FACTS4WORKERS Increasing efficiency trough intelligent information systems in an Automotive Industry Case

Transcription

1 FACTS4WORKERS Increasing efficiency trough intelligent information systems in an Automotive Industry Case FACTS4WORKERS Effizienzsteigerung durch intelligente Informationssysteme anhand eines Beispiels aus der Automobilindustrie Forum Produktion 2016 Juni 2016, Linz, Austria Dr. Alexander Stocker VIRTUAL VEHICLE 1

2 Agenda Virtual Vehicle Humans at the centre of Industry 4.0 EU-H2020-Project Worker-centric Workplaces for Smart Factories (FACTS4WORKERS) Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 2

3 VIRTUAL VEHICLE Research Center AUTOMOTIVE RAIL AEROSPACE HARD FACTS SHAREHOLDERS Founded: July 2002 Staff: 200 Operating Income: EUR 22 m Location: Graz, Austria Dr Jost Bernasch Managing Director Website: Prof Hermann Steffan Scientific Director Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 3

4 VIRTUAL VEHICLE - Five Factors of Success EU Research 25 EU projects 9 leading Non-K Contract research FFG projects Visibility Congresses, meetings GSVF, ISNVH, IAVSD Key Player In project consortia Technology Roadmaps K2-Mobility The solid basis Steadiness Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 4

5 People at the centre of Industry 4.0 Robots and humans mostly work separated from each other. Image: BIBA Robots work together with humans. Image: VDI-Nachrichten A smart factory won t be void of humans because after 35 years of research in the field of artificial intelligence I have realised that in exceptional situations humans with their brain power are superior to the best expert software. Professor Wolfgang Wahlster, Vorsitzender der Geschäftsführung und wissenschaftlicher Leiter des Deutschen Forschungszentrums für Künstliche Intelligenz (quote translated) Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 5

6 People at the centre of Industry 4.0» In contrast to the debate in the 80 s today the paradigm is not anymore humans or computers but humans and computers. «Dr. Constanze Kurz, Ressort Zukunft der Arbeit, IG Metall, Konferenz: HUMAN FACTORS IN THE DIGITAL AGE, , Kaiserslautern (quote translated) To fully understand and manage the roles and workplaces of people in the factories of the future, we have to consider how people work and learn, interact with technology, and add value to manufacturing? Domain 5: Human-centred manufacturing Enhancing the role of people in factories Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 6

7 Developing Smart Factories that are Attractive to Workers (FoF ) H2020-Project Worker-Centric Workplaces in Smart Factories (FACTS4WORKERS)» Therefore, to reach our objective, we need to act quickly and become the avant-garde of digital manufacturing. We have to do this together, and at the right scale if we do not want to lose the game as we have done to some extent with the Internet business so far.«günther H. Oettinger, EU Commissioner ( ) for Digital Economy & Society This project has received funding from the European Union's Horizon 2020 research and innovation programme under Grant Agreement n Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 7

8 Worker-centric workplaces for Smart Factories (FACTS4WORKERS) 4 Large scale enterprises 2 SMEs 5 Research organisations 4 Universities Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 8

9 Worker-centric workplaces for Smart Factories (FACTS4WORKERS) 4 Large scale enterprises 2 SMEs 5 Research organisations 4 Universities Kick-off 12/2014 Project Duration 4 years Project Budget 7,9 Mio Person Months >> 1000 Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 9

10 Worker-centric workplaces for Smart Factories (FACTS4WORKERS) 4 Large scale enterprises 2 SMEs 5 Research organisations 4 Universities Increase problem-solving and innovation skills of workers Kick-off 12/2014 Project Duration 4 years Project Budget 7,9 Mio Person Months >> 1000 Increasing cognitive job satisfaction of workers participating in pilots Increase average worker-productivity of workers participating in pilots by 10% Achieve TRL 5-7 on developed workercentric solutions Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 10

11 Four Industrial Challenges (IC) IC1: Digitally augmented human work IC3: Self-learning workplaces IC2: Worker-centric knowledge sharing IC4: In-situ mobile learning Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 11

12 Traditional Approach Our Approach Use State-of-the-Art (web standards) technology Combine Building Blocks and technologies as useful FACTS4WORKERS Focus on the Workers Alexander Stocker 12

13 Our Approach Develop a Smart Factory Infrastructure that will be able to address all kinds of services Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 13

14 FACTS4WORKERS - Impact dimensions Production worker -> knowledge worker Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 14

15 FACTS4WORKERS: Contexts-of-Use EMO Awareness for flexible production workers Machine maintenance skills of operators SCA Quality control expertise for workers Paperless information management for assembly workers HID Problem solving support for production workers THO Paperless information management for assembly workers HIR Augmented decision making for production workers TKSE Problem solving support for mobile maintenance workers Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 15

