The use of digital technologies and methods for planning and designing production and logistics systems plays an important role in digital factory planning in the context of layout, logistics and material flow planning. It includes the use of computer-aided tools such as dynamic simulations and virtual factory models to support the entire life cycle of a factory, from conception and planning through construction and commissioning to the continuous optimization and adaptation of production systems.

Digital planning makes it possible to compare different scenarios in advance. As a result, the best solution for all stakeholders can be found efficiently, even with competing objectives, such as a high degree of flexibility and maximum space efficiency at the same time. The optimization of production capacity, an efficient, optimal design of the production processes and layout as well as the simulation-supported analysis and optimization of the material flow play an important role here.

We have specialized in various areas of digital factory planning to support companies in planning and designing sustainable and efficient factories:  

Virtual factory planning: Fraunhofer IGCV develops and researches methods and tools for creating virtual models of factories. This includes the acquisition of geometric data using laser scanners, the integration of machine and plant models and the visualization and simulation of factory processes.

Material flow and logistics planning: Fraunhofer IGCV deals with the optimization of material flow in factories. This includes the analysis and simulation of material flow processes, the optimization of storage and order picking of materials as well as the design of efficient logistics and transport concepts.

Factory layout planning: Fraunhofer IGCV develops methods for the collaborative layout planning of factories. This includes the consideration of production processes, ergonomic aspects, safety guidelines and space utilization efficiency. The aim is to design optimal factory layouts that enable smooth and efficient production.  

Examples for research topics

Previous research and development work has shown that data consistency is highly relevant in the context of digital factory planning. Data should be kept as non-redundant as possible and exchanged between planning tools without error-prone, manual activities.

In order to test and further develop digital data consistency for a factory planning project carried out using collaborative planning methods, a demonstrator was set up at Fraunhofer IGCV. The individual steps of factory planning, which are covered at Fraunhofer IGCV, are conveyed using a sample factory.

The demonstrator consists of a physical and a digital factory model. It shows which methods and digital software tools can be used to support planning and how digital consistency can be enabled across the factory planning steps. In addition, the use and added value of VR/AR technologies for visualization and collaboration can be clearly demonstrated. The aim of the demonstrator is to convey the benefits of digital, collaborative planning and to clearly illustrate the core competencies of Fraunhofer IGCV in the field of factory planning.

There are various ways of collaborating in the digital planning process to increase planning quality. Collaborative methods can be used in particular to design the optimum factory layout, taking into account production processes, ergonomic aspects, safety guidelines and space utilization efficiency.

The ARZuKMU project aims to investigate how planning software linked to AR can be used to improve the visualization of planning statuses in the production environment and to what extent the integration of production employees can improve the planning process and make it more efficient and sustainable. In this context, new roles arise in the planning process, which are integrated into the factory planning procedure. The effects of the additional know-how on planning quality are also being investigated as part of the project.

Further information on the ARZuKMU project

When planning battery cell production, various special features must be taken into account, e.g. clean and dry rooms are required. This also leads to special requirements within factory planning, especially logistics planning. For example, materials that are transported to the clean and dry rooms must be cleaned and/or repacked. This can be done manually or automatically in material locks, but must be taken into account in the overall material flow.

In this challenging environment, we deal with the preparation of planning premises and the planning of the logistics system. The latter includes the rough and detailed planning of the individual processes as well as material flow simulation and design.  

Development of a procedure for the introduction of mixed production for the symbiotic manufacture of electric and conventional trucks in the project »eTruckpro«