Thomas Bauernhansl

Universität Stuttgart · Institute of Industrial Manufacturing and Management

In the context of Industry 4.0, ensuring the compatibility of digital twins (DTs) with existing software systems in the manufacturing sector presents a significant challenge. The Asset Administration Shell (AAS), conceptualized as the standardized DT for an asset, offers a powerful framework that connects the DT with the established software infras...

The current literature on the topic of data-driven and service-oriented business models (BM) is rich on frameworks describing strategic and organizational impediments, challenges, and solutions. Nevertheless, there is a lack on frameworks that provide a structured guidance for mechanical and plant engineering companies to implement those BM into th...

Digitalization and Industry 4.0 are catalysts for business model innovation, particularly in machinery and plant engineering. Service-oriented business models (Subscription, pay-per-use, …) have emerged as a promising avenue, fostering sustainable product-service systems (PSS) and nurturing enduring customer relationships. Unlike traditional transa...

In the era of Industry 4.0, Zero Defect Manufacturing (ZDM) has emerged as a prominent strategy for quality improvement, emphasizing data-driven approaches for defect prediction, prevention, and mitigation. The success of ZDM heavily depends on the availability and quality of data typically collected from diverse and heterogeneous sources during pr...

The transformability of factories is an essential design field for future-proof factory planning. In order to shape the ability to change in a targeted manner, corresponding planning approaches provide for an assessment of potential adaptation requirements. These are triggered by so-called change drivers. This article structures the factory environ...

In today's rapidly evolving landscape of automation and manufacturing systems, the efficient resolution of productivity losses is paramount. This study introduces a data-driven ensemble approach, utilizing the cyclic multivariate time series data from binary sensors and signals from Programmable Logic Controllers (PLCs) within these systems. The ob...

In today's rapidly evolving landscape of automation and manufacturing systems, the efficient resolution of productivity losses is paramount. This study introduces a data-driven ensemble approach, utilizing the cyclic multivariate time series data from binary sensors and signals from Programmable Logic Controllers (PLCs) within these systems. The ob...

The mechanical engineering industry is facing significant challenges due to digital transformation. Business model innovation, such as service-oriented business models, is required to maintain competitive advantage. These innovative business models require capabilities that traditional manufacturing companies may not possess. These capabilities can...

Due to the increasing complexity of digital transformation, managing methods in Lean Production Systems 4.0 (LPS 4.0) is a challenging task for industrial engineering practice. This paper aims to address complexity in methods-based productivity management through the development of a process model for the problem-based identification of solutions....

EIMIs face the challenge of adapting to the Paris Agreement and the European Green Deal to achieve carbon neutrality. Driven by consumer interest in low-carbon products, regulatory requirements, and investor priorities, companies are pressured to integrate sustainability beyond short-term financial gains. The growing awareness of the environmental...

The imperative for decarbonization forces businesses to transform their business models (BMs) and to adopt Sustainable Business Models which focus on creating value sustainably. In the context of Sustainable Business Model Innovation, maintaining close relationships within ecosystems is crucial to ensure a sustainable transformation while preservin...

Business-to-business (B2B) manufacturing companies are increasingly confronted with transformative trends such as sustainability, digitalization, and servitization. These trends are changing how product portfolios are developed, and how value contributions are assessed, and therefore have disruptive potential. Dealing with these disruptive factors...

EIMIs face the challenge of adapting to the Paris Agreement and the European Green Deal to achieve carbon neutrality. This change is being driven by consumer interest in low-carbon products, regulatory requirements from climate agreements and investors prioritizing sustainability. This pressure is pushing companies to go beyond short-term financial...

Responding to changing value creation processes in the sheet metal working sector, where the complexity and interchangeability of products challenge traditional differentiation strategies, this exploratory analysis examines the integration of service-oriented and data-driven business models as new paths to ensure competitiveness, especially for sma...

Business-to-business (B2B) manufacturing companies are increasingly confronted with transformative trends such as sustainability, digitalization, and servitization. These trends are changing how product portfolios are developed, and value contributions are assessed, and therefore have disruptive potential. Dealing with these disruptive factors in P...

Responding to changing value creation processes in the sheet metal working sec-tor, where the complexity and interchangeability of products challenge traditional dif-ferentiation strategies, this empirical analysis explores integrating service-oriented and data-driven business models as new paths to ensure competitiveness, especially for small and...

