Innovative Industrial Research and Development at IPH Hannover: Bridging Technology and Economy

1. Software Development in Production Research IPH – Institut für Integrierte ProduktionHannover gemeinnützige GmbH (Institute of Integrated Production Hannover Non-Profit Limited Company)

2. Agenda • What IPH „is“ and „does“ • Research Work • Discussion Björn Eilert, Andreas Bruns

3. Facts and figures –The Institut für Integrierte Produktion Hannover gGmbH • 1988: Foundation of the CIM factory Hanover gGmbH on the initiative of the professors Doege, Tönshoff and Wiendahl as a connecting link between research and industry • 1991: Move to the new institute building at the Marienwerder science park • 1993: Renaming to IPH - Institut für Integrierte Produktion Hannover gGmbH • 1998: Expansion of the institute building • Application-oriented research and development in the field of innovative industrial engineering as well as knowledge and technology transfer into economy • Combination of organizational and technological process chains through the co-operation of interdepartmental, interdisciplinary teams • 72 employees, including 28 engineers • Turnoverof about 2,6 million € in 2009 Björn Eilert, Andreas Bruns

4. Organizational structure Prof. Dr.-Ing. Bernd-Arno Behrens Prof. Dr.-Ing. habil. Peter Nyhuis Prof. Dr.-Ing. Ludger Overmeyer Partner Industry, federal state of Lower Saxony, University Advisory board Dr.-Ing. Dipl.-Oec. Rouven Nickel Managing Director Central Department Dipl.-Wirtsch.-Ing. Dirk Altmann Production automation Dipl.-Wirtsch.-Ing. Henner Gärtner Logistics Dipl.-Ing. Malte Stonis Process technology Björn Eilert, Andreas Bruns

5. Primary Industrial Sectors • Automotive industry and suppliers • Sheet metal forming industry • Mechanical engineering • Electronic industry • Aerospace industry • Forging industry • Mould and die production Björn Eilert, Andreas Bruns

6. Research Sponsors and Partners I • Project coordinators • Public sponsors • Commercial sponsors • Others Björn Eilert, Andreas Bruns

7. Focus on XXL products • XXL products in Lower Saxony • Commercial and special-purpose vehicles:Volkswagen, Krone, Alstom, MAN • Wind turbines:Enercon, Bard Engineering, Nordex • Commercial airplanes:Airbus • Ships:Meyer Werft, Abeking & Rasmussen • Conveyor technique:ContiTech • Exports accounting of Lower Saxony in XXL branches:> 30 % (> 20,2 billion €)1 • Exports accounting of XXL corporations:up to 90 % 1 Source: Lower Saxony State Office for Statistics Meike Wiegand

8. XXL products:Aim and need for action Innovation requirements (examples) XXL products • Simulation Conception • Modelling • Simulation Design • Processautomation • Material flowdesign • Logistics management • Networkmanagement • Production and assembly processes Manufacturing / installation • Conditionmonitoring • Serviceprocesses • Decentralization • Operatormodels Utilization • Simulation • Logistics processes • Mastery ofcomplexity • Dismantling /recovery • Reconditioning • Resourceefficiency Removal • Today´s manufacturing of XXL products equals a manufactory. • The challenge is the industrialization of manufacturing XXL products. Meike Wiegand

9. Research TopicsProcess Technology Department Multi-Functional Tools Cross Sectoral Research Topics • Forging • Hydroforming Profitability of Process Chains Processchain Conversion-Technology • Hybrid Forming (bulk/sheet) Björn Eilert, Andreas Bruns

10. SFB489 Teilprojekt B2Innovative Tool Technologies Initial Situation • Conventional forging leads to flash proportions up to 45 % • Huge post-processing effort Objectives • Reduction of production steps • Enhancement of energy and materialefficiency • Development of new tool concepts Results • Omission of chipping through precision forging • Precision forging of two cylinder crankshaft www.sfb489.uni-hannover.de Source: ThyssenKrupp Gerlach forging sequence Björn Eilert, Andreas Bruns

