Matrix production and SWAP-IT
Opportunity for SMEs in times of skills shortage
Utilization-optimized, flexibly arranged production modules that are loaded by driverless transport systems and can manufacture a variety of products. Production planning and control that flexibly allocates these modules and, thanks to segmentation and intelligent distribution of production scopes, also makes it possible to manufacture large components in small systems: matrix production and SWAP-IT result in a production infrastructure that also enables highly efficient production of smaller quantities.
Such an infrastructure also provides the impetus for new ways of working when previously manual tasks need to be automated. The "InTeleMat" project provides important impetus for ongoing further training - so that valuable human labor can be deployed in an even more value-adding way.
Coordination between people, machines and processes
Matrix production systems are characterized by their flexibility and the possibility of seamless coordination between human work, machines and automated processes. In their expertise prepared for Acatech, the Fraunhofer Institutes IWU and IPA show the extent to which production is affected by changing framework conditions and what options for action are available. Prof. Dr. Steffen Ihlenfeldt, Institute Director at Fraunhofer IWU: "We are observing that markets are changing rapidly and with hardly any predictability. Production speaks of Vuca, an acronym made up of volatility, uncertainty, complexity and ambiguity. Consequently, production must also change radically. We are convinced that matrix architectures or flexible manufacturing systems in general are the perfect answer."
In two current projects, Fraunhofer IWU is working with partners to develop completely new process chains and methods for employee training for the flexible production of tomorrow.
Fraunhofer lead project SWAP
In the financial world, the term "swap" refers to an agreement between two parties who agree to exchange assets or cash flows. This is intended to mitigate risks. The Fraunhofer lighthouse project SWAP is also about this core: if production facilities can manufacture a wide variety of products and are flexibly interlinked, the risk of unintentional downtime along the entire process chain is minimized. Automatically generated production orders make this possible.
New process chain for manufacturing large workpieces
The Fraunhofer IWU plays a central role in the Fraunhofer lighthouse project SWAP. It is contributing its technological expertise in the digitalization of production, the processing of components with mobile machines and the control, regulation and networking of machines. In the "large components" use case, it is researching a completely new process chain for manufacturing large workpieces with small standard machines. The component is segmented digitally according to aspects of component strength and the available machines, processed in individual parts, joined and finalized using a mobile machine. The research institute is also working on communication interfaces and protocols to ensure the smooth exchange of information between the system controls, automated guided vehicles (AGVs) and the higher-level production system. Together with the Fraunhofer IOSB, it is responsible for validating the software developed for SWAP, which must comply with uniform standards (such as OPC UA) and be able to communicate with commercially available control software.
Test field implemented in a matrix architecture
The Fraunhofer Institutes IWU and IOSB have jointly implemented the first use case "Segmentation and production of large components" in the SWAP-IT architecture and the associated description language (Production Flow Description Language, PFDL) and presented it at the Hannover Messe 2023. At the IWU site in Dresden, Dr. Arvid Hellmich's team subsequently structured the test field in a matrix architecture and set up production cells that can be flexibly planned and individually approached by AGVs. The PFDL developed in SWAP is used to orchestrate production orders to implement a sample process chain from 3D printing to assembly. This uses three production cells, links real processes with their digital image and uses an AGV for logistical linking.
Involving employees in matrix production
Dr. Arvid Hellmich: "In our test field, our team can show customers how the flexible production of a component, such as a seat shell, can be achieved with standard machines. Despite increasing automation and networking, humans remain a decisive factor for productivity and quality. The "InTeleMat" project (Informal, technology-supported learning systems in matrix production), funded by the German Federal Ministry of Education and Research, is taking up the challenge of developing innovative strategies, tools and methods to enable employees to master complex production environments with confidence. The project is an initiative of the Fraunhofer IWU and regional industrial partners and research institutions. Supporting employees in acquiring qualifications and skills on the job continuously and as independently as possible is a central concern. Tailor-made assistance systems are among the solutions that will be developed in the course of the project.
People must use their strengths in production systems
Ultimately, SWAP and matrix production are therefore designed with people in mind: where human creativity and flexibility are irreplaceable, the conditions must be created for people to be able to make even better use of their strengths in complex production systems. Monotonous and physically demanding tasks for which there are no longer enough skilled workers available must be automated in future. The Fraunhofer IWU is researching the supporting processes and IT solutions required for this.
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