- Email: [email protected]
Human Robot Interaction – learning how to integrate collaborative robots into manual assembly lines
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Available Availableonline onlineatatwww.sciencedirect.com www.sciencedirect.com Procedia Manufacturing 00 (2019) 000–000 Procedia Manufacturing 00 (2019) 000–000
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Procedia Manufacturing 31 (2019) 26–31 Procedia Manufacturing 00 (2017) 000–000
9th Conference on Learning Factories 2019 9th Conference on Learning Factories 2019
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Human Robot Interaction – learning how to integrate collaborative Human Robot Interaction – learning how to integrate collaborative robots intoInternational manual assembly lines Manufacturing Engineering Society Conference 2017, MESIC 2017, 28-30 June robots into manual assembly lines 2017, Vigo (Pontevedra), Spain
Henning Oberca,*, Christopher Prinza, Paul Glogowskia, Kai Lemmerza, Bernd a a a Henning Oberca,*, Christopher Prinz , Paul Glogowski , Kai Lemmerza, Bernd Kuhlenkötter Costing models for capacity Kuhlenkötter optimization in Industry 4.0: Trade-off a
between used capacity and operational efficiency
Ruhr-Universität Bochum, Chair of Production Systems, Universitätsstraße 150, 44801 Bochum, Germany Ruhr-Universität Bochum, Chair of Production Systems, Universitätsstraße 150, 44801 Bochum, Germany
a a
A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb
Abstract a Abstract University of Minho, 4800-058 Guimarães, Portugal b Human-Robot Collaboration (HRC) is one of the main challenges companies today. Despite the trend on collaborative robots, Unochapecó, 89809-000for Chapecó, SC, Brazil use cases within manufacturing systems seem to be stillchallenges rare. Although collaborative robots are promised to be one of the crucial Human-Robot Collaboration (HRC) is one of the main for companies today. Despite the trend on collaborative robots, innovations for ergonomically for to blue workers, the collaborative integration process intopromised the production process the use cases within manufacturing assistance systems seem be collar still rare. Although robots are to be one of theand crucial preoccupation workers against robot assistance be assumed as biggest process challenges of theand reason innovations forofergonomically assistance for bluealike, collarcan workers, the integration intoforthecompanies. productionOne process the Abstract might be the missing methodology and assistance simulationalike, tools can for quick analysis workplaces, in order to detect possible preoccupation of workers against robot be assumed as of biggest challenges for companies. One of workloads the reason for robots. The given methodology article presentsand a developed seminar for students as well as industrial on how might be the missing simulationlearning tools forfactory quick analysis of workplaces, in order to detect participants possible workloads Under theThe concept of robots "Industry production processes will focuses be students pushed be asincreasingly interconnected, to collaborative into manual assembly lines. This approach on theasto problem based learning structure the forintegrate robots. given article presents a4.0", developed learning factory seminar for well industrial participants onofhow information based arobots real methods time basis necessarily, much more efficient. Intoproblem this context, capacity optimization seminar andcollaborative on the on essential andand, developed concepts which are necessary analyze workplaces, simulate robot to integrate into manual assembly lines. This approach focuses on the based learning structure of the integration possibility of analyzing distributed workload between andanalyze the robot. Tools as asimulate “quick check” goes beyond thethe traditional of capacity maximization, contributing alsoworker for organization’s profitability and value. seminar andwith on the essentialaim methods andthe developed concepts which are the necessary to workplaces, robot analysis for HRC the simulation software Editor of manual work activities (ema) and will be robot. integrated this concept. integration with theand possibility of analyzing the distributed workload between thesuggest worker the Toolsduring as a “quick check” Indeed, lean management and continuous improvement approaches capacity optimization instead of Besides and the different organization of workisby implementing HRC in atopic production process, analysis the for technological HRC andstudy theimplementation simulation software Editor ofand manual workmodels activities (ema) will be research integrated during thisdeserves concept. maximization. The of capacity optimization costing an important that the participants will also the affects and changes for the employees. This willimplementing cover the T-O-P (technology-organizationBesides the technological implementation and the different organization of work by in a production process, contributions from bothdiscuss the practical and theoretical perspectives. This paper presents andHRC discusses a mathematical employee) approach [1] and will help to design an implementation project for HRC. the participants will also discuss the affects and changes for the employees. This will cover the T-O-P (technology-organizationmodel for capacity management based on different costing models (ABC and TDABC). A generic model has been employee) approach [1] and will help to design an implementation project for HRC. developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s © 2019 The Authors. Published by Elsevier B.V. value. The trade-off capacity maximization operational efficiency is highlighted and it is shown that capacity © 2019 The Authors. Published Elsevier B.V. vs Peer review the responsibility of the scientific committee of the 9th Conference on Learning Factories. © 2019 Theunder Authors. Published by by Elsevier B.V. Peer review under thehide responsibility of the scientific committee of theth9th Conference on Learning Factories. optimization might operational inefficiency. Peer review under the responsibility of the scientific committee of the 9 Conference on Learning Factories. © 2017 The Authors. by Elsevier B.V. learning factory; HRC Keywords: Industrie 4.0;Published human machine collaboration; Peer-review under responsibility of the scientific of theHRC Manufacturing Engineering Society International Conference Keywords: Industrie 4.0; human machine collaboration;committee learning factory; 2017. Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency
1. Introduction * The Corresponding author. Tel.: +49-0234-32-27348; +49-0234-32-14157. cost of idle capacity is a fundamentalfax: information for companies and their management of extreme importance address:author. [email protected] * E-mail Corresponding Tel.: +49-0234-32-27348; fax: +49-0234-32-14157. in modern production systems. In general, it is defined as unused capacity or production potential and can be measured E-mail address: [email protected] in several ways: tons of production, available hours of manufacturing, etc. The management of the idle capacity 2351-9789 © 2019 The Authors. Published by Elsevier B.V. * Paulo Afonso. +351 253 Published 510of761; fax: +351committee 253 604 741 Peer review the the scientific of the 9th Conference on Learning Factories. 2351-9789 ©under 2019Tel.: Theresponsibility Authors. by Elsevier B.V. E-mail address: [email protected] Peer review under the responsibility of the scientific committee of the 9th Conference on Learning Factories. 2351-9789 © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017. 2351-9789 © 2019 The Authors. Published by Elsevier B.V. Peer review under the responsibility of the scientific committee of the 9th Conference on Learning Factories. 10.1016/j.promfg.2019.03.005
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Henning Oberc et al. / Procedia Manufacturing 31 (2019) 26–31 Author name / Procedia Manufacturing 00 (2019) 000–000
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1. Introduction In the context of Industrie 4.0 many companies are facing a lot of challenges to ensure a successful viability on the global market. Cyber-physical systems (CPS) are proclaimed to have a great impact within the Industrie 4.0 era. CPS can be defined as “… the integrations of computation with physical processes. Embedded computers and networks monitor and control the physical processes, usually with feedback loops where physical processes affect computations and vice versa.“ [2]. Intelligent assistance systems for workers can be considered as CPS, in case they dynamically interact with the worker and at the same time communicate with the digital world of the working space. Classifications of assistance systems leave to main two main groups, one the hand the physical assistance, on the other hand the psychological assistance. An example for the physical group are collaborative robots (cobots) which provide a co-working-spacing for robots and humans such enabling a physical interaction and collaborative execution in a shared workspace [3]. Human-robot-collaboration (HRC) is expected to increase the quality rate and performance efficiency [4]. Studies show that the market for cobots will increase rapidly in the next years. By 2025, a third of all sold robots will be cobots. [5] The majority of studies regarding HRC explore the technical aspects of cobots. Nevertheless the integration of cobots into human oriented workspaces and the evaluation of HRC potential for workspaces still require new approaches [6, 7] Considering different studies, the highest potential for HRC is seen in assembly scenarios [8]. Based on this premise we have developed a practical learning approach for HRC integration. The aim of this paper is to give an outline of existing trainings on the topic and further more describe the developed training concept, with a characterization of its advantages. 2. Human-Robot-Collaboration In the following chapters, a short current state of the art in the areas of human robot collaboration, as well as the planning of collaborative assembly systems will be presented. 2.1. State of the art HRC is an enabler to combine the ability and flexibility of humans with the benefits of robots. The production will be able to increase productivity, improve the quality and low the ergonomic load for workers [9]. There are different levels of cooperation between humans and robots. The conventional The use of robots in the industry is characterized by a strict separation of the working areas (e.g. protective fences) and is the current state of the art. Access to the working area is only possible for maintenance work, commissioning and teach-in work. [10] In autarkic/coexistent operation there is also a separation of the working area but without physical separators. Access to the robot Work area is possible for short, sporadic stays and is indicated by a residence recognition registered. At the same time, the robot behavior is adjusted (speed/performance force reduction). In synchronized operation, humans and robots work in the same working space, but at different times, so that only one action partner at a time in the workroom. The cooperating cooperation enhances a temporal and spatial separation, so that both action partners can be separated at the same time in the same workspace. However, there is no joint activity. Only in collaboration human being and robot work on a common task without any temporal or spatial separation of the working area. [11] Since the beginning of the 20th century approaches of implementing HRC in assembly lines increases. Approaches of Beumelburg [12], Zülch [13] or Takata and Hirano [14] are well known in many theories. These theories started on a very early need for HRC but do not cover the nowadays requirements. Approaches are developing and including higher developed simulation programs which include quick check analysis and
Henning Oberc et al. / Procedia Manufacturing 31 (2019) 26–31 Author name / Procedia Manufacturing 00 (2019) 000–000
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3
