Fraunhofer IGCV – Industry 4.0 learning factory with 4AVO, 4APS and 4BDE on SAP ERP

Location: 86159 Augsburg, Germany · Industry: Research, learning factory, production technology, Industry 4.0, further education · Products: Learning factory modules, demonstrators, research equipment and training environments for digitalisation and Industry 4.0 · ERP: SAP ERP · Website: https://www.igcv.fraunhofer.de · S4P modules: 4AVO, 4APS, 4BDE

Initial situation

The learning factory at Fraunhofer Institute for Casting, Composite and Processing Technology IGCV maps real production workflows to research and demonstrate methods of digitalisation and networked manufacturing. Based on SAP ERP, an end-to-end planning and data acquisition solution was required that supports research and teaching in a realistic setting. With around 100 employees and varying research and teaching scenarios, the institute has high demands for flexibility in production software and for suitability in training and demonstration contexts.

Challenge

Variant-rich orders, changing scenarios and the ambition to make digitalisation tangible placed high demands on planning and data acquisition. An integrated solution was required that seamlessly connects work preparation, fine planning and shop-floor data collection while embedding SAP ERP as the leading system. For training purposes it was important that the solution allows different planning scenarios to be simulated and typical Industry 4.0 questions — such as bottleneck management, OEE evaluation and sequence optimisation — to be demonstrated in a practical way.

Solution

To support the learning factory, Fraunhofer IGCV relies on S4P solutions. Through integration with SAP ERP, order, planning and feedback data are used end-to-end — from work preparation through fine planning to shop-floor data collection. Modules in use: 4AVO for work preparation and order structuring, 4APS for graphical fine planning with simulation scenarios and a scheduling board, and 4BDE for shop-floor data collection at terminals with order feedback and KPI evaluation. The solution enables different manufacturing scenarios to be mapped live and prepared for didactic use.

Results and benefits

With the S4P solutions, Fraunhofer IGCV can map and convey digitalisation in production in a realistic and practical way. End-to-end data from planning to feedback creates transparency and makes the learning factory a hands-on platform for research and teaching. Planning scenarios can be simulated, KPIs evaluated in real time and typical shop-floor challenges demonstrated. The solution supports the institute in giving companies practical insights into the capabilities of modern MES and APS solutions.