Discrete-Event Simulation in Industry 4.0

Digitalization projects help users represent complex processes more simply and efficiently. However, there are many obstacles to implementation. Reluctance to implement these projects is palpable. This affects, among others, employers and employees, who may fall behind economically by waiting or avoiding change. These observations can be traced back to an overarching research question: What barriers and systemic challenges hinder sustainable transformation within the context of Industry 4.0, particularly when considering human labor in production engineering? What questions are the affected stakeholders asking? The primary goal of this long-term research project is to define these questions decisively and in detail in order to develop a conceptual foundation that integrates research, teaching, and technological development and thus combines the potential of digital technologies with the experiential and practical knowledge of production workers.

Thread forming requires precise lubricant application because high contact pressures and process temperatures strongly influence tool loading, friction, and process stability. Although minimum quantity lubrication (MQL) systems are widely used, current spray-based approaches can still suffer from spray losses, insufficient wetting of the thread grooves, and unstable droplet transport. This article presents a concept for adaptive precision lubrication in thread forming based on computational fluid dynamics (CFD)-supported flow analysis, experimental validation, and artificial intelligence (AI)-assisted optimization. The focus is on droplet size, spray jet geometry, nozzle position, ambient flow conditions, and their influence on wetting intensity. Preliminary simulation-based investigations indicate that data-driven optimization can help identify wetting deficiencies and support the development of future control strategies for resource-efficient lubricant application.

Knowledge drives innovation, which is why digital platforms are increasingly used for knowledge transfer. The People’s Republic of China (PRC) is a global leader in digitalization and digital platforms are central to Chinese knowledge transfer and innovation systems. This study supplements theoretical concepts of knowledge transfer with empirical findings on the (further) development of relevant knowledge platforms. It examines the influence of specific design features on the functionality and quality of digital knowledge platforms. A literature review identifies seven condensed success criteria. Nine leading Chinese knowledge platforms are categorized based on their transfer logic and functional scope. Online survey participants assess the platform-specific manifestations of the identified criteria and highlight potential and areas for improvement in platform-based knowledge transfer.

The VIRAMM research project is developing and prototyping a VR-based training concept for the integration of collaborative robots (cobots) in assembly-oriented U-cells. Since the benefits of cobots depend heavily on process, layout, and role integration, VIRAMM addresses the previously lacking consistent scenario design for variant comparisons with Key Performance Indicator (KPI)-based evaluation.

The increasing automation of intralogistics requires flexible and resilient control concepts for Autonomous Mobile Robots (AMR). While centralized coordination approaches enable stringent control, they quickly reach their limits in terms of scalability and robustness. This paper therefore presents regulations for the decentralized coordination of AMR within the framework of the ORPHEUS project. The focus is on translating known decentralized decision-making principles into a rule framework tailored to industrial material flow scenarios, addressing both operational task assignment and safety-related conflict situations. ORPHEUS thus makes a significant contribution to the methodological structuring, parameterization, and practical transferability of decentralized coordination logics.

Due to its dynamic environment, space planning in intralogistics is not a one-time task but a recurring decision-making process subject to numerous constraints imposed by existing infrastructure. Decisions are often based on incomplete data, resulting in a high risk of poor planning decisions and inefficient use of space. This paper presents a practice-oriented process model for space evaluation in brownfield projects. The proposed approach improves the standardization and consistency of space evaluation and promotes best practices among all stakeholders. By supporting systematic decision-making, the process model contributes to optimized planning and resource allocation, thereby reducing risks and avoiding costly implementation errors.The process model is demonstrated through a case study conducted at a commercial vehicle manufacturer.