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IFAC PapersOnLine 52-25 (2019) 509–512

Trends in Production Automation

Trends
Trends in
in Production
P. Kopacek. Automation
Production Automation
Trends in Production

P. Kopacek.
P. Kopacek. Automation
TU Wien, Institute for Mechanics
P. Kopacek. and Mechatronics, IHRT

TU Wien,
Favoritenstrasse Institute
9-11/E325 A4,for
A 
Mechanics
– 1040 and Mechatronics, IHRT
Wien.(e-mail:kopacek@ihrt.tuwien.ac.at)
TU Wien, Institute for Mechanics and Mechatronics, IHRT
Favoritenstrasse 9-11/E325
TU Wien, A – 1040 Wien.(e-mail:kopacek@ihrt.tuwien.ac.at)
A4,for
Institute
Favoritenstrasse 9-11/E325 A4, A –Mechanics and Mechatronics, IHRT
1040 Wien.(e-mail:kopacek@ihrt.tuwien.ac.at)
Favoritenstrasse 9-11/E325 A4, A – 1040 Wien.(e-mail:kopacek@ihrt.tuwien.ac.at)
Abstract: Process – and manufacturing automation as well as robotics are currently one of the fastest
Abstract:
growing Process – and manufacturing automation as industry
well as robotics are currently one are
of the
not fastest
Abstract:fields
Processin automation. Cyber-physical
– and manufacturing systems,
automation 4.0 and “advanced
as well as robotics are currentlyrobots”
one of the longer
fastest
growing
aAbstract: fields
headline.Processin automation.
Production
– and4.0 is inCyber-physical
realization
manufacturing butsystems,
automation industry
production
as well5.0
as 4.0
is and “advanced
knocking
robotics are on the robots”
currentlydoor.
one are
Production
of the longer
not fastest
4.5
growing fields in automation. Cyber-physical systems, industry 4.0 and “advanced robots” are not longer
awasheadline.
growing Production
introduced
fields one
in year4.0
ago
automation.is in
as realization
an immediate
Cyber-physical but production
step for
systems, small 5.0
and
industry is knocking
medium
4.0 and on the
enterprises.
“advanced door.
They
robots” Production
are some
not 4.5
first
longer
a headline. Production 4.0 is in realization but production 5.0 is knocking on the door. Production 4.5
was
dreams
awas introduced one
on production
headline. Production year ago
6.0.
4.0 as an immediate step for small and medium enterprises. They are some first
introduced one year agoisasinan
realization
immediatebut production
step for small 5.0
andismedium
knocking on the door.
enterprises. TheyProduction 4.5
are some first
Andreams
was on production
important
introduced part
one of 6.0.ago as anautomation
production
year immediate is (semi)
step for automated
small and assembly.
medium This
enterprises.topic is
They currently
are some only
first
dreams on production 6.0.
An important
outlined
dreams thepart
inproduction
on of production
literature
6.0.with some automation
descriptionis (semi) automated
of laboratory assembly.
tests. ConcerningThisoftopic
one isof currently
the scopes only
of
An important part of production automation is (semi) automated assembly. This topic is currently only
outlined
TECIS
An in theof
“End
important literature
partlife
of with some
management
production – description
EoL”
automation an of laboratory
important
is (semi) part tests.
(semi)
automated Concerning
automated
assembly. This oftopic
one is
disassemblyof currently
theis scopes of
currently
only
outlined in the literature with some description of laboratory tests. Concerning of one of the scopes of
TECIS
outlined
missing “End
in theofliterature
all lifethese
of management
with some
concepts. – description
EoL” an important
Therefore in
of this part
laboratory (semi)
contribution
tests. automated
first ideas
Concerning disassembly
of on
one(semi)
of theisautomated
currently
scopes of
TECIS “End of life management – EoL” an important part (semi) automated disassembly is currently
missing
TECIS in all
“End
disassembly of
4.0 of
lifethese
including concepts.
management
new –
tasks Therefore
EoL”
for an in this
important
“advanced” robotscontribution
part
will(semi)
be first
automated
given and ideas ondiscussed.
(semi) isautomated
disassembly
shortly currently
missing in all of these concepts. Therefore in this contribution first ideas on (semi) automated
disassembly
missing
As 4.0 including
in all
a consequence these new
ofofthese tasks for
concepts.
developments “advanced”
Therefore robots
in this
new social, will
andbe
contribution
ethical given
human andideas
first shortly
questions ondiscussed.
(semi) automated
appear.
disassembly 4.0 including new tasks for “advanced” robots will be given and shortly discussed.
As a consequence
Keywords:
disassembly 4.0 of
Manufacturingthese
including developments
Automation,
new tasks for new
Robots,social,
Social
“advanced” ethical and
aspects,
robots will human
Ethics.
be given questions
and appear.
shortly discussed.
© 2019,
As a consequence
Keywords:
As
IFAC of these developments
(International
Manufacturing
a consequence
Federation of new
of these Automation,
developmentsRobots,
social,Control)
Automatic
Social
new social,
ethical and
aspects,
ethical
human
Hosting
andEthics.
questions
by Elsevier appear.
Ltd.
human questions appear.
All rights reserved.
Keywords: Manufacturing Automation, Robots, Social aspects, Ethics.
Keywords: Manufacturing Automation, Robots, Social aspects, Ethics.