16 Example case: Thyssen Krupp Steel Europe AG Central Company Location: Duisburg ~ employees as many as live in a small town 4 blast furnances, ~12 million tons of high quality steel per year 80 km road network 9 square km factory premises five times larger than Monaco Project Scope: Fields of HVAC and electricity 200 employees working in this maintenance division Service and repair electricity systems and air conditioning equipment Responsible for several thousands air conditioning equipment and control boxes for maintenance and trouble-shooting Employees face a number of challenges while troubleshooting Picture of facility ThyssenKrupp Steel Europe AG; Content FACTS4WORKERS, Source: Project Deliverable 1.1 Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 16

17 A Design Reseach-based approach As-Is Situation Case studies Personas Problem scenarios Rich picture of the organisation and the existing working practices Data collection & analysis Ethnography Focus groups Interviews Design & Implementation Employees (workers) Requirements Objectives (of industry partners) Iterative and agile software development Continuous evaluation Worker-centric Smart factory solutions Source:University of Zurich, Facts4Workers Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 17

18 A Design Reseach-based approach As-Is Situation Case studies Personas Problem scenarios Rich picture of the organisation and the existing working practices Data collection & analysis Ethnography Focus groups Interviews Design & Implementation Employees (workers) Requirements Objectives (of industry partners) Mock-up, Sketch of UI (no functionality) Modeling user interactions in UI (using sample data) Demonstrator & Proof of Concept (e.g. using a Javascript framework) Iterative and agile software development > maturity > Continuous evaluation Software implementation (perpetual beta) Worker-centric Smart factory solutions Source:University of Zurich, Facts4Workers Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 18

19 Example: Thyssen Krupp Steel Europe AG Context-of-Use Problem-Solving Support for Mobile Maintenance Workers Personas Content UZH, FACTS4WORKERS, Source: Project Deliverable 1.1 Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 19

20 FACTS4WORKERS: Contexts-of-Use, problem & activity scenarios TKSE Problem Context-of-Use solving support for mobile maintenance workers Shift start missing contextual information Plans are changing Problem missing Scenarios orientation Repair missing support 60 degrees working temperature in the crane and missing activity information Begin of a shift an informed start Activity Scenarios Guided route Repair virtual support On site progressive planning and quick fix Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 20

21 Example case: Thyssen Krupp Steel Europe AG Problem-Solving Support for Mobile Maintenance Workers Problem Scenario 1: Start shift - missing contextual information 6 AM: Morning shift begins. Craft-master Harald is already in the tool-shop and starts dispatching maintenance list and defect reports to workers. Harald has seldom the time to prepare work packaging as wished. Kim & Roland sometimes lack important pieces of information about the unit of equipment, e.g. - Has this fault arisen before? - Who was the last person to maintain or patch the unit of equipment? - Which tool and protective equipment is necessary? - Are their plants that should be handled as priority? Content UZH, FACTS4WORKERS, Source: Project Deliverable 1.1 Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 21

22 Example case: Thyssen Krupp Steel Europe AG Problem-Solving Support for Mobile Maintenance Workers Activity Scenario 1: Beginning of a shift an informed start 6 AM - morning round: Craft Master Harald discussed the working packages briefings which he has already sent to his colleagues smart devices using the FACTS4WORKERS solution, adding the needed contextual information to the fault messages. Among other things, the briefings include the following information - Required tools and protective equipment - Maintenance history Kim logs into his tool shop tablet and sees the personal dashboard. His craft master has uploaded all the relevant work packages for Kim s shift. Kim downloads the briefing which is a list of places where he and Roland will have to fix specific issues. When Harald comes to Kim and Roland they go through all the problems and think on how to solve them. Kim and Roland can optimally prepare themselves for the work day and see which parts are needed or important during their shift and put them inside the transporter. The paperless process gives Kim and Roland enough time to discuss the problems and not how to get the needed information. Kim says now we have the required information at our fingertips. Roland knows most of the facts, but he is impressed with what the modern telephone knows. Content UZH, FACTS4WORKERS, Source: Project Deliverable 1.1 Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 22

23 Example case: Thyssen Krupp Steel Europe AG Problem-Solving Support for mobile maintenance workers Contextual information on machines Way to the site & specifica Contact person on site Service history (knowledge base) Actual status of service Type of incident Spare parts Practical knowledge of colleagues Identification of possible solutions (e.g. sharing photos of equipment) Useful tips on solution procedure Experiences regarding equipment or site Shorter distances Better communication Required information at hand in a smart and mobile way Increased satisfaction and productivity Content UZH, FACTS4WORKERS, Source: Project Deliverable 1.1 Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 23

24 Example case: Thyssen Krupp Steel Europe AG Problem-Solving Support for mobile maintenance workers Mock-Up Increasing problem-solving and innovation skills of workers Increasing worker satisfaction Increasing average worker-productivity Content UZH, FACTS4WORKERS, Source: Project Deliverable 1.1 Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 24

25 Summary: From problem over a scenario-based comic to a first solution artefact Problem Narrative Activity Narrative Content UZH, FACTS4WORKERS Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 25

26 Summary: Contexts-of-Use, problem scenarios and activity scenarios Content UZH, FACTS4WORKERS, Source: Project Deliverable 1.1 Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 26

27 Thank you for your attention! Dr. Alexander Stocker Information & Process Management Alexander Stocker Forum Produktion 2016 (FFG / bmvit) 27