Physisch anspruchsvolle Tätigkeiten verursachen auf die Dauer muskuloskelettale Beschwerden. Fachkräfte sind daher schwierig zu finden und zu halten. In diesem Beitrag werden Modelle und Methoden aus der digitalen Ergonomie zur effizienten und ganzheitlichen Planung von manueller Arbeit und zum Einsatz von Exoskeletten auf zwei Ebenen vorgestellt....

Software-Sensoren gewinnen in Produktion und Logistik zunehmend an Bedeutung, da sie komplexe Messaufgaben lösen und Messgrößen vorhandener physikalischer Sensoren fusionieren können. In diesem Beitrag werden daher die Potenziale von Software-Sensoren mittels eines explorativen Vorgehens untersucht und dargestellt. Hierbei werden die Gründe für den...

The construction sector remains among the least digitized and automated industries, where human cognitive intervention is still necessary for many tasks. These tasks often entail significant physical exertion, increasing the risk of Musculoskeletal Disorders (MSDs) when workers perform unexpected movements or events. While assessment methods and te...

Der unklare Mehrwert von Smart Services in der Produktion ist ein zentrales Hemmnis für deren Einsatz in produzierenden Unternehmen. Vor allem kleine und mittlere Unternehmen (KMU) benötigen aufgrund begrenzter Ressourcen eine zuverlässige Bewertung, um Investitionsentscheidungen abzusichern. In diesem Beitrag werden Anforderungen an eine Methodik...

This paper examines the integration of industrial demand-side management into existing digital energy platforms, considering the global push towards renewable energy sources and climate change mitigation. Despite the proliferation of digital energy platforms, there is a notable lack of energy flexibility measures within these systems, which are ess...

Matrixproduktionssysteme vereinen die Vorteile einer hohen Flexibilität und Produktivität, haben aber häufig eine höhere Komplexität in der Steuerung. Der Mensch übernimmt in Matrixproduktionssystemen oft kurzfristige Entscheidungsaufgaben, etwa bei Änderungen, Störungen oder Planungslücken. In diesem Beitrag werden bereits bestehende Ansätze in di...

When designing industrial work systems, Industrial Engineering encounters many established and emerging challenges and objectives. These include, for example, the consideration of ergonomic aspects, the implementation of lean production principles and harnessing the technological potential of digital transformation. This initial situation reveals t...

Steigende Kosten und der Klimawandel bedingen ein Umdenken im Umgang mit Ressourcen. Ressourcenschonende Entwicklungsansätze wie der Leichtbau sind branchenübergreifend gefragt. Das Wissen zur Leichtbauoptimierung ist in vielen Unternehmen jedoch nicht oder nur implizit vorhanden. Um die Vorteile des Leichtbaus zu heben, muss Leichtbaulösungswissen...

The topic of metaverse has attracted a great deal of attention in recent years. As the next stage in the development of the Internet in three-dimensional space, physical and virtual worlds are to merge with each other in an unprecedented way. The Fraunhofer Institute for Industrial Engineering IAO, the Fraunhofer Institute for Manufacturing Enginee...

In the EU, 75% of buildings are energy inefficient, emphasizing the priority of their renovations or upgrades to reach the EU’s decarbonization goals. However, renovating existing buildings frequently entails physically demanding tasks, which can result in worker injuries, reduced productivity, and health issues. This document highlights the potent...

The literature review outlines a three-step procedure for analyzing corporate venture (CV) tools in the manufacturing industry. Firstly, a selection of general CV tools from the literature was identified. Secondly, tools specific to the manufacturing industry were derived, and their properties were explained. Lastly, the general tools were compared...

Digitale Services und smarte Produkte revolutionieren das Ge- schäft mit Maschinen und Anlagen. Cloud Computing, IoT und KI erlauben Unternehmen, ihre Produkte mit digitalen Services an Kundenbedürfnisse anzupassen. Das traditionelle Verkaufs- geschäft wandelt sich zu serviceorientierten Produkt-Service- Systemen. Wie können Unternehmen attraktive...

