Technologie: Digitalization

Technologies for Assisting Manual Order Picking

Technologies for Assisting Manual Order Picking

From conventional pick-by systems to AI-driven manual picking assistance
Md Khalid Siddiqui ORCID Icon, Jonathan Kressel ORCID Icon, Jürgen Grinninger
Manual picking remains common due to the high initial cost of support systems. This paper reviews existing technologies, presents an exploratory vision-based prototype, and examines existing literature that explores how combining object detection with language systems could enhance manual workflows. The findings suggest a promising, low-cost direction for worker support in logistics.
Industry 4.0 Science | Volume 41 | Edition 4 | Pages 6-19 | DOI 10.30844/I4SE.25.4.6
Enabling the Future of Manufacturing with Digital Twins

Enabling the Future of Manufacturing with Digital Twins

Opportunities and obstacles
Javad Ghofrani, Darian Lemke, Tassilo Söldner
Digital twins connect physical and digital systems, furthering efficiency, enabling predictive maintenance, and allowing the production of more customized products. Despite these advantages, challenges such as high costs, data synchronization, and security risks hinder widespread adoption. This article explores the potential of digital twins and examines key barriers to integration and implementation, also considering some industrial applications including additive manufacturing as a relevant use case.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 72-81
Digital Twins for Production and Logistics Systems

Digital Twins for Production and Logistics Systems

Challenges and focus areas in implementation and use
Deike Gliem ORCID Icon, Nicolas Wittine ORCID Icon, Sigrid Wenzel ORCID Icon
For a successful implementation as well as sustainable use and maintenance of digital twins for production and logistics systems, it is necessary to identify relevant use cases and master the associated challenges. This paper analyzes scientific literature on common applications and challenges in the implementation of digital twins for the planning and operation of production and logistics systems. To confirm the practical relevance of the results, the results of an empirical survey have also been included. The findings are used to derive key focus areas for the successful implementation and long-term use of digital twins in production and logistics.
Industry 4.0 Science | Volume 41 | 2025 | Edition 3 | Pages 42-49 | DOI 10.30844/I4SE.25.3.42
STAG — Bridging Data from Shop Floor to IT World

STAG — Bridging Data from Shop Floor to IT World

An automated mapping approach for improved access to shop floor data
Oliver Amft ORCID Icon, Dovydas Girdvainis ORCID Icon, Christoph Rathfelder ORCID Icon
Collecting data from different sources on the shop floor and making it accessible to different IT systems is one of the core tasks during the process of factory digitization. Due to the different protocols and interfaces, the data collection task comes with unique challenges. With the Sensor Technology Adapter Gateway (STAG), we present a solution that closes the gap between the shop floor and the IT system’s backend. STAG is an industry-grade middleware that automates translations between data models and protocols.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 14-22 | DOI 10.30844/I4SE.25.3.14
Hybrid Learning Landscapes for Technical Concepts

Hybrid Learning Landscapes for Technical Concepts

The digitalization of training via practical concepts and targeted networking
Sebastian Anselmann ORCID Icon, Jessica Wädt, Uwe Faßhauer ORCID Icon
The Länder- und Phasenübergreifende Interface (LPI) (engl. Cross-Regional and Cross-Phase Interface) promotes the sustainable digitalization of vocational and technical education through the systematic provision of expertise and innovative networking formats. The focus is on hybrid learning landscapes (HLL), which interlink physical and digital learning spaces to create individualized, practical learning environments. Innovative approaches such as learning factories, VR/AR and learning analytics are integrated.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 126-132
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
Functional Safety and Cyber Security in the Process Industry

Functional Safety and Cyber Security in the Process Industry

A tension between stability and agility
Thimmo Kugele, Claudia Nowak, Arno Götz, Alexander Lawall ORCID Icon
Functional safety (safety) and cyber security (security) are key aspects of modern industry and technology. Safety aims to minimize risks posed by system malfunctions. This includes measures to protect people and the environment from failures and errors within systems. Security focuses on protecting systems and networks from digital attacks. The primary security objectives include ensuring confidentiality, integrity, and availability. A joint consideration of safety and security is essential for the future of the process industry, as both the physical safety and digital integrity of modern systems must be ensured. In industrial practice, this creates a field of tension: measures to enhance security can negatively impact safety and vice versa. This article analyzes relevant standards and regulations, presents key approaches for the integrated consideration of safety and security, and highlights areas of further research.
Industry 4.0 Science | Volume 41 | 2025 | Edition 2 | Pages 87-93
Why Moving Toward a Circular Economy Is Crucial

Why Moving Toward a Circular Economy Is Crucial

The ten R-Strategies of sustainable management
Ralf T. Kreutzer
As environmental challenges such as climate change and resource scarcity intensify, with Earth Overshoot Day highlighting overconsumption, the circular economy emerges as a crucial solution. Legislation at the national and EU level obliges companies to become more sustainable. Simultaneously, the circular economy strengthens economic resilience, promotes innovation and creates competitive advantages. However, the impact on the labor market is controversial, as fewer primary resources and new products are needed. Sustainable corporate management requires a balanced consideration of the triple bottom line: Planet, People, and Profit, treating each as equally important. In contrast to the linear economy, the circular economy follows the ‘cradle to cradle’ principle and integrates the ten R-Strategies of sustainability. These strategies range from refuse (avoidance) and reduce (reduction) to recycling and repurpose (reuse). Companies should identify which strategies can be swiftly ...
Industry 4.0 Science | Volume 41 | 2025 | Edition 2 | Pages 68-76
Increasing Supply Chain Resilience with Reverse Logistics

Increasing Supply Chain Resilience with Reverse Logistics

Hypotheses for a value model
Jürgen Hamann ORCID Icon, Christoph Wenig ORCID Icon
Manufacturing companies incorporate reverse logistics as a building block of the circular economy for greater sustainability. Case studies show that this can result in strategic opportunities. This article summarizes an analysis of expert interviews on the increase in supply chain resilience attributed to reverse logistics. Potential benefits are highlighted, and companies are encouraged to examine the approach and implement innovative solutions. The result is a hypothesis-based value model that serves as an orientation aid for decision-makers.
Industry 4.0 Science | Volume 41 | 2025 | Edition 1 | Pages 34-40
Computer Use in Industrial Business Processes

Computer Use in Industrial Business Processes

A systematic literature review of the last 40 years
Norbert Gronau ORCID Icon
The most important value-adding industrial business processes are product creation and order processing. For 40 years now, Industry 4.0 Science and its predecessor titles have supported the development and implementation of the software used in these industrial business processes. In honor of the journal’s 40th anniversary, a systematic literature review is carried out to identify trends that played a role in the past but no longer do today. The research provides some surprising insights into the topics that have been important in the last 40 years – as well as those that will remain relevant in the future.
Industry 4.0 Science | Volume 41 | 2025 | Edition 1 | Pages 8-14 | DOI 10.30844/I4SE.25.1.8
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