into economy ■ Combination of organizational and technological process chains through the co-operation of interdepartmental, interdisciplinary teams ■ 72 employees, including 28 engineers ■ Turnover of about 2, 6 million € in 2009 Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 3

Organizational structure Partner Advisory board Prof. Dr. -Ing. Bernd-Arno Behrens Prof. Dr. -Ing. habil. Peter Nyhuis Prof. Dr. -Ing. Ludger Overmeyer Industry, federal state of Lower Saxony, University Managing Director Dr. -Ing. Dipl. -Oec. Rouven Nickel Central Department Production automation Logistics Process technology Dipl. -Wirtsch. -Ing. Dirk Altmann Dipl. -Wirtsch. -Ing. Henner Gärtner Dipl. -Ing. Malte Stonis Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 4

Primary Industrial Sectors ■ Automotive industry and suppliers ■ Sheet metal forming industry ■ Mechanical engineering ■ Electronic industry ■ Aerospace industry ■ Forging industry ■ Mould and die production Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 5

Research Sponsors and Partners I ■ Project coordinators ■ Public sponsors ■ Commercial sponsors ■ Others Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 6

Focus on XXL products ■ XXL products in Lower Saxony ■ Commercial and special-purpose vehicles: Volkswagen, Krone, Alstom, MAN ■ Wind turbines: Enercon, Bard Engineering, Nordex ■ Commercial airplanes: Airbus ■ Ships: Meyer Werft, Abeking & Rasmussen ■ Conveyor technique: Conti. Tech ■ Exports accounting of Lower Saxony in XXL branches: > 30 % (> 20, 2 billion €)1 ■ Exports accounting of XXL corporations: up to 90 % 1 Source: Lower Saxony State Office for Statistics Meike Wiegand © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 7

XXL products: Aim and need for action ■ Today´s manufacturing of XXL products equals a manufactory. ■ The challenge is the industrialization of manufacturing XXL products Conception Design Manufacturing / installation Utilization Removal Innovation requirements • Simulation • Modelling • Process automation • Condition monitoring • Simulation • Material flow design • Service processes • Logistics management • Decentralization • Mastery of complexity • Operator models • Dismantling / recovery (examples) • Simulation • Network management • Production and assembly processes Meike Wiegand • Logistics processes • Reconditioning • Resource efficiency © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 8

Research Topics Process Technology Department Hybrid Forming (bulk/sheet) Björn Eilert, Andreas Bruns 19. 05. 2010 Profitability of Process Chains Hydroforming Multi-Functional Tools Research Topics Forging Processchain Conversion-Technology Cross Sectoral © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 9

SFB 489 Teilprojekt B 2 Innovative Tool Technologies Initial Situation ■ Conventional forging leads to flash proportions up to 45 % ■ Huge post-processing effort Objectives Source: Thyssen. Krupp Gerlach ■ Reduction of production steps ■ Enhancement of energy and material efficiency ■ Development of new tool concepts Results ■ Omission of chipping through precision forging ■ Precision forging of two cylinder crankshaft forging sequence www. sfb 489. uni-hannover. de Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 10

Research Topics Logistics Department Cross Sectoral Resource Management Local Control of Production in Networks Logistics Efficiency Research Topics Design of Production Networks Save Material Flow in Production Networks Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 11

EZ-Pharm - Proving authenticity of folding boxes along the pharmaceutical supply chain Initial Situation ■ Imitations of pharmaceutical products harms health, economy and jobs ■ Bypassing longlasting and costly pharma research attracts imitators ■ Internet-pharmacies and re-imports demand new protective measures in distribution logistics Objectives ■ Prevent the distribution of pharmceutical plagiarisms ■ RFID as electronic originality certificate for pharmaceutical-packaging ■ Detection and safeguarding of plagiarisms at latest at end-consumer Results ■ Folding box with printed antenna and strap with pre-assembled RFID-chip ■ In pharmaceutical sector proven protection concept strap RFID-chip connections folding box strap role antenna sheet fed antenna printing www. ez-pharm. de Björn Eilert, Andreas Bruns 19. 05. 2010 pre-assembly chip on strap assembly imitation detection © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 12

Research Topics Production Automation Department Smart Systems Simulation 10100110 System Consistency Wireless Communication Business Process Design Research Topics Distributed Systems Simulation Technology Cross Sectoral Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 13

Research Project Life-Cycle Idea Approved funding Apply for funding [2 - 3 years] Carry out project Project results New problem Utilize and enhance solution – identify new problems Generate new research ideas Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 14

Research Project Industrial partners Research institute Idea Problem / Idea Workforce … Public sponsor Select Fund … Theoretical solution Test Use Prototype (software or physical) … € € € Supervise Promote … Software Development within Research Projects: ■ Creative – implementation of new ideas asks for new solutions ■ Independent – small team, few constraints (e. g. existing software environments) ■ Interactive – theory and software sometimes impact each other ■ … ■ Often implemented by students Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 15

Agenda ■ What IPH „is“ and „does“ ■ Research Work ■ Discussion Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 16

Working at the IPH ■ First contact ■ Interesting Bachelor thesis ■ Chances at the IPH ■ Self-reliant working ■ Different projects ■ Responsibility ■ Positive aspects ■ Young team ■ Cooperative work atmosphere ■ Hannover ■ Tasks as an Software-Engineer ■ Develop software prototypes ■ Mentoring of students Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 17

