Using a digital twin and smart services to enable automatic generation of context-sensitive instructions

Journal of Manufacturing Systems, vol. 83, pp. 652–674

Abstract

The increasing diversity and shorter life cycles of technical products pose significant challenges for manufacturing companies, particularly in the context of providing specific and context-sensitive instructions to employees, especially in domains including maintenance, assembly and disassembly. This challenge holds significant importance in the context of the current skilled worker shortage. This paper proposes a solution by leveraging digital twin technology and smart services to automate the generation of context-sensitive instructions. The research outlines the development of a smart service system that uses real-time data from digital twins to create and deliver adaptive and user-specific instructions via smart devices. A conceptual design of the smart service system, a prototypical implementation using a rolling mill maintenance task, and the verification and validation of the developed system were carried out. The results indicate that the proposed system effectively addresses the challenges of traditional manual instructions, enhancing efficiency, accuracy, and user satisfaction. • Leverages digital twin technology for context-sensitive manufacturing instructions. • Smart services generate adaptive, user-specific guidance in real-time. • Validated system improves efficiency, accuracy, and user satisfaction in industrial applications. • Demonstrates reduced errors and faster task execution in a rolling mill maintenance case study.

Authors 7

1. Karl Lossie Aachen Fraunhofer Institute for Production Technology IPT

   Fraunhofer Institute for Production Technology IPT

   Affiliation as printed

   Fraunhofer Institute for Production Technology IPT, Steinbachstraße 17, Aachen 52074, Germany

2. Jan Hendrik Hellmich corresponding Aachen Fraunhofer Institute for Production Technology IPT

   Fraunhofer Institute for Production Technology IPT

   Affiliation as printed

   Fraunhofer Institute for Production Technology IPT, Steinbachstraße 17, Aachen 52074, Germany

3. Junjie Liang Aachen Laboratory for Machine Tools and Production Engineering WZL

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University, Campus-Boulevard 30, Aachen 52074, Germany

4. Jonas Baum Aachen Laboratory for Machine Tools and Production Engineering WZL

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University, Campus-Boulevard 30, Aachen 52074, Germany

5. Amon Göppert Aachen Laboratory for Machine Tools and Production Engineering WZL

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University, Campus-Boulevard 30, Aachen 52074, Germany

6. Dennis Grunert Aachen Fraunhofer Institute for Production Technology IPT

   Fraunhofer Institute for Production Technology IPT

   Affiliation as printed

   Fraunhofer Institute for Production Technology IPT, Steinbachstraße 17, Aachen 52074, Germany

7. Robert Heinrich Schmitt Aachen Fraunhofer Institute for Production Technology IPT Laboratory for Machine Tools and Production Engineering WZL

   Fraunhofer Institute for Production Technology IPT · RWTH Aachen University

   Affiliation as printed

   Fraunhofer Institute for Production Technology IPT, Steinbachstraße 17, Aachen 52074, Germany

   Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University, Campus-Boulevard 30, Aachen 52074, Germany