Flexible production systems, such as matrix production systems, are increasingly being implemented in companies. The aim is to achieve greater resilience in a turbulent environment and to produce a wide variety of variants. A matrix production system offers individual order flows and short-term decision-making of the order flow. In addition to the...

Lean Production Systems are enterprise-specific, methodical frameworks for the continuous orientation of all enterprise processes to the customer in order to achieve overall objectives. Due to the increasing complexity of digital transformation, the management of methods in Lean Production Systems 4.0 (LPS 4.0) is a challenging task for industrial...

Cyber-physical systems (CPS) offer immense optimization potential for manufacturing processes through the availability of multivariate time series data of actors and sensors. Based on automated analysis software, the deployment of adaptive and responsive measures is possible for time series data. Due to the complex and dynamic nature of modern manu...

Progressive digitization accelerates the evolution of human-machine interface (HMI) technologies. In mechanical engineering, HMIs are decisive for accomplishing user-friendly, efficient, and effective machine control. Although various technologies, such as AR-glasses, have already been applied in industrial practice, mechanical engineering companie...

Zahlreiche Simulationsanwendungen unterstützen heutzutage Produktionsplaner und Supply-Chain-Manager bei der Planung und Verbesserungen von Prozessen. Die Transparenz von Statusänderungen und die Kommunikation kurzfristig aufkommender Ereignisse über die Grenzen des eigenen Unternehmens hinaus, werden von gängigen Simulationsanwendungen nicht abged...

The manufacturing industry is facing increasing volatility, uncertainty, complexity, and ambiguity, while still requiring high delivery reliability to meet customer demands. This is especially challenging for complex job shops in the semiconductor industry, where the manufacturing process is highly intricate, making it difficult to predict the cons...

The resilient and relatively new production system “matrix production” challenges the design of the material supply. Through its dynamic behavior, the time, place and amount of material demand is uncertain. To support the supply planning process, it takes a method that predicts the material required in a given planning period. The usage of simulati...

Biointelligent systems are among the most important enablers for a sustainable transformation of industry. The convergence of bioware, hardware and software generates completely new system architectures that allow products to be manufactured and utilized more decentralized, autonomous, and demand-driven. With the increasing amount of (heterogeneous...

Matrixproduktionssysteme haben eine hohe Flexibilität bei gleichzeitig hoher Produktivität. Sie bestehen aus frei anfahrbaren Prozessmodulen. Bei großen Produkten, vielen Montageschritten und einer begrenzten Fläche ist die Planung dieser Prozessmodule aufgrund der vielen Freiheitsgrade und Restriktionen noch sehr aufwendig. In diesem Beitrag wird...

Anwendungen aus dem Bereich „Mixed Reality“ (MR) bieten große Potenziale bei der Lösung komplexer Planungsaufgaben. In diesem Beitrag wird die MR-Anwendung „HoloLayouts“ zur Fabrikplanung mit der Microsoft „HoloLens 2“ vorgestellt. Diese erlaubt die direkte Zusammenarbeit bei der Entwicklung und Validierung von 3D-Produktionslayouts im Team. Im Rah...

Die zunehmende Individualisierung von Produkten stellt Unternehmen vor neue Herausforderungen. Haupttreiber sind hierbei kundenindividuelle Produkte, die in kleinen Stückzahlen aber zu Kosten einer Großserienfertigung produziert werden sollen. In einer Praxisstudie des Leistungszentrums „Mass Personalization“ in Stuttgart wurden vor diesem Hintergr...

In Business-Ökosystemen werden Werte geschaffen, die Unternehmen alleine nicht generieren können. Bei der Umsetzung von Smart Services in der smarten Fabrik müssen heterogene Ressourcen vernetzt werden. Dies erfordert die Kooperation aller an der Datenwertschöpfung beteiligten Akteure von der Datengenerierung bis zur Datennutzung. In diesem Beitrag...

Der Beitrag untersucht die Treiber der Dekarbonisierungsziele und deren Auswirkungen auf nachhaltige Geschäftsmodellinnovationen in der Stahl-, Zement- und chemischen Industrie mittels einer systematischen Literaturrecherche und einer qualitativen Expertenbefragung. Die identifizierten Treiber werden in die Cluster Politik, Ökonomie und Gesellschaf...

