Michael Lütjen

Bremer Institut für Produktion und Logistik GmbH | BIBA · Data Analytics & Process Optimization

The ‘intelligent container’ represents a novel transport system with the ability to make autonomous decisions regarding the condition of its transported goods. For example, fruit in cold chain logistics networks is very sensitive to mould and tends to perish. This can cause huge losses during transport, because the state-of-the-art reefer container...

The industrialization of CFRP production demands for new planning and engineering tools in order to develop more efficient production processes and higher automated production systems. This thesis presents a new concept for digital production engineering in the context of digital factory, which is focused on the integrated planning and simulation o...

During the last decades, a continuous trend towards miniaturisation leads to an increasing demand of metallic micromechanical components. To achieve an economic production on an industrial scale, the planning and configuration of process chains has become a key success factor. Thereby, the occurrence of so-called size-effects renders the planning a...

Purpose: Wind energy is a promising technology to produce sustainable energy. While higher wind speeds at sea result in higher energy production, they also impede the installation of wind farms. Several authors proposed optimization- or simulation-based scheduling models. This article provides a framework to instantiate different models and discuss...

Digital Twins mirror physical assets in the digital world, enriching them with additional capabilities and features such as decision-making or lifecycle management. Due to their diverse possibilities, their design and implementation are also wide-ranging. This paper aims to contribute to the formalization and standardization of the description of D...

With the increasing popularity of Augmented Reality (AR) applications, especially for mobile devices, the technology supports several construction projects. Here, AR helps to communicate planned construction projects, as its visualization increases the immersion and is better understood than common approaches. However, these use cases are mainly ou...

The integration of Autonomous Guided Vehicles (AGVs) into smart factories is transforming modern manufacturing, creating coexistence between humans and robotic systems. In this evolving landscape, one critical aspect is the seamless coordination of AGVs and human workers within factory settings. To achieve this, our research presents a portable ind...

Employee assistance systems are essential for companies to manage the growing complexity of information and processes. However, current systems mainly provide process-oriented support through documentation options, leaving a gap in real-time quality assessment. Real-time or in-process quality assessment becomes increasingly attractive for large and...

Wind energy constitutes a main contributor to clean and renewable energy. While the offshore sector received much attention from research and industry, onshore wind farms still make up the largest share of installation projects. Thereby, onshore installations retain similar wind speed restrictions as their offshore counterparts but additionally int...

Eine zentrale Herausforderung bei der Mensch-Technik-Interaktion im Hinblick auf (teil-)autonome Arbeitsumgebungen ist es, ein intuitives Prozessverständnis zur Veranlassung von unterstützenden Aktionen zu schaffen. Im vorliegenden Beitrag wird der Einsatz von am Körper getragenen Bewegungssensoren zur Aktivitätserkennung mit dem übergeordneten Zie...

With increasing digitalization and a shift towards Industry 4.0, new technologies are also finding their way into production. Especially in the training of technical professions, many processes are becoming more digital in order to also create a familiarization for the workforce of the future in manufacturing. To support the training of aircraft me...

Reducing ice formation on wind turbine rotor blades is mandatory to increase the economic viability of wind energy in cold regions. In our research, we propose a predictive anti-icing system as the solution to this problem. This system consists of a machine learning model which uses a combination of data from numerical weather prediction (NWP) and...

Abstract In industrial assembly and logistics processes, repetitive carrying and lifting of heavy loads, overhead work or forced postures lead to severe physical stress, which results in high health-related personnel absenteeism rates and low work attractiveness. Based on the Operator 5.0 idea, this paper presents a novel concept for the combined u...

Sustainability is gaining importance and the economy is changing into a circular economy, especially with regard to climate change and the need to create more resilient value chains. The organization of work is meeting these challenges with, among other things, the digitalization of increasingly changeable production. Collecting and understanding d...

The production of apparel and footwear has a significant impact on the environment. In 2016, these two product categories accounted for about 8 % of global climate emissions. To reach global emission goals, different production strategies are required. As an additive manufacturing process, 3D printing offers the possibility of mass customisation by...