ergonomically considerations for example two approaches of the Fraunhofer IAO or the quick check from the project KOMPI [15, 16]. 2.2. Comparison of available seminars regarding HRC The following table 1. shows a few seminars on training of HRC. They were listed and summarized in a secondary analysis with the topics and the focus in their trainings. This comparison emphasizes the necessity of new trainings for HRC. All compared seminars take place in Germany and last between one and five days so that there is a high variance in duration. But in this paper we will only focus on the topics not on the duration. The organizers vary from academic institutions to industrial companies or academies. The analysis of different available trainings shows that the main focus is on technology itself as well as safety aspects. Because cobots are deployed in an environment which human workers, safety is of the main challenges in HRC and have a high significance. [17] While all of the analyzed trainings focus on technology and safety aspects, only a few incorporate financial aspects when planning HRC applications. A key aspect of all when considering the integration of cobots is the HRC potential. In order to anticipate the advantages of HRC in each individual field of application, potential analysis are required. Since the presented concept will take place in Germany topics as co-determination cannot be neglected. This aspect will have a great impact in the training what will make the seminar very useful for the participants to integrate HRC in the industry. Underestimating the topic of co-determination and including workers’ councils often leads to a delayed implementation of HRC because important aspects such as protection of the workers’ data is not considered enough. Table 1. Comparison of HRC trainings. Technology
Organization
Personnel
Finance
Codetermination
Safety
HRC Potential
Simulation (program, real)
Fraunhofer academy
x
-
-
x
-
x
x
program
IHK/ABB
x
-
-
-
-
x
-
real
WEKA Akademie
x
-
-
-
-
x
-
-
Managementcircle
x
-
-
x
?
x
x
real
PILZ
x
-
-
-
-
x
-
real
Stuttgarter Produktionsakademie
x
-
-
-
-
x
x
?
Seminars
3. Training concept The training is set in a learning factory environment and focuses on students as target audience. As shown in table 1. most approaches address the technical implementation of HRC. The developed training emphasizes on organization and personnel aspects. It sensitizes about HRC and introduces tools to analyze (manual) assembly workstations with lean management principles and quick check analysis in order to determine the potentials of HRC. Since the training will take place in the LPS learning factory in Bochum the approach is also action-oriented and problem solving.
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3.1. Procedure of the training The training concept is a continuous change of theory and practice in 4 cycles. At the start, students or participants will get a theoretical introduction on HRC basics. The introduction will cover HRC issues with topics such as technology, organization and personnel. It will be a good introduction to the seminar but will only focus on a few problems occurring during the implementation of HRC. Cycle 1 To get a first overview of the focused work area, students will go to a real assembly line in the LPS-Learning factory where a bottle cap is produced and assembled. In the next step, students will analyze this assembly line with the help of the value stream method to get a better understanding of the whole process. At the end of each cycle, the students will present their results to the rest of the course. Cycle 2 For the analysis of manual workstations and processes with regards to HRC potential, students use appropriate evaluation systematics [9, 18, 19] in the next cycle. These systematics provide initial decision-making aids for the selection of automated or robot tasks. In addition, feasibilities of the redesign to a collaborative assembly application will be estimated. In this context, the use of evaluation methods such as the so called Quick-Check [16] or the potential check developed by the Fraunhofer IAO [20] are one of the key aspects besides the classical time determination (e.g. by MTM). Individual work stations and process steps, as well as components and assembly equipment are assessed with regards to various criteria (parts provision, component geometry, ergonomics, safety etc.). Cycle 3 After the analysis of the assembly line and its HRC potential, participants will focus on further aspects. Because of the industrial constitution law in Germany there has to be a special focus on operational co-determination, as every new introduction of a technology is co-determination obligatory. The other focus of the students will be costs. They will look at costs or effort of reprogramming, or the simple investment in different robot and safety systems. Cycle 4 The last part of the seminar is the technical implementation of the concepts. It starts with a simulation software called Editor for Manual Work Activities (ema) [11, 21]. This tool offers an intuitive evaluation of ergonomics (EAWS etc.) and process time (MTM-UAS etc.) of a modelled manual workflow and a realistic visualization of human movements. The results of the simulation studies are expected to provide further redesign support beyond the previously described rough HRC potential analysis. After the analysis in ema, the next task is to design the new work places. The last step is the programming of the robots. The technical equipment in the learning factory for different robots is very widespread. There are different robots the students or participants can use in the technical implementation phase. The robots are YuMi from ABB, iiwa from KUKA, a robot from the company PILZ and Franka Emika. Both the YuMi and Franka Robot can be programmed with a teaching technique that is easy to handle. At this point, it should be mentioned that the LPS is currently engaged in research activities in the field of a holistic HRC planning and simulation environment. Hereby the functional integration of a robot simulation and programming framework into the above-mentioned ema tool takes place [22]. Fig. 1 summarizes the different cycles in a short overview. The fundament of the seminar concept is built by the access to theory. This knowledge is important for the HRC integration phase that is followed. It starts with the skills and the practices. The decision of integration HRC by including the factor cost and laws. At the end of each cycle there will be an evaluation or reflection.
