Processes in the high-wage country of Germany have to be rigorously automated for efficiency and reliability. To this end, we are developing solutions even for hitherto “unautomatable” things, such as highly individualized manufacturing processes, complex operations and environments in which humans and robots collaborate closely without safety fencing.

Automated solutions ensure availability in these times of a shortage of skilled labor, especially for heavy physical labor or hazardous work environments. Autonomous robots are used just as much as sensors and AI security technologies for complex logistics environments. We additionally rely on automated process transparency and control.

Net-zero manufacturing is evolving from a mere vision into a real competitive advantage. Our research scientists are envisioning the net-zero approach far beyond energy management. We treat manufacturing and energy processes in their entirety and integrated in overriding management. We incorporate many different technologies and identify the single best solution for more sustainability and climate change mitigation and sustainability in manufacturing.

Our research approach and stated goal is to make the circular economy reality. New technologies enable economical use and reuse of resources, establish flexibility among producers and consumers and thus make new viable business models possible.

Digital twins are often mentioned when talking about data models of industrial plants. Digital twins can vary considerably, though: The digital family has many different members, from complex three-dimensional plant models to digitalized process simulations to software or platform solutions for data exchange. A “family member’s” form depends on many factors: the level of digitalization in a company, the way data is generated and preprocessed and, especially, the use of the data. The technologies and software solutions employed play an important role too.

At Fraunhofer IFF, we treat every form of digital twin singly and are researching solutions for the efficient generation, expedient connectivity and commercialization of data in value creation cycles. So that the digital twin can reach its full potential, we are researching the exchange of such data securely, confidentially and efficiently – beyond the confines of companies and industries too.

Humans will remain essential in factories. Their experiential knowledge makes their creativity and decision-making skills unsurpassable. They will also remain the factor driving value creation in highly automated factories.

The skilled labor shortage is resulting in more than just an exodus of labor from factories to other sectors, though. It will only be possible to safeguard jobs in the long-term in the future too when they provide people a healthy, motivating and decent environment.

With our automated and digitalized solutions, we are creating such jobs that lighten people’s workload and simultaneously boost their particular strengths.

Our digital assistant solutions provide assistance with day-to-day work and motivate to lifelong learning. They enable knowledge retention and transfer so that valuable experiential knowledge is no longer lost.