1. INTRODUCTION (Kopacek, 2015)

1. INTRODUCTION (Kopacek, 2015)
1. INTRODUCTION
The main Manufacturing (Kopacek,
Systems2015) Evolution Drivers are: Internet protocol IPv62 introduced in 2012 sufficient
1.
The INTRODUCTION
main Manufacturing (Kopacek,
Systems 2015)
Evolution Drivers are: Internet
addresses protocol
are available IPv62 introduced
to enable universal in direct
2012 sufficient
- Global growth & competition,
The main Manufacturing Systems Evolution Drivers are: Internet protocol IPv62 introduced in 2012 networking
sufficient
addresses are available to enable universal direct
2012 networking
The main --- Knowledge
Global growth
Manufacturing
Global growth
&Systems
competition,
Economy,
& competition, Evolution Drivers are: Internet
of
addresses protocol
smart objects via IPv62
are available introduced
the toInternet.
enable Now isinpossible
universal direct tosufficient
network
networking
of smart objects via the toInternet. Now is possible to network
--- Environmental
Knowledge
Global growth
Knowledge Economy,
Economy,
& competition,
pressures, addresses
resources, are available
information, enable
objects universal
and people
of smart objects via the Internet. Now is possible to network direct
to networking
create the
-- Molecular
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of smart
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Things via the
and objects
Internet.
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Now people
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to the
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manufacture,
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-- Conflict
Molecular manufacture, “Internet
resources, of Things
information,and Services”.
objects and people to create the
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Molecular over pressures,
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Environmentally and Services”.
Conscious Manufacturing. Efficient use of
-- Ideology,
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in production, Efficient
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cleaner in
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need, manufacturing, cleaner production and sustainable
- Physical Product manufacturing).
manufacturing, cleaner production and sustainable
A manufacturing - Physical Product
process consists of processing operations Design manufacturing).
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A manufacturing process consists of processing operations manufacturing).
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minimum environment (DFE).
to produce, Select
select materials
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minimize
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is oneto
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which transforms a work material from one state of Design minimum forenergy
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select design materials
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the final recycled
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and
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Assembly
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how
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give
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attention to how the product will be disposed of at the end of materials, give
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This yields,
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approach
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changes requirements.
production.
in Such
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factories
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allow
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Integrated in the past, to the development
(CIM), Intelligent of Computer to
Manufacturing to
fulfill individual customer requirements. Because of their
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fulfill last-minute changes in production are possible.
This yields, in the past, to the development of Computer The mainindividual
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factory inis to produce
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limited andthetherefore industrial applications of were
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limited and therefore industrial applications of AMS not Smart production,
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economic.
Agile products
production, “smart”
manufacturing systems are now realized based on Smart products are uniquely identifiable, may be easily are uniquely
robots identifiable,
communication may be easily
economic. production, “smart” robots communication
Agile manufacturing systems are now
CPS realized based on located at all times, are know theiridentifiable,
own history,may currentbe status,
Cyberphysical
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realized based on Smart
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uniquely
to know
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their history, current
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(Kopacek,
easily
Cyberphysical
machines,
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manufacturing systems
systems
systems(CPS).
and are CPS realized
production
now comprise
facilitiesbasedsmart
capableon located at all times, know their own history, current status,
Cyberphysical systems (CPS). CPS comprise smart 2018). alternative
located at routes
all times, to achieving
know their their
own target
history, state. (Kopacek,
current status,
ofmachines,
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autonomously storagesystems
systems (CPS).
and production facilities capable
CPS triggering
comprise smart alternative routes to achieving their target state. (Kopacek,
machines, storageexchanging
systems andinformation,
production actions
facilities capable 2018).
alternative routes to achieving their target state. (Kopacek,
of
and autonomously
machines,
controlling storage exchanging
each systems
other and information,
production