The installation of offshore wind farms constitutes a highly weather-dependent process. Despite this dynamic, practice and research generally assume fixed resupply cycles to deliver components from their production sites to the installation's base port, resulting in high storage requirements. This article proposes a cascading discrete-event simulat...

Die jüngere Vergangenheit der Pandemiebekämpfung zeigt, dass Veranstaltungen und insbesondere Großveranstaltungen einer angemessenen Personenlenkung für den sicheren Betrieb bedürfen. Neben den klassischen Informations- und Sicherheitsanforderungen muss angemessen auf die Gefahrenlage bspw. mit Sicherheitsabständen zur Pandemiebekämpfung reagiert w...

During the COVID-19 pandemic, an uncontrolled spread of the virus worldwide was observed. To reduce the world wide spread of highly contagious viruses in the future, it is essential to target situations with a high risk for spreading contagious diseases. The risk of rapidly spreading of diseases is characterized by the fact that prevention measures...

The industry is shifting from a selection between a few ready-made models by the customer towards highly customizable, individualized, made-on-demand final products. This also encompasses the footwear industry, where 3D printing presents a modern solution for customizable shoes. While fashionable shoes can already be produced by this method, this s...

Offshore wind energy constitutes a promising technology to achieve the world’s need for sustainable energy. However, offshore wind farm installations require sophisticated planning methods due to continuous trends towards increasing resource demands and the processes’ high dependence on viable weather conditions. Current literature provides several...

In the literature, different authors attribute between 15% to 30% of a wind farm’s costs to logistics during the installation, e.g., for vessels or personnel. Currently, there exist only a few approaches for crew scheduling in the offshore area. However, current approaches only satisfy subsets of the offshore construction area’s specific terms and...

The use of LNG propulsion in ships has significant environmental benefits but also creates challenges in handling the LNG. Due to the safety regulations, the maintenance of the LNG ship systems is essential and requires a high degree of reliability and accuracy. Here, digital assistance systems, e.g., based on Augment-ed Reality (AR) technology, ca...

The installation of offshore wind farms constitutes a highly weather-dependent process. Despite this dependency, practice and research generally apply a single, rigid resupply cycle to transport components from their production sites to the installation's base port, resulting in high storage costs. This article proposes combining mathematical optim...

This work presents a prototype of a decision-support system for Offshore Wind Farm (OWF) construction based on the Timed Petri-Nets (TPN) approach, which aims to help the decision-maker in the industry to optimize the process execution. The objective function evaluates the solutions or alternatives to find the optimums. We also present a decoupled...

Text mining tools are now widely used for the efficient management of information and resources in business, academic and research organizations. This paper provides a comprehensive overview of research articles on the application of text mining techniques in the field of Supply Chain Risk Management and the apparel industry. Research articles publ...

In the era of digitalization, electronic Kanban (e-Kanban) extends the traditional Kanban with additional data and information sharing that allows for more flexible and optimized inventory planning. The lack of automated fill level measurements for load carriers still hinders the full automation of the process. Our aim is to develop a self-learning...

Downtimes due to ice formation on rotor blades reduce the economic efficiency of wind turbines. An accurate ice prediction is required to operate active de-icing measures such as blade heating as an anti-icing system. Building upon our previous research, this paper proposes the use of a convolutional neural network model with dual inputs and one-di...

Ice formation on rotor blades of wind turbines cause significant downtimes in cold regions. Existing ice sensors can detect, but cannot predict ice. Therefore, our research aims to develop an ice prediction system based on historical and forecasted data. In a first step, the detection process is analyzed in this research paper. Two machine learning...

Over the last decade, offshore wind energy has become a viable source of sustainable energy. During the installation of offshore wind farms, the dimensioning of related base ports became increasingly important. Base ports act as central logistics hubs for the installation and, thus, need to provide sufficient space and equipment to store and handle...

