Industrie 4.0

A considerable part of global greenhouse gas emissions is caused in the industrial sector. Its digitialization is often seen as a means to increase sustainability. At the same time, ecological and social risks emerge. Their exploration is still in its infancy, however, previous findings point out multiple challenges. These must be conceptually taken into account in order to realize a sustainable industry 4.0. Building on a literature analysis, the following contribution presents current developments in research, industry, and policy. We shed light on a number of selected approaches, which aim at a sustainable industry 4.0. Finally, practical design options are outlined.

Managers are still facing significant challenges in implementing Industry 4.0 technologies and many companies have not gone beyond their initial Industry 4.0 lighthouse project to date. In the midst of this ongoing transformation, the European Commission published a white paper in January 2021 dealing with the “Industry 5.0 concept”. This paper investigates the term “Industry 5.0” with regard to the contribution of the European Commission and illustrates the connection with current Industry 4.0 initiatives.

The digital twin has moved into the focus of manufacturing companies and has been identified by Gartner as a key technology [1]. In the automotive industry, VW uses the digital twin in the cloud to plan, control and optimize production at all 122 locations in the future [2]. The digital twin is also the basis and an integral part of new, digital business models and the digitization of production companies. This article gives an overview of the current state of the art and describes a flexible reference model for planning and optimizing production systems based on the digital twin. The focus is on the one hand on the optimization of static layouts and material flows and on the other hand on the optimization of dynamic material flows and the temporal organization of processes.

Digitalization is changing manufacturing substantially. The design of user interfaces in the digitalized production environment is of utmost importance. In this article, potential combinations of approaches to human-machine interaction are shown and examples of applications are presented. Multimodal user interfaces offer a high degree of immersion. As a result, approaches of (among others) VR-, gesture- and speech-based types of interaction are compared with the dialogue principles and their suitability in practice as work and learning support for employees is presented.

Remanufacturing, previously characterized by manual and cost-intensive processes, is a critical step on the way to a resource-efficient circular economy. Industry and research agree that the introduction of Industry 4.0 technologies is the key to the development of automated and economical remanufacturing systems. Based on a systematic literature review, this paper is dedicated to the analysis of promising Industry 4.0 approaches with a focus on the overall process as well as the sub-processes of disassembly and inspection. The results suggest that there is a need for additional knowledge, experience and research in the development and real demonstration of the approaches and their transferability to broader application fields.

Smart Factory is the vision of a production environment in which manufacturing plants and logistics systems organize themselves as far as possible without human intervention. The article describes a project, at the start of which none of the participants created a relation to “Smart Factory” or “Industry 4.0”. Rather, the objective was to drastically reduce the current delivery time of 6-8 weeks. The result is a completely digitized business process from order creation, product development, design, manufacturing as well as processing for “batch size 1” with a reduction in lead time to less than 10 %.