BRAGECRIM

Learnstruments for the transition of

Brazilian and German manufacturing companies

to Industry 4.0

Mateus C. Gerolamo, Assistant Professor, EESC-USP

Tim Stock, Dipl.-Wirtsch.-Ing., TU Berlin

Slide 2

Project Team

Mateus Gerolamo

Prof. Dr. - USP São Carlos

Edson Cazarini

Prof. Dr. - USP São Carlos

Henrique Rozenfeld

Prof. Dr. - USP São Carlos

Kleber Espôsto

Prof. Dr. - USP São Carlos

Daniel Braatz

Prof. Dr. - UFSCAR São Carlos

Holger Kohl

Prof. Dr. Ing. - TU Berlin

Günther Seliger

Prof. Dr. Ing. - TU Berlin

Tim Stock

Dipl.-Wirtsch.-Ing. - TU Berlin

Bernd Muschard

Dipl. Ing. - TU Berlin

Omar Chaim

PhD Candidate - USP São Carlos

Ana Carolina Falcão

Master Degree Student -

USP São Carlos

Núbia Carvalho

Master Degree Student -

USP São Carlos

Esdras Paravizo

Undergraduate Student -

UFSCAR São Carlos

Vinícius de Camargo

Undergraduate Student - USP São Carlos

Slide 3

Project Objective

To create learning tools, i.e. Learnstruments, to support the transition

towards Industry 4.0 and which:

Are intuitive;

Promote implicit learning;

Address learning by doing in an interactive learning environment.

The Learnstruments facilitate the learning of:

What is Industry 4.0;

How it affects production and value creation;

How it affects human labor.

Slide 4

Project Phases

Industry and Education Qualification

Requirement Definition

Definition of Methodology

(Learnstrument Development)

Prototype and Test

(Learnstrument)Implementation

Researc

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Researc

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Project Phases

Slide 5

Target Group

Undergraduate students from both universities and learners in

professional/ continuous education courses are the main focus for the

development of the Learnstruments.

Companies can benefit from the methodologies for developing

Learnstruments, the shared assets and results, as well as the Learnstrument

itself.

Slide 6

Concepts Review

Slide 7

Industry 4.0 – How is Value Created?

Value Creation Modules, e.g. factories

Material flow

Raw Material Acquisition

Manufacturing

Use and Service

End of Life

Product Life Cycle

Value Creation Networks and Product Life Cycles

Business

Model

Slide 8

Industry 4.0 – Definition

“Industry 4.0 aims at connecting resources,

services, and humans in real-time throughout

the production on the basis of cyber physical

systems (CPS) and the internet of things

(IoT).”

Wissenschaftliche Gesellschaft für Produktionstechnik, “WGP-Standpunkt Industrie 4.0”, p. 6, 2016 [WGP-2016]

Slide 9

Industry 4.0 – Characteristics

New disruptive business models

based on smart data offering

functionality and access rather than

the product ownership to the

customer.

Value creation modules, e.g. factories, are

digitally connected throughout the

complete value creation network for the life

cycle of a product and thus enabling real-

time value creation networks.

Block chain technologies are applied for

securely controlling equipment as well as for

enabling new services throughout the network

by supporting transparent transactions

between the value creation factors.

Value Creation Network & Product Life CycleBusiness Models

Value mainly in product content

Value mainly in service content

Service content (intangible)

Product Service Systems

Product content (tangible)

[ACATECH-2013; PLATIND-2015]

Slide 10

Industry 4.0 – Characteristics

Decision making will be shifted away from

a central instance towards decentralized

instances considering local

information.

Customer orders (products) will

autonomously negotiate their own way

through the value creation networks.

New manufacturing technologies, such as

additive manufacturing, will be

increasingly deployed which enables the

design of new complex, stronger, and

more lightweight geometries.

ProcessOrganization

3D printed prosthesis[HAG-2015, KLE-2015]

Slide 11

Industry 4.0 – Characteristics

Smart products will actively support the

manufacturing process.

The products will be manufactured in

batch size one according to the

individual requirements of the customer.