Service-Support through Semantic Web-Technologies (software engineer required) Initial Situation ■ For complex machines and devices failure resolution requires huge amount of know-how ■ Service employees spend much time on information retrieval (e. g. in failure-databases) ■ Simple information retrieval technologies do not bring forth high quality results in adequate time Objectives ■ Support of service-hotlines during retrieval of similar service-cases through the utilization of semantic web-technologies ■ Implementation of a software prototype Results ■ Algorithms for the retrieval of similar service -cases on the basis of meaning instead of simple syntax (usage of ontologies) ■ Web-based database solution to ease service-case acquisition and retrieval Björn Eilert, Andreas Bruns xxxx 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 18

Semantic. Helpline ■ History ■ 2004 – 2005: Erfahrungsbasierte Verknüpfung von Fehlerinformationen beim Betrieb von Werkzeugmaschinen zur Unterstützung von Service Hotlines Experience-Based linking of failure information at tool machines to support service-hotlines ■ Case documentation ■ Search with phonetic encoding ■ PHP / Oracle ■ 2007 – 2009: Semantic Web-Technologien zur Unterstützung des Service am Beispiel Maschinenbau Service support through semantic web-technologies at the example of Mechanical Engineering ■ Semantic categorization with FIZ-Thesaurus ■ Java (Seam) / Oracle, Postgre. SQL, MS SQL ■ 2009 – 2010: Semantic. Helpline ■ Semantic search with FIZ-Thesaurus as DB & Wiktionary as DB Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 19

Semantic. Helpline – Search Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 20

Semantic. Helpline – Thesaurus search Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 21

Intelligente Schnittstellen in wandlungsfähigen Lieferketten (ISI-WALK) (electrical / software engineer required) Initial Situation ■ Today‘s supply chains suffer from multiple obstacles. ■ Exemplary obstacles are rigidly automated conveying and storage systems as well as an insufficient consistency between physical and digital material logistics. Objectives ■ The projects aims at the development of specific technologies and methods to realize an efficient and economic operation of versatile supply chains. Results ■ positioning system based on optical technology ■ versatile warehouse management system ■ system for 3 D object recognition ■ method for plannung and evaluation of versatility www. isi-walk. de (work in progress) Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 22

Automatisierte, CAD-basierte Kalkulation und Konstruktion (Auto. Kal. K) (software engineer required) Initial Situation ■ Tool manufacturers must improve revenue and expense of their tender preparation ■ Production processes are to be planed flexibly in dependence of mould design and the trend of costs during the tool production is to be supervised Objectives ■ The project’s aim is to develop a method for automated CAD model creation and CAD-based costing of tools Results ■ Automated strip chart-based generation of CAD models ■ Automated and CAD-based costing and monitoring using artificial intelligence algorithms Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 23

Smart Tools for Abrasive Cutting (electrical / software engineer required) Initial Situation ■ Over 67% of the total production costs of granite flaggings and boards are determined by the abrasive cutting process ■ Major energy and material costs are caused by high chipping ratios (cutting width / board width ~ 1) Objectives ■ Development of a smart cutting tool that allows to reduce the cutting-wheel width as well as the risk of cut deviations Results ■ Integration of measuring technology into the cutting-wheel for data acquisition (piezo-electric sensor) and preprocessing (chip) ■ Wireless data transfer to machine control ■ Reduction of cut deviations by automated control mechanisms Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 24

Student Jobs @ IPH ■ www. iph-hannover. de Wissen Studium Newsletter Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 25

Agenda ■ What IPH „is“ and „does“ ■ Research Work ■ Discussion Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 26

Discussion Questions !? ■ Questions about IPH? ■ Questions about how to do a research project? ■ Questions about the introduced projects? ■ Other questions or remarks? Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 27

Contacts Dipl. -Wirt. -Ing. Björn Eilert Andreas Bruns Bachelor of ICT, NL IPH – Institut für Integrierte Produktion Hannover g. Gmb. H Hollerithallee 6 30419 Hannover Tel. : +49 511 279 76 - 228 Fax: +49 511 279 76 - 888 E-Mail: eilert@iph-hannover. de www. iph-hannover. de Björn Eilert, Andreas Bruns 19. 05. 2010 © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 28

Ablauf der Semantischen Suche Servicefall-Erfassung 1 Vorverarbeitung 2 Phonetische Codierung 3 § Dokumentation der Servicefälle und Speicherung in der Datenbasis § Entfernung von Stoppwörtern, Umlauten, Satzzeichen, Abkürzungen, etc. § Grundformreduktion § Codierung des Textes zur Toleranz ggü. Rechtschreibfehlern Dokumentierte Servicefälle Fallbasis Relevanter Suchtext Codierter Suchtext Synonymsuche 4 Identifikation von ähnlichen Servicefällen 5 Björn Eilert, Andreas Bruns § Ermittlung von Synonymen § Kategorisierung der Begriffe § Berechnung des Ähnlichkeitsmaßes für Servicefälle in der Datenbasis § Ausgbe der ähnlichen Servicefälle nach Relevanz 19. 05. 2010 Kategorisierte Begriffe Thesauri Ergebnisliste mit ähnlichen Servicefällen © IPH – Institut für Integrierte Produktion Hannover gemeinnützige Gmb. H 29