International Center for Networked, Adaptive Production

Predictive analytics for adaptive process chains

Digital assistance systems and technology apps in networked adaptive production operations help the engineers to monitor the data, to control process conditions and to apply their personal skills and competences with maximum efficiency. Visualization tools such as smartphones, tablets and smart glasses can provide immediate information, allowing flexible adjustments and quick changes of production plans or processes.

Data from model-based simulations optimize the decision-making about possible improvements of products and processes. The software detects critical situations during the manufacturing process and accounts for frequent changes of product specifications in the production of prototypes or small series, allowing the process planning to reach high levels of efficiency even before the first component leaves the production line. Constant checks and comparisons of real data and matching simulation data ensure that the models are continuously improved, with direct benefits for the quality and performance of the end product.

Benefit of digital assistants and simulations in production

  • Predictive planning of concrete process chains and processing sequences in view of specific result targets
  • Better, more profound understanding of the processes involved through more accurate simulations of the individual process steps using recent real data
  • Higher levels of component quality and shorter manufacturing times by adjusting downstream process steps
  • Earlier recognition and automated correction of errors through online adaption in ongoing production processes

Pilot lines using predictive analytics

Predictive process chain design in tool manufacturing

The key element in the tool manufacturing process is the production of a prototype which requires the successful implementation of the “First Part Right” principle. On the basis of different process chain models, engineers provide estimates for the duration of the individual processes, the component quality and the manufacturing costs. By adapting process chain plans to different manufacturing conditions, it is possible to predict the results of the production process under review with significantly higher levels or precision.

Flexible design and production of battery modules

The adaptive production of battery modules accounts for given restrictions such as spatial conditions, weight and properties including energy and power. Different types of cells are used in the production of small to medium-sized series of modules. Laser beam welding and laser bonding are applied in the manufacturing of connecting elements. Process information and data are immediately integrated into the design process. An integrated technology and configuration application supports the – fully digitalized – process of designing systems and manufacturing processes.