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Author name / Procedia Manufacturing 00 (2019) 000–000 Henning Oberc et al. / Procedia Manufacturing 31 (2019) 26–31
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Fig. 1. short summary of the four training cycles
After the technical implementation the concepts have to be evaluated. The best way to do so is to simulate the new value creation process and compare it with the value stream from the beginning of the training. Besides the different techniques or the different organization of work there will also be a change in key figures of the production process. 4. Evaluation of the training concept Since the developed training concept hasn’t been evaluated to prove its effectiveness, this paper introduces the constructed evaluation method. The reason for evaluating the concept is to prove and improve the effectiveness of the training. The evaluation concept consists of different methods described by Rae and by Rohrschneider and Lorenz questionnaires before and after the training, [23] feedback interviews after the training and exam at the end of the semester. The training will be introduced to different groups of bachelor students and master students. At the beginning of the training each participant will be given a questionnaire to retrieve the existing knowledge about HRC. The questionnaire is divided into topics. These topics cover questions about general knowledge on HRC, methods to analyze HRC potential and integration, issues on co-determination, economical aspects, etc. The results will be compared to the results of a second questionnaire at the end of the training. This questionnaire will be given to the group again after 4 weeks to show the recollection rate of the practically implemented knowledge. In addition, a feedback interview at the end should give some indication of the seminar’s success rate, however this is subject to the subjective assessment of each participant. The last success control mechanism is an exam at the end of the semester. In contrast to the questionnaires the exam is a rather detailed control mechanism. 5. Conclusion and outlook Companies are more and more interested in human robot collaboration. However general applications in the production environment seemed to be rare. Although manual assembly processes have been identified to have the highest potential for HRC. Furthermore, simple methods to analyse the specific potential of workplaces, finance aspects and co-determination aspects for HRC are matter of research as well as training concepts to impart knowledge how to use such methods. The described concept aims at closing this gap. With an action-oriented and problem-solving training concept within a learning factory, the presented approach focuses the training not on the detailed technical aspects of HRC but rather on the organisational and personnel topics. Further studies have to show the effectiveness of the approach, which will be subject to described evaluation.
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References [1] Strohm, O., Escher, O.P., Editors, 1997. Unternehmen arbeitspsychologisch bewerten: Ein Mehr-Ebenen-Ansatz unter besonderer Berücksichtigung von Mensch, Technik und Organisation. vdf Hochschulverl. an der ETH Zürich. [2] Verein Deutscher Ingenieure e.V., Editor, 2013. Cyber-Physical Systems: Chancen und Nutzen aus Sicht der Automation. [3] Colgate, J.E., Wannasuphoprasit, W., Peshkin, M., Editors, 1996. COBOTS: ROBOTS FOR COLLABORATION WITH HUMAN OPERATORS. [4] Vallespir, B., Editor, 2010. Advances in Production Management Systems. New Challenges, New Approaches: IFIP WG 5.7 International Conference, APMS 2009, Bordeaux, France, September 21-23, 2009, Revised Selected Papers. IFIP International Federation for Information Processing. [5] 2018. FREE THE COBOTS!: Mobile Roboter stellen die Fertigung auf den Kopf. [6] Schraft, R.D., Meyer, C. "The need for an intuitive teaching method for small and meadium enterprises" in Robotik 2006, p. 95. [7] Mourtzis, D., Vlachou, E., Dimitrakopoulos, G., Zogopoulos, V., 2018. Cyber- Physical Systems and Education 4.0 –The Teaching Factory 4.0 Concept 23, p. 129. [8] Bauer, W.(E.), Bender, M., Braun, M., Rally, P., Scholtz, O. Lightweight robots in manual assembly – best to start simply!: Examining companies’ initial experiences with lightweight robots, 2006. [9] Linsinger, M., Sudhoff, M., Lemmerz, K., Glogowski, P. et al., 2018. Task-based Potential Analysis for Human-Robot Collaboration within Assembly Systems, in Tagungsband des 3. Kongresses Montage Handhabung Industrieroboter, Springer Berlin Heidelberg, Berlin, Heidelberg, p. 1. [10] Thomas, C., 2017. Entwicklung einer Bewertungssystematik für die Mensch-Roboter-Kollaboration. [11] Bauer, S., 2015. Prozesssprachenbasiertes System zur Ansteuerung digitaler Menschmodelle als Teilkomponente einer Software zur Planung und Visualisierung menschlicher Arbeit in der Digitalen Fabrik, Chemnitz. [12] Beumelburg, K., Editor, 2005. Fähigkeitsorientierte Montageablaufplanung in der direkten Mensch-Roboter-Kooperation. Jost-Jetter. [13] Zülch, G., Becker, M., 2010. A simulation-supported approach for man-machine configuration in manufacturing 125, p. 41. [14] Takata, S., Hirano, T., Editors, 2011. Human and robot allocation method for hybrid assembly systems. [15] Bauer, W., Rally, P., Scholtz, O., Editors, 2018. Schnelle Ermittlung sinnvoller MRK-Anwendungen. [16] Ermer, A.