Autonomous, self-organizing production

equipment which is highly adaptive to

changes in terms of product, process,

organization, and human will replace

passive manufacturing systems.

EquipmentProduct

3D printed prosthesisAdidas Shoe Configurator Collaborative robots at BMW

rob

oticsa

nd

au

tom

atio

nne

ws.c

om

[ACATECH-2015; HAG-2015]

Slide 12

Industry 4.0 – Characteristics

Manufacturing jobs are facing a risk for being automated.

Humans will be strongly affected by an increase in knowledge work and uncertainty

of tasks.

Human

Low33% Employment

Medium19% Employment

High47% Employment

Probability of Computerization0 0.2 0.4 0.6 0.8 0.9

Transportation

Production

Installation, Maintenance, Rep

Construction, Extraction

Farming, Fishing, Forestry

Office, Administrative Support

Sales and Related

Service

Healthcare Practitioners

Education, Legal, Arts, Media

Comp., Engineering, Science

Mangmnt., Business, Financial

Emp

loym

ent

0M

100M

300M

400M

[FRE-2013; SPA-2013]

Slide 13

Design Principles for Industry 4.0

In order to exploit the main aspects and characteristics related to Industry 4.0, a

framework of six design principles has been defined based on an extensive literature

review.

Decentralization

Virtualization

Interoperability

Modularity

Real-Time Capability

Service Orientation

Slide 14

Learnstruments

Learnstruments are objects which automatically demonstrate their

functionality to the learner.

They

use existing and new information and communication

technology (ICT)

aim at increasing the learning and teaching productivity

provide adequate learning goals to the user

support the user in achieving the learning goals

Learnstruments can be used directly in the work process.

Enable employees to overcome occurring problems

Improve the efficiency of the process

Slide 15

Learnstruments – Example

Solar charging station for e-bikes

Demonstrating the field of application for

photovoltaic systems

Different experiments can be performed by

the learner to gain knowledge about

different influencing factors, such as angle

of irradiation, battery status, type of solar

module, …

Slide 16

Methodology

Industry and Education Qualification

Requirement Definition

Definition of Methodology

(Learnstrument Development)

Prototype and Test

(Learnstrument)Implementation

Researc

h O

bje

cti

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Researc

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ch

ievem

en

ts

Project PhasesMethodology

Literature Review

Survey

Structured Product

Development

Literature Review

Field Testing

Interviews

Field Testing

Interviews/Survey

Cost Analysis

Questionnaire

Slide 17

Scientific Cooperation

Industry and Education Qualification

Requirement Definition

Definition of Methodology

(Learnstrument Development)

Prototype and Test

(Learnstrument)Implementation

Researc

h O

bje

cti

ve

Researc

h A

ch

ievem

en

ts

Bernd Muschard -

EESC USP

Ana Carolina

Falcão - TU Berlin

Bernd Muschard -

EESC USP

Omar Chaim -

TU Berlin

Mateus Gerolamo -

TU Berlin

Tim Stock -

EESC USP

Project PhasesScientific

Cooperation Missions

Three More

Missions

EESC USP, TU

Berlin

Methodology

Literature Review

Survey

Structured Product

Development

Literature Review

Field Testing

Interviews

Field Testing

Interviews/Survey

Cost Analysis

Questionnaire

Slide 18

Partial Results

Industry and Education Qualification

Requirement Definition

Definition of Methodology

(Learnstrument Development)

Prototype and Test

(Learnstrument)Implementation

Researc

h O

bje

cti

ve

Researc

h A

ch

ievem

en

ts

Bernd Muschard -

EESC USP

Ana Carolina

Falcão - TU Berlin

Bernd Muschard -

EESC USP

Omar Chaim -

TU Berlin

Mateus Gerolamo -

TU Berlin

Tim Stock -

EESC USP

Project PhasesScientific

Cooperation MissionsMethodology

Paper

Survey

Dev. Platform

Papers (2)

Partial Results

Workshop

Prototype

Three More

Missions

EESC USP, TU

Berlin

Literature Review

Survey

Structured Product

Development

Literature Review

Field Testing

Interviews

Field Testing

Interviews/Survey

Cost Analysis

Questionnaire

Slide 19

Partial Results

Literature Review:

The project team carried out a bibliographical review regarding the

Industry 4.0 and its respective concepts. This review consists of:

350 articles found;

255 abstract read;

62 relevant articles;

Such revision assisted in the identification and definition of the six design

principles, as well as the main outcomes resulting from their activity.

