Datenfabrik.NRW: How Schmitz Cargobull and CLAAS are bringing digitalisation and AI to the production floor

In Vreden, Westphalia (Germany), it is clear to see how profoundly digital technologies and artificial intelligence are changing industrial practice. At this site, Schmitz Cargobull is investing over €50 million in expanding its production capacities for refrigerated trailers and box trucks – a clear commitment to the innovative strength of ‘Made in NRW’.

This major project is accompanied by a digital innovation push that is setting new standards. As part of Datenfabrik.NRW, the company has fundamentally rethought the planning process and addressed the challenges of modern manufacturing systems with a holistic digital approach. This sees virtual factory planning, AI-supported analysis and intelligent workplace design seamlessly integrated.

A key result is the creation of a digital factory model as a common database (‘single source of truth’), which enables consistent planning across different tools and creates a common database for all parties involved. This is complemented by AI-supported processing of 3D point clouds from scans that are directly integrated into existing planning systems.

Traditional workplace design is also undergoing a digital transformation: cardboard workshops, in which workplaces are normally recreated using cardboard models, now take place virtually – efficiently, collaboratively and with minimal risk of error. Planning results can, therefore, be validated in digital environments, which speeds up implementation and minimises planning errors. Intuitive layout tools and motion mining technologies – processes that analyse movement data – were also used to analyse and optimise existing workplaces.

“The results impressively demonstrate how digital technologies are transforming industrial value creation – in a practical, scalable and forward-looking way,” says Lukas Ptock, Project Manager of Datenfabrik.NRW at Schmitz Cargobull.

Combine harvester production at CLAAS, in Harsewinkel, is characterised by high variability and low quantities. For employees, this means they have to remember a lot of complex work content. Before the project, they were only given paper lists on which the relevant variants were marked with highlighters. Technical changes had to be manually incorporated into production on a regular basis – a cumbersome process that was time-consuming and prone to errors. This made it particularly difficult for new employees to get started.

In the Datenfabrik.NRW project, CLAAS developed a worker assistance system that initially digitally mapped the sequence of orders, marked them with colours and displayed them via a web-based interface. But that was only the beginning. Step by step, further information was added: product audit data, 3D models, technical changes and assembly instructions are now provided automatically.

The system is directly connected to the factory via an IIoT (Industrial Internet of Things) connection. Driverless transport systems digitally locate their position within the hall and automatically report back orders. This means that employees always see the relevant information at their workplace. Changes are indicated by a traffic light signal and acoustic signals, helping to keep errors to a minimum.

“In this use case, we are guided by the well-known 6Rs from logistics: the right information, at the right time, in the right quantity, in the right quality, in the right place and with the right effort. It is important not to overwhelm anyone with information, but to provide targeted support,” says Timo Westerbusch, Project Manager for Data-Driven Manufacturing at CLAAS.

The system was designed to be scalable from the outset. Today, it is already in use at 120 workstations in Harsewinkel, and an international roll-out is in preparation.

The topic of artificial intelligence is not being left out either. At the same time, CLAAS is testing the integration of a chatbot based on generative AI, a technology that can generate language independently. In future, this assistant will provide assembly information as needed. Initial tests, such as the automated provision of warning stickers, are proving promising.

“It is important to us that all information displayed in our system is reliable. If an error occurs due to incorrect data, it can happen that acceptance of the system is lost. That’s why we place particular emphasis on intensive testing of our results before integrating them into the productive environment,” adds Westerbusch.

The data factory has shown that AI applications do not have to remain in the experimental stage, they can also be implemented. This is shown by the 51 use cases in real factories and a clear process model for transfer turn individual projects into recurring solutions that can also be transferred to other companies.

The AI.NRW competence platform also emphasises the importance of this strategy. “At Datenfabrik.NRW, AI systems are used directly in factory planning, production, logistics and corporate architecture. The partners show that AI is not a pipe dream, but already a great help to companies today. In the project, we see a strong transfer from research to application,” says Dr Christian Temath, Managing Director of KI.NRW.

KI.NRW has included Datenfabrik.NRW in its flagship initiative, supported the visualisation of the project results and networked project staff with AI experts from other fields. KI.NRW flagships are highly innovative and application-oriented AI projects in individual and joint ventures from various industries, such as trade, production, crafts and health.

In future, it’s OWL will ensure that the approaches developed do not remain in the pilot plants, but become usable for SMEs in North Rhine-Westphalia and beyond. Together with the partners involved, the Artificial Intelligence Technology Network is bringing the concept from the drawing board to the factory floor. Companies can draw on tried-and-tested methods and tools instead of starting from scratch.

Caption:
From left: Dr Arno Kühn (Head of Strategy, R&D, Extended Management Board, it's OWL), Jan-Hendrik Mohr (CEO, CLAAS), Mona Neubaur (Minister for Economic Affairs, Industry, Climate Protection and Energy, North Rhine-Westphalia), Dr Günther Schweitzer (COO, Schmitz Cargobull)

Photo credit: it's OWL