Die zunehmende Personalisierung von Produkten führt zu neuen Herausforderungen sowie Chancen. In der Produktentwicklung und den Produktionsprozessen personalisierter Produkte können durch die Einbindung von Kunden Wettbewerbsvorteile erzielt werden. Hierbei nutzen Unternehmen die Personalisierung auch als Differenzierungsstrategie. Das Leistungszen...

Neue Konzepte wie die Wertsteigernde Kreislaufwirtschaft bieten Lösungsansätze, Nachhaltigkeit durch Digitalisierung in Unternehmen gewinnbringend zu realisieren. Um die notwendigen Kompetenzen parallel zum bestehenden Geschäft aufzubauen, gibt es verschiedene Ansätze der organisationalen Ambidextrie. Mittels einer quantitativen Literaturrecherche...

For decades, the operations on the shop floor of manufacturing organizations have been supported by Manufacturing Execution Systems. In this paper, we investigate the trends of Manufacturing Operations Management in the research community and analyze of the adoption in the industry. Our literature review identifies the following trends for Manufact...

Lean Production Systems are enterprise-specific, methodical frameworks for the continuous orientation of all enterprise processes to the customer in order to achieve overall objectives. Due to an increasing complexity of the digital transformation, the design of Lean Production Systems 4.0 is a challenging task for industrial engineering practice....

Occupational exoskeletons are a promising solution to prevent work-related musculoskeletal disorders (WMSDs). However, there are no established systems that support heavy lifting to shoulder height. Thus, this work presents a model-based analysis of heavy lifting activities and subsequent exoskeleton concept optimization. Six motion sequences were...

Life Cycle Assessment (LCA) is increasingly being applied in corporate accounting. Recently, especially carbon footprinting (CF) has been adopted as ‘LCA light’ in accordance with the Greenhouse Gas Protocol. According to the strategy ‘balance, reduce, substitute, compensate’, the approach is intended to provide the basis for optimization towards c...

Companies are facing changing market demands, high variance, and volatile quantities. Resilient production systems are needed to meet these challenges. The matrix production is such a system. It offers degrees of freedom in terms of operation sequence flexibility and work distribution flexibility through redundantly used resources. For the material...

Volatile markets continue to complicate manufacturing companies’ production system design, leading to efficiency losses due to imperfect system setups. In such a market environment, a perfect system setup cannot be achieved. Therefore, changeable production systems that cope with immanent uncertainty gain interest in research and industry. For seve...

This study aims to assess the whole-body physiological effects of wearing an exoskeleton during a one-hour standardized work task, utilizing the Cardiac Index (CI) as the target parameter. N = 42 young and healthy subjects with welding experience took part in the study. The standardized and abstracted one-hour workflow consists of simulated welding...

This study aims to investigate the possible effects of wearing exoskeletons during welding on heart rate. Additionally, the validity of a measuring instrument for determining acute heart rate is to be assessed. N = 15 young healthy subjects with welding experience took part in the study. The study design defines a one-hour workflow that abstracts w...

Digitalization opens new possibilities for data acquisition and processing as a basis for forward-looking business models in the mechanical engineering industry. Customer needs are increasingly being met by software solutions and competitors from outside the sector are trying to occupy the digital customer interface. Furthermore, margins in the tra...

Current trends such as the increasing commoditization of hardware and the growing generation of customer benefits through software-based services are forcing companies in the mechanical and plant engineering industry to develop innovative Smart Product-Service Systems (PSS) based on new business models. The associated increasing complexity requires...

Musculoskeletal disorders (MSDs) induced by industrial manual handling tasks are a major issue for workers and companies. As flexible ergonomic solutions, occupational exoskeletons can decrease critically high body stress in situations of awkward postures and motions. Biomechanical models with detailed anthropometrics and motions help us to acquire...

Purpose The aim of this study is to investigate the effects of wearing exoskeletons during welding on the quality of the weld seam. Material and methods A total of n = 15 young healthy subjects with welding experience took part in the study. The study design defines a 1-hr workflow that abstracts welding and grinding tasks. The sequence is based o...

Driven by the digital transformation, manufacturing companies face the challenge of managing, but more importantly, enabling rapid operationalization of AI to achieve the full advantage of the exponential data growth. Heterogeneous data structures, the continuously growing variety of implementation frameworks, and the lack of standards for the sema...