{"id":108504,"date":"2025-04-15T12:00:00","date_gmt":"2025-04-15T10:00:00","guid":{"rendered":"https:\/\/industry-science.com\/?post_type=article&p=108504"},"modified":"2026-05-04T13:29:03","modified_gmt":"2026-05-04T11:29:03","slug":"small-batch-body-in-white","status":"publish","type":"article","link":"https:\/\/industry-science.com\/en\/articles\/small-batch-body-in-white\/","title":{"rendered":"Boosting Competitiveness in Small Batch Production"},"content":{"rendered":"

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Challenges in the\u00a0scalable and flexible (body-in-white) production line With shorter life cycles and greater product variety, the automotive industry needs higher flexibility and reconfigurability of its production systems to evolve at market speed. The production of sheet metal in body-in-white, which is used in car manufacturing, precedes painting and integrating elements like motor and chassis into the structure [1]. The latter differs by the manufacturing steps but has fixed sequences. In each body-in-white production step, the manufacturing processes will define the geometry and …<\/div>\n

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Subscription<\/th>\nincluded<\/th>\nPurchase<\/th>\n
without<\/td>\n−<\/td>\n29,00 \u20ac<\/td>\n
Digital<\/td>\n−<\/td>\n27,55 \u20ac<\/td>\n
Expert<\/td>\n−<\/td>\n26,10 \u20ac<\/td>\n
Professional<\/td>\n✓<\/span><\/td>\n0,00 \u20ac<\/td>\n
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Industry 4.0\u2014Progress and Digitalization in Limbo<\/h4>\n
Status of sustainable transformation and digitalization in production engineering<\/div>
Christian Donhauser<\/a> \n \"ORCID<\/a>, Daniel Riepl<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
\n
\n\t\t\t \n\t\t\t <\/div>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. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2026 | Edition 3 | Pages 56-60<\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n
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\n \n \n \n \"AI-Powered\n <\/picture>\n <\/div>\n
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AI-Powered Lubrication Strategies for Thread Forming<\/h4>\n
Adaptive spray jet control to increase process reliability and tool life<\/div>
Reinhard Schmied<\/a>, Marco Susic<\/a>, Christian Donhauser<\/a> \n \"ORCID<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
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\n\t\t\t \n\t\t\t <\/div>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. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2027 | Edition 3 | Pages 76-83<\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n
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\n \n \n \n \"Optimized\n <\/picture>\n <\/div>\n
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Optimized Manual Processes in Automotive Production<\/h4>\n
A module-based approach for the efficient creation of work system simulations<\/div>
Barbara Brockmann<\/a>, Tobias Jurk<\/a>, Beate Stoffels<\/a>, Jochen Deuse<\/a> \n \"ORCID<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
\n
\n\t\t\t \n\t\t\t <\/div>In the manufacturing industry, the integration of digital human models into the product development and manufacturing process is becoming increasingly important. Particularly in assembly, which is characterized by a high proportion of manual tasks, motion simulations enable a realistic representation of human work and thus make a significant contribution to the evaluation of motion economy, process validation, and efficiency improvement. However, widespread application in production planning faces various challenges, such as the high initial effort required to create human simulations as well as volatile planning conditions. This article presents a practice-oriented solution from the automotive assembly sector that enables the creation of simulations with reduced effort as well as their early and consistent use in the planning process. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2026 | Edition 3 | Pages 48-55<\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n
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\n \n \n \n \"Application\n <\/picture>\n <\/div>\n
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Application Potentials of Chinese Knowledge Platforms<\/h4>\n
Digital platforms for knowledge transfer in research and education<\/div>
Yunhao Su<\/a>, Martin Braun<\/a> \n \"ORCID<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
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\n\t\t\t \n\t\t\t <\/div>Knowledge drives innovation, which is why digital platforms are increasingly used for knowledge transfer. The People\u2019s 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. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2026 | Edition 3 | Pages 84-93<\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n
\n \n
\n \n \n \n \"SmartBending\u2014Inline\n <\/picture>\n <\/div>\n
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SmartBending\u2014Inline Measurement for Process Correction<\/h4>\n
Inline process optimization for error compensation in swivel bending<\/div>
Christian Donhauser<\/a> \n \"ORCID<\/a>, Reinhard Schmied<\/a>, Marco Susic<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
\n
\n\t\t\t \n\t\t\t <\/div>Swivel bending is an established forming process that minimizes material loss and enables efficient use of resources. However, the process requires complex optimizations that have traditionally relied heavily on the expertise of machine operators. This results in significant time and material costs, as optimization steps are performed iteratively. Given the shortage of skilled workers, a technological upgrade of the machines in line with Industry 4.0 is necessary. As part of a research project, intelligent sensor technology was used to record critical influencing factors that reveal correlations between product defects and machine deformations. Based on this, a methodology was developed that forms the foundation for inline compensation, enabling the equipment to autonomously adjust process parameters to correct product defects and, in the long term, enable defect-free production from the very first component. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2026 | Edition 3 | Pages 134-141<\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n
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\n \n \n \n \"VR\n <\/picture>\n <\/div>\n
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VR Training for Multimodal Cobot Interaction<\/h4>\n
Virtual learning environments for collaborative robots<\/div>
Christoph S. Zoller<\/a>, Justus Langer<\/a>, Kristoffer Waldow<\/a> \n \"ORCID<\/a>, Merle Meyer<\/a>, Arnulph Fuhrmann<\/a> \n \"ORCID<\/a><\/div>\n <\/td>\n <\/tr>\n <\/table>\n
\n 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. <\/div>\n <\/div>\n
Industry 4.0 Science<\/strong> | Volume 42 | 2026 | Edition 3 | Pages 106-112<\/div> <\/div>\n <\/div>\n <\/a>\n <\/div>\n<\/div>\n\n","protected":false},"excerpt":{"rendered":"