Slide 20

Partial Results

Papers:

“Manufacturing in the fourth industrial revolution: A positive prospect in

Sustainable Manufacturing”;

“Exploring gamification to support manufacturing education on Industry

4.0 as an enabler for innovation and sustainability”;

“Insertion of sustainability performance indicators in an industry 4.0 virtual

learning environment”;

“Fourth Industrial Revolution: Key perspectives and opportunities for skills

and abilities development” (abstract).

Slide 21

Partial Results

Workshop “Learning for the Fourth Industrial Revolution - A virtual factory

learnstrument”;

First functional prototype “Going Fo[u]rth - The Journey to Industry 4.0”;

Booklet for the Workshop in Haifa, Israel;

Survey “Qualification Profile”.

Slide 22

Workshop - 15th GCSM - Haifa, Israel

“Learning for the Fourth Industrial Revolution - A virtual Factory

Learnstrument”

Henrique Rozenfeld, Omar Chaim, Bernd Muschard

Objective: To promote the learning of the industry 4.0 design principles

connected to factory floor implementation projects.

Slide 23

Workshop - 15th GCSM - Haifa, Israel

The workshop:

Participants were given a set of cards

(physical) containing definitions for both

design principles and outcomes;

Each was assigned a project to explore

in the virtual environment and asked to

connect the principles and outcomes

cards to that project;

The participants then filled out a

feedback form.

Slide 24

Workshop - 15th GCSM - Haifa, Israel

Slide 25

Big Picture of the Project

Next Steps

Industry and Education Qualification

Requirement Definition

Definition of Methodology

(Learnstrument Development)

Prototype and Test

(Learnstrument)Implementation

Researc

h O

bje

cti

ve

Researc

h A

ch

ievem

en

ts

Bernd Muschard -

EESC USP

Ana Carolina

Falcão - TU Berlin

Bernd Muschard -

EESC USP

Omar Chaim -

TU Berlin

Mateus Gerolamo -

TU Berlin

Tim Stock -

EESC USP

Project PhasesScientific

Cooperation MissionsMethodology

Paper

Survey

Dev. Platform

Papers (2)

Partial Results

Workshop

Prototype

Three More

Missions

EESC USP, TU

Berlin

Literature Review

Survey

Structured Product

Development

Literature Review

Field Testing

Interviews

Field Testing

Interviews/Survey

Cost Analysis

Questionnaire

Slide 26

Global Expected Results

Next Steps

Industry and Education Qualification

Requirement Definition

Definition of Methodology

(Learnstrument Development)

Prototype and Test

(Learnstrument)Implementation

Researc

h O

bje

cti

ve

Researc

h A

ch

ievem

en

ts

Bernd Muschard -

EESC USP

Ana Carolina

Falcão - TU Berlin

Bernd Muschard -

EESC USP

Omar Chaim -

TU Berlin

Mateus Gerolamo -

TU Berlin

Tim Stock -

EESC USP

Project Phases

- Literature Review

- Surveys

- Literature Review

- Field Testing

- Interviews

- Field Testing

- Interviews

- Surveys

- Field Testing

- Interviews

- Surveys

Scientific

Cooperation MissionsMethodology

Paper

Survey

Dev. Platform

Papers (2)

Partial Results

Workshop

Prototype

Three More

Missions

EESC USP, TU

Berlin

Dissemination of the developed Learnstrument

via a free and open-access online platform;

Proposition of a methodology to facilitate the

development of Learnstruments;

Functional and fully evaluated Learnstruments

for supporting the transition towards Industry

4.0.

Slide 27

Thank you

Mateus Cecílio Gerolamoe-mail address: gerolamo@sc.usp.br

Tim Stocke-mail address: stock@mf.tu-berlin.de