-K., Seckelmann, T., Barthelmey, A., Lemmerz, K. et al., 2019. A Quick-Check for Assembly Systems' HRI Potential, in 4. MHI Fachkolloqium, Springer Verlag, (accepted). [17] Berg, J., Reinhart, G., 2017. An Integrated Planning and Programming System for Human-Robot-Cooperation 63, p. 95. [18] Ermer, A.-K., Steckelmann, T., Barthelmey, A., Lemmerz, K. et al. A Quick-Check for Assembly Systems’ HRI Potential. [19] Thomas, C., 2017. Entwicklung einer Bewertungssystematik für die Mensch-Roboter-Kollaboration, Bochum. [20] Bauer, W., Rally, P., Scholtz, O., 2018. Schnelle Ermittlung sinnvoller MRK-Anwendungen 113, p. 554. [21] Fritzsche, L., Jendrusch, R., Leidholdt, W., Bauer, S. et al., 2011. Introducing ema (Editor for Manual Work Activities)-A New Tool for Enhancing Accuracy and Efficiency of Human Simulations in Digital Production Planning, in HCI (17), p. 272. [22] Lemmerz, K., Glogowski, P., Hypki, A., Kuhlenkötter, B., 2018. Functional Integration of a Robotics Software Framework into a Human Simulation System, in 50th International Symposium on Robotics (ISR 2018), Munich, Germany. [23] Rohrschneider, U., Lorenz, M., Editors, 2011. Der Personalentwickler: Instrumente, Methoden, Strategien, 1st edn. Gabler Verlag / Springer Fachmedien Wiesbaden GmbH Wiesbaden.
ScienceDirect ScienceDirect
Available Availableonline onlineatatwww.sciencedirect.com www.sciencedirect.com Procedia Manufacturing 00 (2019) 000–000 Procedia Manufacturing 00 (2019) 000–000
ScienceDirect ScienceDirect
www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia
Procedia Manufacturing 31 (2019) 26–31 Procedia Manufacturing 00 (2017) 000–000
9th Conference on Learning Factories 2019 9th Conference on Learning Factories 2019
www.elsevier.com/locate/procedia
Human Robot Interaction – learning how to integrate collaborative Human Robot Interaction – learning how to integrate collaborative robots intoInternational manual assembly lines Manufacturing Engineering Society Conference 2017, MESIC 2017, 28-30 June robots into manual assembly lines 2017, Vigo (Pontevedra), Spain
Henning Oberca,*, Christopher Prinza, Paul Glogowskia, Kai Lemmerza, Bernd a a a Henning Oberca,*, Christopher Prinz , Paul Glogowski , Kai Lemmerza, Bernd Kuhlenkötter Costing models for capacity Kuhlenkötter optimization in Industry 4.0: Trade-off a
between used capacity and operational efficiency
Ruhr-Universität Bochum, Chair of Production Systems, Universitätsstraße 150, 44801 Bochum, Germany Ruhr-Universität Bochum, Chair of Production Systems, Universitätsstraße 150, 44801 Bochum, Germany
a a
A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb
Abstract a Abstract University of Minho, 4800-058 Guimarães, Portugal b Human-Robot Collaboration (HRC) is one of the main challenges companies today. Despite the trend on collaborative robots, Unochapecó, 89809-000for Chapecó, SC, Brazil use cases within manufacturing systems seem to be stillchallenges rare. Although collaborative robots are promised to be one of the crucial Human-Robot Collaboration (HRC) is one of the main for companies today. Despite the trend on collaborative robots, innovations for ergonomically for to blue workers, the collaborative integration process intopromised the production process the use cases within manufacturing assistance systems seem be collar still rare. Although robots are to be one of theand crucial preoccupation workers against robot assistance be assumed as biggest process challenges of theand reason innovations forofergonomically assistance for bluealike, collarcan workers, the integration intoforthecompanies. productionOne process the Abstract might be the missing methodology and assistance simulationalike, tools can for quick analysis workplaces, in order to detect possible preoccupation of workers against robot be assumed as of biggest challenges for companies. One of workloads the reason for robots. The given methodology article presentsand a developed seminar for students as well as industrial on how might be the missing simulationlearning tools forfactory quick analysis of workplaces, in order to detect participants possible workloads Under theThe concept of robots "Industry production processes will focuses be students pushed be asincreasingly interconnected, to collaborative into manual assembly lines. This approach on theasto problem based learning structure the forintegrate robots. given article presents a4.0", developed learning factory seminar for well industrial participants onofhow information based arobots real methods time basis necessarily, much more efficient. Intoproblem this context, capacity optimization seminar andcollaborative on the on essential andand, developed concepts which are necessary analyze workplaces, simulate robot to integrate into manual assembly lines. This approach focuses on the based learning structure of the integration possibility of analyzing distributed workload between andanalyze the robot. Tools as asimulate “quick check” goes beyond thethe traditional of capacity maximization, contributing alsoworker for organization’s profitability and value. seminar andwith on the essentialaim methods andthe developed concepts which are the necessary to workplaces, robot analysis for HRC the simulation software Editor of manual work activities (ema) and