Baustellen zeichnen sich durch einen sehr hohen Anteil analoger Bauprozesse aus. Doch auch hier wächst der Druck zu Digitalisieren. Schaut man sich die Elektroinstallation an, so ist die direkte Verknüpfung mit einem BIM-Modell trotz digitaler Entfernungsmesser noch in weiter Ferne. So wird beispielsweise der Verlauf von Stromleitungen immer noch v...

Besides managing accruing data in production systems, Digital Twins provide additional services like the simulation or control of production systems. The Digital Twin and its real-world physical counterpart need to be interconnected using sensors and actuators to enable such services. This article proposes a simulation-based method to design and ev...

Despite the success in developments of wind energy technology, there remain challenges, for example, in offshore wind energy installation. Due to changeable and unstable offshore weather conditions, it is hard to effectively schedule the installation logistics. In this work, we propose a simulation-based scheduling strategy to help the operators an...

Offshore wind farms provide the means to generate significant streams of sustainable energy. The installation of such farms comes at high costs due to the large dimensions and weight of turbine components and the high specialization of involved resources. During the installation of wind farms, companies need to provide vast areas, capable of buffer...

The increasing demand for miniaturization is having an immense impact on manufacturing technologies and is leading to the development of many novel and innovative production processes for high-precision micro parts.

The design of micro production processes and systems faces a variety of significant challenges today. This is due both to economic and to technological challenges. Generally speaking, in most industries micro production tends to be characterized by mass production, meaning very high lot sizes from several thousands (e.g. in medical technology) to l...

Wind energy is a promising technology to cover the world’s need for sustainable energy production. Nevertheless, the construction of offshore wind farms imposes particular challenges. While about 15% to 20% of the costs for offshore wind farms can be attributed to logistics during the construction, highly dynamic weather conditions render accurate...

Offshore wind farms provide a promising technology to produce renewable and sustainable energy. Nevertheless, the installation and operation of offshore wind farms pose a particular challenge to the planning and execution of operations. This article aims to identify requirements towards a decision support tool for the installation planning. Therefo...

Digital twins perform process-accompanying services of machining processes or even of complete production systems. This article examines the interconnection between a physical production system and its digital twin, focusing on required sensors and the number of synchronization points to realize a dedicated control by the digital twin. Therefore, t...

To enhance the planning of finished vehicle logistics on port terminals, accurate localization of every car is needed. The outdoor positioning task is sufficiently covered by (D-)GPS. However, vehicles on port terminals are also parked in multi-story car parks where GPS is not available. Common indoor positioning methods like Wi-Fi fingerprinting o...

The installation of offshore wind farms poses particular challenges due to expensive resources and quickly changing weather conditions. Model-based decision-support systems are required to achieve an efficient installation. In the literature, there exist several models for scheduling offshore operations, which focus on vessels but neglect the influ...

Digital twins perform process-accompanying services of machining processes or even of complete production systems. This article examines the interconnection between a physical production system and its digital twin, focusing on required sensors and the number of synchronization points to realize a dedicated control by the digital twin. Therefore, t...

Dough fermentation plays an essential role in the bread production process, and its success is critical to producing high-quality products. In Germany, the number of stores per bakery chain has increased within the last years as well as the trend to finish the bakery products local at the stores. There is an unsatisfied demand for skilled workers,...

Purpose: Generally, the model-based installation planning of offshore wind farms knows two approaches: event-discrete simulations and mathematical optimizations. Both provide advantages in terms of computational time, detail and optimality. This article aims to identify common structural elements in the descriptions of both approaches, enabling the...

The operation of wind turbines includes the regular surface inspection of their rotor blades. This leads to considerable downtimes and expenses due to the manual inspection process. A possible solution is the automation of this process by using drones or robots. In this article, we present a key component for such an approach by automating the visu...

One of the major consequences of disasters is the destroyed infrastructure, such as power supply, communication, or roads, which makes it difficult to help affected people. Efficient help requires communication facilities to organize the disaster response but although rebuilding the infrastructure is one of the first priorities, it takes several da...