independently. triggering
facilities
Based on the actions
capable
new 2018).
of autonomously exchanging information, triggering actions 2018).
and
of controlling each other independently. Based on the new
andautonomously
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2405-8963 © 2019,each
exchanging
IFACother
information,Based
independently.
(International
triggering
on theactions
Federation of Automatic new
Control) Hosting by Elsevier Ltd. All rights reserved.
and controlling each other independently. Based on the new
Peer review under responsibility of International Federation of Automatic Control.
10.1016/j.ifacol.2019.12.595
510 P. Kopacek / IFAC PapersOnLine 52-25 (2019) 509–512
2. PRODUCTION 4.0
The Industry 4.0 vision is not limited to automation of a
single production facility. It incorporates integration across
core functions, from production, materials sourcing, supply
chain, and warehousing all the way to sale of the final
product. This high level of integration and visibility across
business processes will enable greater operational efficiency,
responsive manufacturing, and improved product design.
3. PRODUCTION 5.0
We are now in manufacturing automation in the field of
Production 4.0 and Production 5.0 is knocking on the door.
Industry 5.0 focuses to validate creativity, high-quality
custom-made products and life standard. It aims to increase
the life quality of human and not only to increase the
technology. It can be called as the fifth revolution of
mankind. Smart services are for both communication of
humans and non-humans. The communication between
humans and non-humans is the sharing of information and
data regarding the system. It is important that to design and
generate organizations, data-sharing platform and
technologies which support the system to interact for the
goal.
For Industry 5.0, it is necessary to turn regular machines into
safe and self-learning devices to improve their overall
performance and maintenance management with the
surrounding interaction. Industry 5.0 seeks to build an open
and intelligent manufacturing platform for industrial network
information applications. The critical requirements of
Industry revolution are real-time data monitoring and product
location, as well as instructions to control manufacturing.
Industry 5.0 is based on four principles
• Interoperability: The collaboration of machines, tools, and
computers in a system.
• Information clarity: The capacity of the sensor-stocked
computer systems to create a virtual version of real machines
and objects.
• Technical support: Computer systems and artificial
intelligence to support workers with strategy, decision
making, and work.
• Fragmented decision: The computer systems can complete
several and specific task on their own.
Industry 5.0 focuses to validate creativity, high-quality
custom-made products and life standard. It aims to increase
the life quality of human and not only to increase the
technology. It can be called as the fifth revolution of
mankind. Smart services are for both communication of
humans and non-humans. The communication between
humans and non-humans is the sharing of information and
data regarding the system. It is important that to design and
generate organizations, data-sharing platform and
technologies which support the system to interact for the
goal.
It can be called as the fifth revolution of mankind. Smart
services are for both communication of humans and non-
humans. The communication between humans and non-
humans is the sharing of information and data regarding the
system. It is important that to design and generate
organizations, data-sharing platform and technologies which
support the system to interact for the goal.
4. ROBOTS IN INDUSTRY 5.0
Cobots will play the primary role in industry 5.0
(a) The machine tending: The robot moves parts for
machining inside and outside the machine. While the robot is
loading and unloading the workpiece, the operator can do
other tasks.
(b) Pick-and-place. The robot moves from the process to the
input of another. For instance, it could be grabbed and placed
on a tray.
(c) Assembly: (d) Quality tests: the robot loads the products
in a quality test machine and takes away them once the test is
finished.
(d) Other lightweight weighing applications: The robot
performs basic packaging, refining, gluing and other tasks.
Evoke that Cobots can do most of the thing’s humans do if
they do not require great skill.
Most of these applications include tasks without added value
(i.e., functions that are not added something about a product
that the customer would be ready to pay for). Because it has
no added value, the functions are accessible for the Cobots to
do and free the man from boring and repetitive work. For the
implementation of Cobot, it is best to start small and keep it
modest. They can accumulate more complicated applications
after you have more experience with Cobots. (Karabegović,
P. D. 2018)
5. ASSEMBLY 4.0
Assembly represents the last phase of production processes.
Thus, assembly operations manage the whole product
differentiation and customization.
Assembly Automation was introduced 1978 with the
realization of the first Semi-automatized Assembly Cells
(Kopacek, Probst; 1992), (Kopacek, Noe; 1994).
Later the first mostly theoretical papers were published like
(Bortolini et.al, 2017)
The robot performs simple tasks when assembling parts that
require little skill. (On the same time, assembly tasks that
require high skill are perfect for human-robot collaboration:
the robot can accomplish the simplest assembly tasks and
then move the parts into an area where the man can do the
job.
6. DISASSEMBLY 4.0
Disassembly automation came up in 1998 with the realization
of the first industrial semi-automatized disassembly cells.
(Kopacek, Noe; 1994), (Kopacek, Gschwendtner; 1998),
(Kopacek, 2000).
Semi- or fully automatized disassembly especially of
electr(on)ic devices was not only because of the
standardization by the European Commission (directive on
waste from electrical and electronic equipment – WEEE) at
that time a hot topic. Usually only the toxic components were
 P. Kopacek / IFAC PapersOnLine 52-25 (2019) 509–512 511