will be robot. integrated this concept. integration with theand possibility of analyzing the distributed workload between thesuggest worker the Toolsduring as a “quick check” Indeed, lean management and continuous improvement approaches capacity optimization instead of Besides and the different organization of workisby implementing HRC in atopic production process, analysis the for technological HRC andstudy theimplementation simulation software Editor ofand manual workmodels activities (ema) will be research integrated during thisdeserves concept. maximization. The of capacity optimization costing an important that the participants will also the affects and changes for the employees. This willimplementing cover the T-O-P (technology-organizationBesides the technological implementation and the different organization of work by in a production process, contributions from bothdiscuss the practical and theoretical perspectives. This paper presents andHRC discusses a mathematical employee) approach [1] and will help to design an implementation project for HRC. the participants will also discuss the affects and changes for the employees. This will cover the T-O-P (technology-organizationmodel for capacity management based on different costing models (ABC and TDABC). A generic model has been employee) approach [1] and will help to design an implementation project for HRC. developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s © 2019 The Authors. Published by Elsevier B.V. value. The trade-off capacity maximization operational efficiency is highlighted and it is shown that capacity © 2019 The Authors. Published Elsevier B.V. vs Peer review the responsibility of the scientific committee of the 9th Conference on Learning Factories. © 2019 Theunder Authors. Published by by Elsevier B.V. Peer review under thehide responsibility of the scientific committee of theth9th Conference on Learning Factories. optimization might operational inefficiency. Peer review under the responsibility of the scientific committee of the 9 Conference on Learning Factories. © 2017 The Authors. by Elsevier B.V. learning factory; HRC Keywords: Industrie 4.0;Published human machine collaboration; Peer-review under responsibility of the scientific of theHRC Manufacturing Engineering Society International Conference Keywords: Industrie 4.0; human machine collaboration;committee learning factory; 2017. Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency
1. Introduction * The Corresponding author. Tel.: +49-0234-32-27348; +49-0234-32-14157. cost of idle capacity is a fundamentalfax: information for companies and their management of extreme importance address:author. [email protected] * E-mail Corresponding Tel.: +49-0234-32-27348; fax: +49-0234-32-14157. in modern production systems. In general, it is defined as unused capacity or production potential and can be measured E-mail address: [email protected] in several ways: tons of production, available hours of manufacturing, etc. The management of the idle capacity 2351-9789 © 2019 The Authors. Published by Elsevier B.V. * Paulo Afonso. +351 253 Published 510of761; fax: +351committee 253 604 741 Peer review the the scientific of the 9th Conference on Learning Factories. 2351-9789 ©under 2019Tel.: Theresponsibility Authors. by Elsevier B.V. E-mail address: [email protected] Peer review under the responsibility of the scientific committee of the 9th Conference on Learning Factories. 2351-9789 © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017. 2351-9789 © 2019 The Authors. Published by Elsevier B.V. Peer review under the responsibility of the scientific committee of the 9th Conference on Learning Factories. 10.1016/j.promfg.2019.03.005
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Henning Oberc et al. / Procedia Manufacturing 31 (2019) 26–31 Author name / Procedia Manufacturing 00 (2019) 000–000
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1. Introduction In the context of Industrie 4.0 many companies are facing a lot of challenges to ensure a successful viability on the global market. Cyber-physical systems (CPS) are proclaimed to have a great impact within the Industrie 4.0 era. CPS can be defined as “… the integrations of computation with physical processes. Embedded computers and networks monitor and control the physical processes, usually with feedback loops where physical processes affect computations and vice versa.“ [2]. Intelligent assistance systems for workers can be considered as CPS, in case they dynamically interact with the worker and at the same time communicate with the digital world of the working space. Classifications of assistance systems leave to main two main groups, one the hand the physical assistance, on the other hand the psychological assistance. An example for the physical group are collaborative robots (cobots) which provide a co-working-spacing for robots and humans such enabling a physical interaction and collaborative execution in a shared workspace [3]. Human-robot-collaboration (HRC) is expected to increase the quality rate and performance efficiency [4]. Studies show that the market for cobots will increase rapidly in the next years. By 2025, a third of all sold robots will be cobots. [5] The majority of studies regarding HRC explore the technical aspects of cobots. Nevertheless the integration of cobots into human oriented workspaces and the evaluation of HRC potential for workspaces still require new approaches [6, 7] Considering different studies, the highest potential for HRC is seen in assembly scenarios [8]. Based on this premise we have developed a practical learning approach for HRC integration. The aim of this paper is to give an outline of existing trainings on the topic and further more describe the developed training concept, with a characterization of its advantages. 