CIOReview | | 9 SEPTEMBER - 2023that suits our product. The result of this analysis is the definition of a process module with a decision architecture comparable to a decision tree. With the help of this decision tree, when the process step is called up in our digital assistance system on the shop floor, the step is controlled according to the requirements of the entire process, and the employee is given appropriate instructions based on the step's demands. The requirement is defined by product characteristics or parameters from the PLM (Digital Twin) or ERP system. An MES system reads the product characteristics from the systems, and the parameters of those characteristics then control the decision tree. As a result, a digital instruction for the employee and the tool is generated.Let me illustrate the advantage of this approach with a simple example using screw tightening. When the process module is called up, the selection of the tool used, the screw tightening parameters in the tool, and additional inspections at the end of the process are defined based on the screw tightening requirements. Additionally, the employee may be instructed on the screen to mark the screw connection with a colored stripe. Furthermore, other subsequent process steps may be assigned tasks to complete the process step. In this example, a downstream robot equipped with a vision smart sensor would verify the colored marking of the screw connection. Simplified, this process would already be the result, but where does the detailed advantage lie? In this example, achieving the correct torque at the end of the process should be sufficient. However, the path to achieving that goal can have different requirements. An experienced employee knows from their experience that this particular screw connection is problematic in execution. In the past, there have been issues with this specific screw connection. Therefore, the employee uses a better tool to tighten the screw and double-checks the torque at the end. To ensure that they have properly tightened and checked the screw, they mark the connection with a colored stripe. This way, they or a quality assurance employee can quickly verify if this particular screw connection was tightened perfectly.The process module specifies this approach for screw tightening with higher requirements. Additionally, many parameters are collected as a byproduct of digitization for documentation purposes. This further enhances the value of the screw tightening process. If the screw connection does not require this level of effort, the instructions for the employee and the process requirements would be much simpler. In summary, through automated process design enabled by the digital product characteristics of the Digital Twin, processes can be digitally tailored to their value. This not only increases quality by aligning the execution of the process step precisely with the requirements but also enhances manufacturing efficiency. Only the process execution necessary for the requirements is selected. Additionally, any skilled worker, even without experience, can perform these work steps without the need for specialized departments to create an individual process flow in the background. In our analysis, Industry 4.0 should not be just a buzzword or an inflated and costly process
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