The purpose of real‐time predictive maintenance is the fast identification and classification of possible incipient faults and their locations. This chapter introduces the concept of complex event processing (CEP) in the field of predictive maintenance. This concept enables a surveillance of the system state in real‐time using complex event process...

In micro manufacturing, a precise configuration of manufacturing processes constitutes an essential factor for success. The continuing miniaturization of work pieces results in ever decreasing tolerances, whereas machines and processes become more and more specialized. As a result, a precise determination of each process result is important to guar...

Over the recent years Convolutional Neural Networks (CNN) have become the primary choice for many image-processing problems. Regarding industrial applications, they are hence especially interesting for automated optical quality inspection. However, with well-optimized processes is it often not possible to obtain a sufficiently large set of defectiv...

In micro forming, a precise planning of processes constitutes a challenging task due to inherent uncertainties. The method “Micro - Process Planning and Analysis” uses cause-effect networks to achieve this task. This article presents a method, which enables updating these networks based on new data regularly. It enables the use of discrete and cont...

Conventional fossil fuels are becoming more expensive and cannot cover the rising global energy needs with the remaining reserves in the future. In this context, the relevance of offshore wind energy (OWE) has increased steadily because of high wind resource availability. However, the installation of an offshore wind farm is challenging and cost-in...

The Web 2.0 and the emergence of numerous social media services enable individual users to publish and share information on the one hand and to discuss diverse topics online on the other hand. Accordingly, different research streams have emerged in order to tackle the diverse phenomena related to social media. Social media analytics as an interdisc...

Neuartige Produktionstechnologien haben ein inhärentes Einsatzrisiko, aber auch etablierte Produktionstechnologien lassen sich nicht immer problemlos auf neue Produkte bzw. Bauteile übertragen. Entsprechend müssen diese technischen Risiken bei der Planung von Produktionssystemen berücksichtigt werden. In diesem Beitrag wird ein Ansatz für die optim...

Pick-by-light is used for fast localization of items at the picking process in ware-house logistics. In general, pick-by-light systems are installed on racks or shelves which have to be powered by wires. This is very expensive and often involves complex installation procedures, wherefore wireless pick-by-light systems have gained a lot of research...

Databased prediction models are used to estimate a possible outcome for previously unknown production parameters. These forward models enable to test new production designs and parameters virtually before applying them in the real world. Cause-effect networks are one way to generate such a prediction model. Multiple inputs and stages are being conn...

Quality inspection is an integral part of the production process and often part of the quality management agreements between manufacturer and customer. Especially when it comes to safety-relevant parts, i.e. in the automobile or medical industry, often a 100% quality inspection is mandatory. Here, we present a solution comprised of a digital hologr...

Vorhersagemodelle basierend auf Versuchsreihen ermöglichen die Projektion eines neuen Prozessparameters auf einen festgelegten, gesuchten Output. Im Rahmen einer Fertigung kann beispielsweise auf Basis solcher Modelle abgeschätzt werden, welche Werkstückeigenschaften unter Verwendung bestimmter Prozessparameter erzielt werden. In der vorliegenden A...

The online grocery market is facing big challenges. In addition to products for daily use, it is necessary to deliver fresh, chilled and frozen foods quickly and reliably to the customer. For decades frozen products have been delivered to the customers by using small cooling vans. Since some years, also normal parcel delivery services in combinatio...

The manufacturing of compound feed is subject to highly dynamic influences. On the one hand, compound feed is usually manufactured in a make-to-order production mode, whereby a great variety of ingredients can be used to manufacture the same end product. In the use case presented, the energy consumption of the manufacturing process constitutes a ma...

Processes in manufacturing and logistics are characterized by a high frequency of changes and fluctuations, caused by the high number of participants in logistic processes. The heterogeneous landscape of data formats for information storage further complicates efforts to automatically extract process models from this data with the tools from Proces...

Die allumfassende Digltalisierung der Arbeitswelt schafft groBe Herausforderungen Im Umgang mlt neuen Medlen Im Hinbllck auf elne erwelterte Mensch-Technik-lnteraktion. Dabel hat sich die lnstandhaltung als eln wesentllches Anwendungsfeld fur diese Form von lndustrle 4.0 herauskristalllslert. Trotz hoher Prozessanforderungen aufgrund von kurzfrlstl...