Due to the higher customization of products to customer groups and needs, body-in-white manufacturing industries are facing higher variant assembly at the later stages of the production line, thus increasing production costs per unit. Flexible production processes that involve flexible material flows, non-rigid manufacturing sequences, and the automatic reconfiguration of tools are regarded as the pillars of a resilient production system. This article presents a conceptual solution for flexible Body-in-White sheet metal production with autonomous collaborative robotic systems to make product costs affordable for a higher competitive advantage.<\/p>\n","protected":false},"featured_media":108506,"menu_order":0,"template":"","categories":[],"tags":[79627],"product_cat":[79304],"topic":[67617,68760,68206,79371,79333,67701],"technology":[71524,68674,67717,67634],"knowhow":[],"industry":[69251,79494,79354],"writer":[83650],"content-type":[],"potential":[67894,67658],"solution":[69358,67610,78673,67687,67776,67577,67824],"glossary":[],"class_list":["post-108504","article","type-article","status-publish","has-post-thumbnail","tag-industrie-4-0-en","product_cat-articles","topic-adaptability","topic-factory-design","topic-industry-4-0","topic-logistics","topic-process-optimization","topic-production-system","technology-additive-manufacturing","technology-robotics","technology-simulation-en","technology-tools","industry-automotive-en","industry-manufacturing-en","industry-smart-objects","writer-martin-manns-en","potential-innovation-en","potential-profitability","solution-assembly","solution-logistik-en","solution-logistics-technology","solution-process-management","solution-production-control","solution-production-planning","solution-risk-management","product","first","instock","downloadable","virtual","sold-individually","taxable","purchasable","product-type-article"],"uagb_featured_image_src":{"full":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239.jpeg",1400,788,false],"thumbnail":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-150x150.jpeg",150,150,true],"medium":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-666x375.jpeg",666,375,true],"medium_large":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-768x432.jpeg",768,432,true],"large":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-1024x576.jpeg",1020,574,true],"front-page-entry":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-1032x320.jpeg",1032,320,true],"post-entry":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-764x376.jpeg",764,376,true],"post-teaser":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-392x320.jpeg",392,320,true],"post-teaser-mobile":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-608x496.jpeg",608,496,true],"post-custom-size":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-640x325.jpeg",640,325,true],"whitepaper-teaser":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-274x376.jpeg",274,376,true],"card-big":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-514x292.jpeg",514,292,true],"card-portrait":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-320x440.jpeg",320,440,true],"card-big-company":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-514x289.jpeg",514,289,true],"gp-listing":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-196x180.jpeg",196,180,true],"1536x1536":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239.jpeg",1400,788,false],"2048x2048":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239.jpeg",1400,788,false],"woocommerce_thumbnail":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-510x510.jpeg",510,510,true],"woocommerce_single":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-510x287.jpeg",510,287,true],"woocommerce_gallery_thumbnail":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-100x100.jpeg",100,100,true],"dgwt-wcas-product-suggestion":["https:\/\/industry-science.com\/wp-content\/uploads\/2025\/04\/AdobeStock_348747239-64x36.jpeg",64,36,true]},"uagb_author_info":{"display_name":"Florian Goldmann","author_link":"https:\/\/industry-science.com\/en\/author\/"},"uagb_comment_info":0,"uagb_excerpt":"Due to the higher customization of products to customer groups and needs, body-in-white manufacturing industries are facing higher variant assembly at the later stages of the production line, thus increasing production costs per unit. Flexible production processes that involve flexible material flows, non-rigid manufacturing sequences, and the automatic reconfiguration of tools are regarded as the…","_links":{"self":[{"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/article\/108504","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/article"}],"about":[{"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/types\/article"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/media\/108506"}],"wp:attachment":[{"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/media?parent=108504"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/categories?post=108504"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/tags?post=108504"},{"taxonomy":"product_cat","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/product_cat?post=108504"},{"taxonomy":"topic","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/topic?post=108504"},{"taxonomy":"technology","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/technology?post=108504"},{"taxonomy":"knowhow","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/knowhow?post=108504"},{"taxonomy":"industry","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/industry?post=108504"},{"taxonomy":"writer","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/writer?post=108504"},{"taxonomy":"content-type","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/content-type?post=108504"},{"taxonomy":"potential","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/potential?post=108504"},{"taxonomy":"solution","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/solution?post=108504"},{"taxonomy":"glossary","embeddable":true,"href":"https:\/\/industry-science.com\/en\/wp-json\/wp\/v2\/glossary?post=108504"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}