2. Human-Robot-Collaboration In the following chapters, a short current state of the art in the areas of human robot collaboration, as well as the planning of collaborative assembly systems will be presented. 2.1. State of the art HRC is an enabler to combine the ability and flexibility of humans with the benefits of robots. The production will be able to increase productivity, improve the quality and low the ergonomic load for workers [9]. There are different levels of cooperation between humans and robots. The conventional The use of robots in the industry is characterized by a strict separation of the working areas (e.g. protective fences) and is the current state of the art. Access to the working area is only possible for maintenance work, commissioning and teach-in work. [10] In autarkic/coexistent operation there is also a separation of the working area but without physical separators. Access to the robot Work area is possible for short, sporadic stays and is indicated by a residence recognition registered. At the same time, the robot behavior is adjusted (speed/performance force reduction). In synchronized operation, humans and robots work in the same working space, but at different times, so that only one action partner at a time in the workroom. The cooperating cooperation enhances a temporal and spatial separation, so that both action partners can be separated at the same time in the same workspace. However, there is no joint activity. Only in collaboration human being and robot work on a common task without any temporal or spatial separation of the working area. [11] Since the beginning of the 20th century approaches of implementing HRC in assembly lines increases. Approaches of Beumelburg [12], Zülch [13] or Takata and Hirano [14] are well known in many theories. These theories started on a very early need for HRC but do not cover the nowadays requirements. Approaches are developing and including higher developed simulation programs which include quick check analysis and
Henning Oberc et al. / Procedia Manufacturing 31 (2019) 26–31 Author name / Procedia Manufacturing 00 (2019) 000–000
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ergonomically considerations for example two approaches of the Fraunhofer IAO or the quick check from the project KOMPI [15, 16]. 2.2. Comparison of available seminars regarding HRC The following table 1. shows a few seminars on training of HRC. They were listed and summarized in a secondary analysis with the topics and the focus in their trainings. This comparison emphasizes the necessity of new trainings for HRC. All compared seminars take place in Germany and last between one and five days so that there is a high variance in duration. But in this paper we will only focus on the topics not on the duration. The organizers vary from academic institutions to industrial companies or academies. The analysis of different available trainings shows that the main focus is on technology itself as well as safety aspects. Because cobots are deployed in an environment which human workers, safety is of the main challenges in HRC and have a high significance. [17] While all of the analyzed trainings focus on technology and safety aspects, only a few incorporate financial aspects when planning HRC applications. A key aspect of all when considering the integration of cobots is the HRC potential. In order to anticipate the advantages of HRC in each individual field of application, potential analysis are required. Since the presented concept will take place in Germany topics as co-determination cannot be neglected. This aspect will have a great impact in the training what will make the seminar very useful for the participants to integrate HRC in the industry. Underestimating the topic of co-determination and including workers’ councils often leads to a delayed implementation of HRC because important aspects such as protection of the workers’ data is not considered enough. Table 1. Comparison of HRC trainings. Technology
Organization
Personnel
Finance
Codetermination
Safety
HRC Potential
Simulation (program, real)
Fraunhofer academy
x
-
-
x
-
x
x
program
IHK/ABB
x
-
-
-
-
x
-
real
WEKA Akademie
x
-
-
-
-
x
-
-
Managementcircle
x
-
-
x
?
x
x
real
PILZ
x
-
-
-
-
x
-
real
Stuttgarter Produktionsakademie
x
-
-
-
-
x
x
?
Seminars
3. Training concept The training is set in a learning factory environment and focuses on students as target audience. As shown in table 1. most approaches address the technical implementation of HRC. The developed training emphasizes on organization and personnel aspects. It sensitizes about HRC and introduces tools to analyze (manual) assembly workstations with lean management principles and quick check analysis in order to determine the potentials of HRC. Since the training will take place in the LPS learning factory in Bochum the approach is also action-oriented and problem solving.
