The path to automation in SMEs

Automation is a key lever for effectively countering the shortage of skilled workers. However, SMEs often still have reservations about automation solutions or the use of robots. Yet there are now innovative and easy-to-implement solutions.

Fraunhofer IWU has condensed the results of many years of research and experience from the implementation of innovative automation solutions for manufacturing companies into a method box: "How-to-Automate". The aim is to support manufacturing companies of all sizes in optimizing their production and to exploit automation potential in a targeted manner so that qualified employees can concentrate more on their core tasks.

Flexible machine concepts enable the quick and uncomplicated integration of automation solutions into existing production environments. This means that noticeable improvements can be achieved within just a few weeks - from the initial analysis to the implementation of efficient solutions.

The path to medium and long-term solutions for more complex tasks leads via state-of-the-art technologies such as controller-based simulation, capability-based control or virtual commissioning. The spectrum of possible solutions ranges from selective improvements to completely new production architectures.

Short-term as well as more in-depth redesigns should be able to fit perfectly into existing production environments. To ensure this succeeds, Fraunhofer IWU supports companies from analysis to implementation.

Phase 1: Analyze inventory, identify automation potential

The starting point is a structured analysis of the processes - all processes and workflows must first be recorded in detail. Value stream and material flow analyses create transparency across the entire value chain and form the basis for a clear understanding of machining processes and the flow of materials and information. Inefficiency, waste and bottlenecks can thus be identified and potential for improvement uncovered. The focus here is on precisely those use cases in the company that promise the greatest added value and can be automated in a technically and economically sensible way through the use of mobile and stationary robotics.

Phase 2: Development and implementation of efficient automation solutions

After the analysis, we continue with the design, validation and optimization of an automation concept so that the most sensible solution can be created in terms of technology and costs. The development and detailing of the system technology and control system are carried out in parallel and based on models. During the implementation of the system hardware, a final virtual commissioning ensures that up to 70% of errors in the source code are detected before installation. A largely error-free control code enables rapid commissioning of the hardware and a delay-free start of production. The deployment time of the automation can thus be reduced by up to 20 % - while minimizing the downtime of existing systems.

Practical examples of the range of solutions: RoboOperator and REAL-M

The RoboOperator developed by Fraunhofer IWU together with Industrie-Partner GmbH is a mobile, flexible robot cell that can step in immediately in the event of personnel absence. This is made possible by an interface-free machine connection and an intelligent camera system that localizes components, adjusts handling movements and visually evaluates the machine status. The RoboOperator operates the machine's switches and doors independently; after a one-off teach-in, the cell is ready for use in just a few minutes without any robot programming knowledge. Thanks to the large parts buffer, it can operate machines independently for long periods of time.

Even complex automation systems can be implemented quickly and cost-effectively. The Robotics Engineering Application Lab for Matrixproduction (REAL-M), for example, can help with this by mapping the complete manufacturing cell of an innovative, efficiently automated production process. The flexibly arranged production modules of REAL-M are networked by a driverless transport system and enable a product-optimized material flow. Medium-sized companies benefit here from tried and tested concepts. The REAL-M demonstrates the possibilities of multi-robot solutions in which robots cooperate and interact in teams with employees or even directly with each other. State-of-the-art control and safety technology paves the way for particularly efficient processes that were not considered feasible until recently.

Dr. Christer-Clifford Schenke, Head of Department IIoT Controls and Technical Cybernetics at Fraunhofer IWU