The ESPRIT project UPSIDE has developed software tools to increase flexibility, responsibility and motivation of personnel in industrial manufacturing environments. The modular, Intranet-based approach integrates information functionality, communication facilities, shop floor-oriented scheduling, production monitoring and simulation of schedules. The highly scalable and flexible solution integrates easily into existing infrastructures using industrial standards for data exchange.
It supports the flexibility of production by offering advanced information, scheduling and simulation mechanisms and thus enabling the worker to take over responsibility for his tasks. The system is based on a modular client-server architecture to support the implementation of tailored solutions in further cases. The different support modules are optional to the implementation and the system can be customised to the end-users' needs. Integrated real-time production scheduling, production monitoring, resource utilisation, user-dependant task information, open and closed groups for information exchange and interactive 3D visualisation of workpieces build the basic toolset for the end-user oriented production-support system.
The software is aimed at medium-sized manufacturing industry companies with a high product variance or one-off production, e.g. shipbuilding. The system uses industry standards in Intranet technology, database access and networking, and can be integrated into the standard IT infrastructures found on many of today's shop floors. The production support system has been integrated in two quite different shop floors of the Odense Steel Shipyard and has been tested in the industrial environment.
In one trial, electronic CAD-drawings created in the product design phase are distributed to pipe fitters in order to support the assembly process. 3D visualisation of pipe features (bends, fittings, flanges) allow the fitters to understand the assembly task before it actually starts out physically. As a result the number of faulty pipes produced has been significantly decreased.
The results have attracted considerable interest from manufacturing companies industry who want a more flexible, human-centred approach to organising work that will offer a new level of participation to the workers. A potential market is seen in many kinds of industries. Although the solutions are relevant to all manufacturing environments, their greatest potential is for companies with a high product variance or one-off production.
The software developed by the project is based on a client-server approach. All modules communicate using commonly available networking technology and are designed to interact with databases already available in the enterprise. The overall system is - due to its modular design - very scalable and can be adapted to a wide range of requirements of specific workshops or manufacturing methods. The distributed client-server architecture makes interconnections between different shop floors for instance for communication or scheduling possible. The system integrates user-oriented, innovative access to information and planning functionalities.
A suite of productivity tools for production workers is fully integrated into an Intranet server. An electronic discussion board system combined with email facilitates easy communication between workers and between workers and administrative levels (design, production preparation and planning). The increased level of communication ensures good co-ordination between workers on different shifts and between workers and administrative people from different departments. Plans can be generated specifying order sequences for workers, machines and line areas. A bill of material viewer allows workers to investigate status and location of missing parts.On-line monitoring of production progress provides workers with a common understanding of where resources are needed or can be spared. Evaluation reports to workers and foremen documents the line performance.
The consortium is currently in the phase of negotiation of an agreement on future exploitation efforts concerning the clarification of property rights, marketing methods and exchange of business contacts.