Branche: Technical Services

Open-Source Implementation of the Industrial Metaverse

Open-Source Implementation of the Industrial Metaverse

Case study and best practices
Henning Strauß ORCID Icon, Tim Johannsen
The digital transformation of small and medium-sized enterprises (SMEs) in the manufacturing sector is hampered by vendor lock-in, high cloud costs, and stringent data sovereignty requirements when implementing Industrial Metaverse solutions. Although the Industrial Metaverse is quickly becoming a key concept in Industry 5.0, SMEs are often at a disadvantage when using proprietary solutions. This paper demonstrates how Industrial Metaverse applications can be realized by combining proven communication standards with open web technologies, thereby reducing barriers. This makes immersive applications for training, maintenance, and monitoring feasible even in SMEs. Using an open-source-based prototype as a best-practice implementation, the paper illustrates how the Industrial Metaverse can be made technologically and economically accessible to SMEs.
Industry 4.0 Science | Volume 42 | Edition 3 | Pages 68-73
Operationalizing Ethical AI with tachAId

Operationalizing Ethical AI with tachAId

Validating an interactive advisory tool in two manufacturing use cases
Pavlos Rath-Manakidis, Henry Huick, Björn Krämer ORCID Icon, Laurenz Wiskott ORCID Icon
Integrating artificial intelligence (AI) into workplace processes promises significant efficiency gains, yet organizations face numerous ethical challenges that stakeholders are often initially unaware of—from opacity in decision-making to algorithmic bias and premature automation risks. This paper presents the design and validation of tachAId, an interactive advisory tool aimed at embedding human-centered ethical considerations into the development of AI solutions. It reports on a validation study conducted across two distinct industrial AI applications with varying AI maturity. tachAId successfully directs attention to critical ethical considerations across the AI solution lifecycle that might be overlooked in technically-focused development. However, the findings also reveal a central tension: while effective in raising awareness, the tool’s non-linear design creates significant usability challenges, indicating a user preference for more structured, linear guidance, especially ...
Industry 4.0 Science | Volume 42 | 2026 | Edition 1 | Pages 50-59 | DOI 10.30844/I4SE.26.1.48
Digital Competence Lab (DCL) for Speech Therapy

Digital Competence Lab (DCL) for Speech Therapy

Designing a learning platform to advance digital skills
Anika Thurmann ORCID Icon, Antonia Weirich ORCID Icon, Kerstin Bilda, Fiona Dörr ORCID Icon, Lars Tönges ORCID Icon
The digital transformation of healthcare results in lasting changes in speech therapy. Smart technologies and artificial intelligence (AI) are creating new opportunities to ensure therapy quality, address care bottlenecks, and actively involve patients in exercise processes. At the same time, these developments are expanding the role of speech therapists, who increasingly use digital systems as supportive tools in addition to their core therapeutic tasks. Based on a feasibility study of the AI-supported application ISi-Speech-Sprechen in a real-world setting of complex Parkinson's therapy (PKT), this article outlines the key challenges associated with implementing smart technologies.
Industry 4.0 Science | Volume 42 | 2026 | Edition 1 | Pages 110-118 | DOI 10.30844/I4SE.26.1.102
Camera-Based Ergonomics Assessment

Camera-Based Ergonomics Assessment

Developing a method for use in manual assembly
Jannik Liebchen ORCID Icon, Burak Vur, Michael Freitag ORCID Icon
Targeted ergonomic design of workplaces and processes can counteract the challenges of manual assembly and improve working conditions. However, current expert ergonomics assessments are time-consuming and resource-intensive. This article presents an automated assessment method based on the Rapid Upper Limb Assessment (RULA). Results from a laboratory study within an assembly scenario are consistent with expert evaluations.
Industry 4.0 Science | Volume 41 | 2025 | Edition 5 | Pages 120-126 | DOI 10.30844/I4SE.25.5.116
Human-Centered AI-Paired Work Systems