11. Research Topics Logistics Department Cross Sectoral Research Topics Design of Production Networks Local Control of Production in Networks Logistics Efficiency Resource Management • Save Material Flow in Production Networks Björn Eilert, Andreas Bruns

12. EZ-Pharm - Proving authenticity of folding boxes along the pharmaceutical supply chain Initial Situation • Imitations of pharmaceutical products harms health, economy and jobs • Bypassing longlasting and costly pharma research attracts imitators • Internet-pharmacies and re-imports demand new protective measures in distribution logistics Objectives • Prevent the distribution of pharmceutical plagiarisms • RFID as electronic originality certificate for pharmaceutical-packaging • Detection and safeguarding of plagiarisms at latest at end-consumer Results • Folding box with printed antenna and strap with pre-assembledRFID-chip • In pharmaceutical sector proven protection concept www.ez-pharm.de RFID-chip folding box connections strap strap role antenna sheet fed and antenna printing pre-assembly chip on strap strap assembly imitation detection Björn Eilert, Andreas Bruns

13. Research TopicsProduction Automation Department Simulation 101001100110 Cross Sectoral Research Topics • Distributed Systems • Wireless Communication Simulation Technology Business Process Design System Consistency • Smart Systems Björn Eilert, Andreas Bruns

14. Research Project Life-Cycle Idea Approved funding Project results New problem [2 - 3 years] Apply for funding Carry out project Utilize and enhance solution – identify new problems Generate new research ideas Björn Eilert, Andreas Bruns

15. Research Project Industrial partners Research institute Public sponsor Idea Workforce … Select Fund … Problem / Idea € € Theoretical solution € Prototype(software or physical) Test Use … Supervise Promote … Software Development within Research Projects: • Creative – implementation of new ideas asks for new solutions • Independent – small team, few constraints (e. g. existing software environments) • Interactive – theory and software sometimes impact each other • … • Often implemented by students Björn Eilert, Andreas Bruns

16. Agenda • What IPH „is“ and „does“ • Research Work • Discussion Björn Eilert, Andreas Bruns

17. Working at the IPH • First contact • Interesting Bachelor thesis • Chances at the IPH • Self-reliant working • Different projects • Responsibility • Positive aspects • Young team • Cooperative work atmosphere • Hannover • Tasks as an Software-Engineer • Develop software prototypes • Mentoring of students Björn Eilert, Andreas Bruns

18. Service-Support through Semantic Web-Technologies Initial Situation • For complex machines and devices failure resolution requires huge amount of know-how • Service employees spend much time on information retrieval (e. g. in failure-databases) • Simple information retrieval technologies do not bring forth high quality results in adequate time Objectives • Support of service-hotlines during retrieval of similar service-cases through the utilization of semantic web-technologies • Implementation of a software prototype Results • Algorithms for the retrieval of similar service-cases on the basis of meaning insteadof simple syntax (usage of ontologies) • Web-based database solution to ease service-case acquisition and retrieval (software engineer required) Björn Eilert, Andreas Bruns xxxx

19. SemanticHelpline • History • 2004 – 2005: Erfahrungsbasierte Verknüpfung von Fehlerinformationen beim Betrieb von Werkzeugmaschinen zur Unterstützung von Service HotlinesExperience-Based linking of failure information at tool machines to support service-hotlines • Case documentation • Search with phonetic encoding • PHP / Oracle • 2007 – 2009: Semantic Web-Technologien zur Unterstützung des Service am Beispiel MaschinenbauService support through semantic web-technologies at the example of Mechanical Engineering • Semantic categorization with FIZ-Thesaurus • Java (Seam) / Oracle, PostgreSQL, MS SQL • 2009 – 2010: SemanticHelpline • Semantic search with FIZ-Thesaurus as DB & Wiktionary as DB Björn Eilert, Andreas Bruns

