Efficient production logistics with SMART FACE - flexibility through cyber-physical systems

The interdisciplinary SMART FACE research project aimed to develop highly flexible and decentralized material flow units in order to meet the growing demands of small series production. Cyber-Physical Systems (CPS) were used to implement lean production planning, which enabled an efficient and versatile production structure.

Particular attention was paid to networking production processes with digital platforms. In this context, the store floor was connected to the "Logistics Mall" cloud platform to enable dynamic production control.

Challenges and innovative solutions

The increasing demand for individualized products, shorter product life cycles and flexible production posed challenges for conventional logistics systems. Automated assembly lines offered maximum productivity, but no decentralized control. SMART FACE therefore developed an IoT-based control concept that flexibly adapted material flows to production requirements.

The combination of decentralized control concepts and lean production planning made it possible to make production processes more efficient. The added value of this technology was particularly evident in the production of electric vehicles or other individualized products.

Technological implementation and key results

SMART FACE made it possible for components to be processed to find their own way through production. Networked control and data analysis made it possible to dynamically adapt the production sequence.

Core technologies in the project were:

• Cyber-Physical Systems (CPS): Linking physical production processes with digital control systems.
• Cloud integration: Development of a platform for decentralized planning and control.
• IoT-supported sensor technology: real-time monitoring and control of material flows.

A key project result was dynamic and scalable production control, which enabled better use of resources. The solutions developed showed that production processes can be made more efficient and sustainable through adaptive control.

Practical applications and benefits

The concepts from SMART FACE were used particularly in small series production. Flexible control and decentralized material flow optimization enabled production capacities to be used more efficiently.

• Higher utilization of production facilities through adaptive production control.
• Reduction of set-up times and material flow bottlenecks.
• Scalability for various industries, from electric vehicles to consumer goods production.

Project partners and cooperation

The project was implemented in an interdisciplinary consortium. Scientific and industrial partners worked together on the realization of cyber-physical systems for logistics and developed a practical concept for adaptive manufacturing.