Human-Centered AI-Paired Work Systems

Integrating GenAI and the human factor in work system theory
Katharina Hölzle ORCID Icon, Udo-Ernst Haner
The work system is the key unit of analysis within the discipline of human factors/ergonomics (HFE); it is also considered a fundamental element for value creation within other domains. Its concept is based on sociotechnical systems theory and, within HFE, it conveys a distinctly human-centered perspective. So far, work system models have focused on one or several people working within a defined setting as the only (intelligent) actors within the system. The introduction of generative artificial intelligence (genAI) into work systems, particularly as an intelligent and autonomous actor (agent) with potentially specific social abilities and personality traits, calls for reconceptualization. This article elaborates on the new requirements related to the introduction of genAI and develops a human-centered AI-paired work system model that recognizes the significantly expanded capabilities of AI-enabled collaborative social robots.
Industry 4.0 Science | Volume 41 | 2025 | Edition 5 | Pages 38-48 | DOI 10.30844/I4SE.25.5.38
Empathic Assembly Assistance

Empathic Assembly Assistance

Combining AI-based data analysis and empathic human digital twins
Joachim Lentes, Christian Saba-Gayoso, Matthias Lück ORCID Icon, Katharina Hölzle ORCID Icon
Industrial companies in Germany face demographic change and stagnating productivity in an increasingly complex world. Manual assembly remains essential for complex, low-volume products, yet productivity and quality lag due to human variability. This paper introduces a concept and demonstrator for an empathic assembly assistance system that merges a human digital twin and AI-based screwdriver data analytics within a modular architecture. Tightening anomalies are classified, linked to inferred worker states and translated into information and recommendations.
Industry 4.0 Science | Volume 41 | 2025 | Edition 5 | Pages 6-13 | DOI 10.30844/I4SE.25.5.6
Increasing Resilience in Logistics with IT

Increasing Resilience in Logistics with IT

Investigating supply chain risk management information systems
Alexander Baur, Jasmin Hauser, Dieter Uckelmann ORCID Icon
The blockage of the Suez Canal in 2021, caused by the accident involving the container ship Ever Given, clearly illustrates the need to design global supply chains in such a way that they can respond quickly to disruptions. In a volatile, uncertain, complex, and ambiguous (VUCA) environment, conventional logistics processes that focus on efficiency, and supply chain management methods in particular, are increasingly reaching their limits. Resilience, achieved through a combination of robustness and agility, is essential to ensure responsiveness. This article analyzes how risk management information systems (RMIS) can increase resilience. The analysis covers data availability, data transparency, modeling and simulation of risk scenarios, and the development of appropriate emergency action plans. Despite existing challenges in designing IT infrastructure, the measures mentioned have the potential to increase resilience in logistics.
Industry 4.0 Science | Volume 41 | Edition 4 | Pages 36-42
Open-Source and Cost-Effective Digital Twin

Open-Source and Cost-Effective Digital Twin

A case study with two weeks to succeed
Shantall Cisneros Saldana ORCID Icon, Sonali Pratap, Parth Punekar, Sampat Acharya, Heike Markus ORCID Icon
Digital Twin (DT) adoption remains a challenge due to high costs, complexity and lack of skills. This study proposes a cost-effective, TRL 5-validated DT model that can be built using open-source and office suite tools within just two weeks. Integrating real-time sensor data, predictive analytics, anomaly detection and notification, the model improves efficiency and sustainability in agriculture. Even with cloud service constraints, the system delivers a 7.76% average relative error and rapid, automated notifications. The findings show how open-source in combination with common commercial tools technologies can make advanced digital tools accessible to all, creating scalable, human-centered, and affordable solutions in line with Industry 5.0 principles.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 62-68 | DOI 10.30844/I4SE.25.3.62
The Advantages of Microservices

The Advantages of Microservices

An examination of current literature on its application in companies
Ralph Riedel ORCID Icon
The intensive use of the term microservice calls for a theoretical analysis of the technology. Since service-oriented architecture approaches have produced rather disappointing results, the focus should be on the advantages of microservices. This article questions which principles justify the use of microservices as a system architecture. So far, some of the advantages mentioned in the examined literature have not been further explained or defined. There is also a lack of key figures for measuring success.
Industry 4.0 Science | Volume 41 | 2025 | Edition 1 | Pages 50-59
Cloud-Agnostic Platform-as-a-Service (PaaS)

Cloud-Agnostic Platform-as-a-Service (PaaS)

An approach to prevent vendor lock-in
Modern cloud architectures benefit, among other things, from improved availability due to different cloud locations and greater flexible scalability due to the theoretically unlimited computing power of the cloud. However, in addition to challenges regarding data protection and data security, companies are increasingly concerned about the growing dependency on their cloud provider. In this article, we present a prototype implementation for switching between cloud services from different providers at the PaaS level.
Industry 4.0 Science | Volume 41 | 2025 | Edition 1 | Pages 68-73
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