20. SemanticHelpline – Search Björn Eilert, Andreas Bruns

21. SemanticHelpline – Thesaurus search Björn Eilert, Andreas Bruns

22. Intelligente Schnittstellen in wandlungsfähigen Lieferketten (ISI-WALK) Initial Situation • Today‘s supply chains suffer from multiple obstacles. • Exemplary obstacles are rigidly automated conveying and storage systems as well as an insufficient consistency between physical and digital material logistics. Objectives • The projects aims at the development of specific technologies and methods to realize an efficient and economic operation of versatile supply chains. Results • positioning system based on optical technology • versatile warehouse management system • system for 3D object recognition • method for plannung and evaluation of versatility www.isi-walk.de (work in progress) (electrical / software engineer required) Björn Eilert, Andreas Bruns

23. Automatisierte, CAD-basierte Kalkulation und Konstruktion (AutoKalK) Initial Situation • Tool manufacturers must improve revenue and expense of their tender preparation • Production processes are to be planed flexibly in dependence of mould design and the trend of costs during the tool production is to be supervised Objectives • The project’s aim is to develop a method for automated CAD model creation and CAD-based costing of tools Results • Automated strip chart-based generation of CAD models • Automated and CAD-based costing and monitoring using artificial intelligence algorithms (software engineer required) Björn Eilert, Andreas Bruns

24. Smart Tools for Abrasive Cutting Initial Situation • Over 67% of the total production costs of granite flaggings and boards are determined by the abrasive cutting process • Major energy and material costs are caused by high chipping ratios (cutting width / board width ~ 1) Objectives • Development of a smart cutting tool that allows to reduce the cutting-wheel width as well as the risk of cut deviations Results • Integration of measuring technology into the cutting-wheel for data acquisition (piezo-electric sensor) and preprocessing (chip) • Wireless data transfer to machine control • Reduction of cut deviations by automatedcontrol mechanisms (electrical / software engineer required) Björn Eilert, Andreas Bruns

25. Student Jobs @ IPH • www.iph-hannover.de  Wissen  Studium  Newsletter Björn Eilert, Andreas Bruns

26. Agenda • What IPH „is“ and „does“ • Research Work • Discussion Björn Eilert, Andreas Bruns

27. Discussion Questions !? • Questions about IPH? • Questions about how to do a research project? • Questions about the introduced projects? • Other questions or remarks? Björn Eilert, Andreas Bruns

28. Contacts Dipl.-Wirt.-Ing. Björn Eilert Andreas Bruns Bachelor of ICT, NL IPH – Institut für Integrierte Produktion Hannover gGmbH Hollerithallee 6 30419 Hannover Tel.: +49 511 279 76 - 228 Fax: +49 511 279 76 - 888 E-Mail: eilert@iph-hannover.de www.iph-hannover.de Björn Eilert, Andreas Bruns

29. Ablauf der Semantischen Suche Dokumentierte Servicefälle 1 Relevanter Suchtext 2 Codierter Suchtext 3 Kategorisierte Begriffe 4 Ergebnisliste mit ähnlichen Servicefällen 5 Servicefall-Erfassung • Dokumentation der Servicefälle und Speicherung in der Datenbasis Fall- basis • Entfernung von Stoppwörtern, Umlauten, Satzzeichen, Abkürzungen, etc. • Grundformreduktion Vorverarbeitung Phonetische Codierung • Codierung des Textes zur Toleranz ggü. Rechtschreibfehlern Synonymsuche • Ermittlung von Synonymen • Kategorisierung der Begriffe Thesauri • Berechnung des Ähnlichkeitsmaßes für Servicefälle in der Datenbasis • Ausgbe der ähnlichen Servicefälle nach Relevanz Identifikation von ähnlichen Servicefällen Björn Eilert, Andreas Bruns