Für die Massivumformung von Drahtwerkstücken im Mikrobereich stellt das Rundkneten einen zuverlässigen und kostengünstigen Fertigungsprozess dar. Beim Einstechrundkneten wirken unterschiedliche Prozessparameter, die gemeinsam mit der Beschaffenheit und Geometrie der eingesetzten Werkzeuge und des Ursprungsmaterials die endgültige Form und Qualität...

In this paper, we discuss the basic constraints and objectives of a unified logistics modeling language that allows to model dynamic logistic systems on various levels of concern from the requirements definition to their design and realization. It should, furthermore, support the compositionality and interoperability among all processes and other c...

Optical systems are a popular choice for quality inspection because they are not only contactless and precise but also comparably fast. Measurement speed is an important issue, especially for safety-relevant products where 100% quality inspection is required. This is particularly true for micro products, which have higher variances due to so called...

Im Rahmen der Fertigung von Mikrobauteilen ist die genaue Planung und Auslegung der Prozessketten von hoher Bedeutung, da neben besonders geringen Toleranzen und sehr hohen Qualitätsanforderungen, z.B. bezüglich der Oberflächengüte, hohe Produktionsraten erreicht werden müssen, um eine wirtschaftliche Fertigung zu garantieren. Die Methode μProPlAn...

In diesem Fachbeitrag wird die modellbasierte Planungsmethodik „Gramosa“ vorgestellt. Sie erlaubt eine automatische Generierung von Simulationsmodellen ausgehend von der graphischen Prozess- und Systemmodellierung. Im Schwerpunkt wird dabei auf die spezifischen Anforderungen der CFK (carbonfaserverstärkte Kunststoffe)-Serienfertigung sowie die Mode...

A continuous trend to function integration, miniaturization and densification opens new opportunities in industry and research. Tools, materials and technologies have to be scaled down from the macro to the micro domain in order to manufacture micro products fast and reliable. Thereby, the downscaling of classical processes leads to unexpected proc...

We present a framework for realization of a decentralized decision support system for deployment in production scenarios with a low level of automation, such as in multi-site construction. Furthermore we present the insights concerning the improvements of the production process when applying online simulation based optimization methods in that scen...

In diesem Fachbeitrag wird die modellbasierte Planungsmethodik „Gramosa“ vorgestellt. Sie erlaubt eine automatische Generierung von Simulationsmodellen ausgehend von der graphischen Prozess- und Systemmodellierung. Im Schwerpunkt wird dabei auf die spezifischen Anforderungen der CFK (carbonfaserverstärkte Kunststoffe)-Serienfertigung sowie die Mode...

Die Bedeutung von Data Science für Produktion und Logistik nimmt stetig zu, da durch Industrie 4.0-Technologien zunehmend mehr Daten anfallen und für Prozess- und Systemoptimierungen genutzt werden können. Darüber hinaus erlauben verbesserte Methoden und Werkzeuge der Datenanalyse eine einfachere Bearbeitung anwendungsspezifischer Fragestellungen,...

Im Bereich der Mikrofertigung werden hohe Anforderungen an die Messtechniken gestellt, da Fertigungstoleranzen bis zu einem Mikrometer innerhalb von Zehntelsekunden untersucht werden müssen. Entsprechend spielt die Auswahl und Integration geeigneter Messtechniken und –verfahren für die Prozessketten eine wichtige Rolle. Auf Basis dieser Messtechnik...

In den letzten zehn Jahren hat es im IT-Bereich rasante Entwicklungen gegeben, um immer größere Datenmengen speichern und performant verarbeiten zu können. Dadurch wurde eine wesentliche Voraussetzung für die Umsetzung der vernetzten Produktion im Sinne von Industrie 4.0 geschaffen. Die vernetzte Produktion verfolgt die Idee, dass mittels des Inter...