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3.1. Procedure of the training The training concept is a continuous change of theory and practice in 4 cycles. At the start, students or participants will get a theoretical introduction on HRC basics. The introduction will cover HRC issues with topics such as technology, organization and personnel. It will be a good introduction to the seminar but will only focus on a few problems occurring during the implementation of HRC. Cycle 1 To get a first overview of the focused work area, students will go to a real assembly line in the LPS-Learning factory where a bottle cap is produced and assembled. In the next step, students will analyze this assembly line with the help of the value stream method to get a better understanding of the whole process. At the end of each cycle, the students will present their results to the rest of the course. Cycle 2 For the analysis of manual workstations and processes with regards to HRC potential, students use appropriate evaluation systematics [9, 18, 19] in the next cycle. These systematics provide initial decision-making aids for the selection of automated or robot tasks. In addition, feasibilities of the redesign to a collaborative assembly application will be estimated. In this context, the use of evaluation methods such as the so called Quick-Check [16] or the potential check developed by the Fraunhofer IAO [20] are one of the key aspects besides the classical time determination (e.g. by MTM). Individual work stations and process steps, as well as components and assembly equipment are assessed with regards to various criteria (parts provision, component geometry, ergonomics, safety etc.). Cycle 3 After the analysis of the assembly line and its HRC potential, participants will focus on further aspects. Because of the industrial constitution law in Germany there has to be a special focus on operational co-determination, as every new introduction of a technology is co-determination obligatory. The other focus of the students will be costs. They will look at costs or effort of reprogramming, or the simple investment in different robot and safety systems. Cycle 4 The last part of the seminar is the technical implementation of the concepts. It starts with a simulation software called Editor for Manual Work Activities (ema) [11, 21]. This tool offers an intuitive evaluation of ergonomics (EAWS etc.) and process time (MTM-UAS etc.) of a modelled manual workflow and a realistic visualization of human movements. The results of the simulation studies are expected to provide further redesign support beyond the previously described rough HRC potential analysis. After the analysis in ema, the next task is to design the new work places. The last step is the programming of the robots. The technical equipment in the learning factory for different robots is very widespread. There are different robots the students or participants can use in the technical implementation phase. The robots are YuMi from ABB, iiwa from KUKA, a robot from the company PILZ and Franka Emika. Both the YuMi and Franka Robot can be programmed with a teaching technique that is easy to handle. At this point, it should be mentioned that the LPS is currently engaged in research activities in the field of a holistic HRC planning and simulation environment. Hereby the functional integration of a robot simulation and programming framework into the above-mentioned ema tool takes place [22]. Fig. 1 summarizes the different cycles in a short overview. The fundament of the seminar concept is built by the access to theory. This knowledge is important for the HRC integration phase that is followed. It starts with the skills and the practices. The decision of integration HRC by including the factor cost and laws. At the end of each cycle there will be an evaluation or reflection.
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Author name / Procedia Manufacturing 00 (2019) 000–000 Henning Oberc et al. / Procedia Manufacturing 31 (2019) 26–31
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Fig. 1. short summary of the four training cycles
After the technical implementation the concepts have to be evaluated. The best way to do so is to simulate the new value creation process and compare it with the value stream from the beginning of the training. Besides the different techniques or the different organization of work there will also be a change in key figures of the production process. 4. Evaluation of the training concept Since the developed training concept hasn’t been evaluated to prove its effectiveness, this paper introduces the constructed evaluation method. The reason for evaluating the concept is to prove and improve the effectiveness of the training. The evaluation concept consists of different methods described by Rae and by Rohrschneider and Lorenz questionnaires before and after the training, [23] feedback interviews after the training and exam at the end of the semester. The training will be introduced to different groups of bachelor students and master students. At the beginning of the training each participant will be given a questionnaire to retrieve the existing knowledge about HRC. The questionnaire is divided into topics. These topics cover questions about general knowledge on HRC, methods to analyze HRC potential and integration, issues on co-determination, economical aspects, etc. The results will be compared to the results of a second questionnaire at the end of the training. This questionnaire will be given to the group again after 4 weeks to show the recollection rate of the practically implemented knowledge. In addition, a feedback interview at the end should give some indication of the seminar’s success rate, however this is subject to the subjective assessment of each participant. The last success control mechanism is an exam at the end of the semester. In contrast to the questionnaires the exam is a rather detailed control mechanism. 5. Conclusion and outlook Companies are more and more interested in human robot collaboration. However general applications in the production environment seemed to be rare. Although manual assembly processes have been identified to have the highest potential for HRC. Furthermore, simple methods to analyse the specific potential of workplaces, finance aspects and co-determination aspects for HRC are matter of research as well as training concepts to impart knowledge how to use such methods. The described concept aims at closing this gap. With an action-oriented and problem-solving training concept within a learning factory, the presented approach focuses the training not on the detailed technical aspects of HRC but rather on the organisational and personnel topics. Further studies have to show the effectiveness of the approach, which will be subject to described evaluation.
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