Fraunhofer Institute for Industrial Engineering IAO
Fraunhofer Institute for Industrial Engineering IAO

Model Factory

Model factory with innovative assembly systems

© Bernd Müller, Fraunhofer IAO

The Fraunhofer IAO model factory as a test environment

How to make assembly systems as efficient as possible? Fraunhofer IAO has set up a model factory where a range of assembly systems for small and mid-size products can be demonstrated live and tested.
© Bernd Müller, Fraunhofer IAO

Smart connectivity in Industry 4.0

Industry 4.0 will see production work increasingly move towards smart connectivity. It enables machines, plants, products, warehouses and tools to communicate with each other – and, thanks to mobile devices, with workers as well.
© Bernd Müller, Fraunhofer IAO

Data collection and communication in real time

Sensors make it possible to gather data in real time and to network machines and plants. As a result, not just people but also machines can communicate with one another and be part of a smart factory.
© Bernd Müller, Fraunhofer IAO

Real-time data collection using sensors

Thanks to real-time sensor data collection, production workers benefit from a new level of data processing.
© Bernd Müller, Fraunhofer IAO

Industry 4.0: The robot as a new colleague

Close collaboration between people and lightweight robots calls for new modes of work organization and a participatory design. Fraunhofer IAO helps companies identify and create suitable applications within their business.
© Uwe Völkner | FOX

Industry 4.0: Using lightweight robots in production

A mobile lightweight robot can be used at various points within a given work system or in a variety of different work systems. This increases operating times and cost effectiveness.
© Uwe Völkner | FOX

Industry 4.0: Integrating lightweight robots into work organization

Lightweight robots can be programmed as easily as a smartphone app – facilitating easy integration into the work organization. Fraunhofer IAO is researching new types of work organization and highlighting the requisite competencies.
© Uwe Völkner | FOX

Industry 4.0: Working in partnership with robots

This is what direct collaboration between people and lightweight robots could look like. Processes with lightweight robots have to be designed so that people continue to set the pace and can intervene in the process at any time.
© Uwe Völkner | FOX

Industry 4.0: U-shaped assembly lines in the model factory

U-shaped assembly lines with special personnel assignment strategies support workstations outside the workflow and workers with a range of abilities.
© Uwe Völkner | FOX

Collaborative assembly: Robot colleague

Close collaboration between people and lightweight robots calls for new modes of work organization and a participatory design. Fraunhofer IAO helps companies identify and create suitable applications within their business.
© Uwe Völkner | FOX

Manual assembly: Individual work stations in the model factory

Creating individual workstations for manual assembly: Easy-to-reach containers and change carts for quick retooling.
© Uwe Völkner | FOX

Manual assembly: One-set flow in the model factory

In most cases, small product assembly using the one-set flow principle further increases productivity compared to the one-piece flow principle in the U-shaped assembly line. In such cases, a set of parts is laid out ready for processing on a workpiece holder. This boosts productivity because the tool needed to process all the parts on the work tray now has to be picked up and returned only once – and not for every product, as with the one-piece flow principle.

How to make assembly systems as efficient as possible?

 A Model Factory was set up at the Fraunhofer IAO in which innovative assembly systems for small and medium-volume products can be practically tested at first hand.

In addition to the frequently used Carrée system, the model plant also showcases solutions for the manual assembly based on a star configuration, with a one-piece flow system (U line) or the one-set flow system, which has not yet found widespread use. Specific product examples are utilized to illustrate realistically how and for which areas the individual systems can economically be deployed. 

Grasp and experience Industry 4.0

  • Digitized Assembly Workplace
  • The suitable light and all necessary information individual and digital at the right time at the right spot.
  • Intelligent Kanban Supermarket
  • A real-time inventory mapping function connected to mobile devices as smart watches and smart phones with Social Media.
  • Real-Time Value Stream Visualization
  • Get an overview from everywhere about the actual real-time situation in the production through an innovative system.
  • Wearables in Logistics
  • Support your employees systematically and punctually in special work situations with smart glasses.
  • Social Media on the Shopfloor
  • Simpler. Better. Collaboration. 4tasks is used for assignment-, incident- and escalationmanagement in order to Industry 4.0.