removed manually and the rest of the materials were shred
and deposed. Manual disassembly of such devices is today
the state of the art. Because of this EC regulation and the
increasing amount of electronic scrap manual disassembly get
more and more inefficient in the nearest future. Hence
automation of the disassembly process was absolutely
necessary.
Fig.1 shows all different parts of a modular, flexible
disassembly cell. According to the figure the main modules
of such a cell are:
Industrial robots or handling devices with special features
like high accuracy, path- and force control (disassembly
robot).
Special gripping devices for a broad spectrum of parts
with different geometries and dimensions.
Disassembly tools especially developed for robots.
Feeding systems for the products to be disassembled.
Transport systems – similar as for assembly cells.
Fixture systems for parts with different geometries and
dimensions.
Manual disassembly stations.
Intelligent control units able to process information from
extended sensors.
Component database including data of reusable and
remanufacturable parts.
(„cost oriented“) vision systems for part recognition.
Various sensors for force and moment limitations,
position, distance, etc.
Storage systems for tools and parts.
(Intell.) Cell
Control Unit
are new. This is not the case for disassembly because usually
the parts could be deformed, corroded …
Otherwise in disassembly we can destroy some parts and
fixtures.
Disassembly 4.0 requires new types of robots because they
must be able to communicate with other parts and machine
tools……….. Furthermore for cracking operations they have
to be very robust. This will be the necessary features of
Cobots in the future.
These novel disassembly systems are modularly structured as
“smart disassembly stations” and “smart part logistic”. These
system elements communicate and cooperate with each other
and with humans in real time, monitoring physical processes
and creating a virtual copy of the physical disassembly
process to enable quick and decentralized decisions.
Beneficial effects are a significant improvement of flexibility
and speed of the whole system that enables more customized
products, an efficient and scalable production, and a high
variance in production control. Finally, proper optimization
models, control algorithms, automation technologies and
management methods have to be developed to allow the
aforementioned smart cyber physical systems of self-
optimization, self-configuration, self-diagnosis and intelligent
support to workers in their increasingly complex tasks.
7. INFLUENCES FOR TECIS
There are also many hitches stand in the implementation of
Industry 4.0
• If the Industry 4.0 is once fully implemented, many
uneducated or not educated workers to get jobless.
• To implement Industry 4.0, high skilled factory engineers
are needed, so highly educated people are required.
• IT security problems: since Industry 4.0 is highly depended
on IT, it is essential to keep the IT security efficiently.

Disassembly Storage
• Fear of IT bugs: There are chances for sudden temporary
Robot Devices malfunctions of IT, so many of the essential and confidential
processes may get misshapen.
Robot Transport
Gripper System
Disassembly • Reliability problems with the machine to machine
Cell communication, still it is not reliable at the level of stability
Disassembly Clamping
Tools Device and overall performance according to Industry 4.0 standards.

Components Manual Disas- Shortly, it is expected that advanced detection potential in

Database sembly station cyber-human technology will abolish the risk of defects
which increases the chances of adoption Industry 4.0 by
many companies. Now, many of the participants are agreeing
Sensors
that cyber systems are more reliable than manually operated
Force Visual Pos. systems producing exact precision.
Torque Dist.

The view that the 5.0 industry is a new form of collaboration

Fig. 1 Modules of an intelligent flexible disassembly cell.
(Kopacek P. & B.; 1999)
The differences between semi-automatized assembly and
disassembly are: In assembly we can assume that all the parts
between humans and robots is to harness the capabilities of
machines and people. The machines are more precise and
efficient, and the workers have skills, reasoning, and critical
thinking. This mode is appropriate for jobs that lie between
fully manual and fully automatic manufacturing lines.
Working with Cobotics enables companies of all sizes, the
512 P. Kopacek / IFAC PapersOnLine 52-25 (2019) 509–512
implementation of automation and in places where this is not
profitable or difficult to implement. This is also due to the
rising demand of customers for personalized products that
meet their needs and desires.
In general, four key components (CPS, Internet of Things
(IoT), Internet of Services and Smart Factory) and six
significant technologies artificial intelligence (AI), Big Data,
virtual reality, (Internet Industrial of Things (IIoT), CPS,
additive manufacturing (3D printing) and collaboration robot
(CoBot) and) to advance Industry 4.0. The focus is on the
technical aspects of the application. The main thing is human
resources exist only in possible changes in the labour market
produced by Industry 4.0. This situation is unacceptable and
is reflected in several articles related to Industry 4.0.
Although Industry 4.0 is only in the early phases of growth
and the main achievements cannot be expected before 2020-
2025, you can see the image of a new model of Industry 5.0.
It means the entrance of artificial intelligence into the
common life of man, his "cooperation" with the goal of
improving man's ability and man's return to the "centre of the
universe." (Vuksanović, Dragan & Vešić, Jelena & Korčok,
Davor. 2016)
8.SUMMARY AND FURTHER DEVELOPMENTS
In this paper some trends of production or manufacturing
automation, based on previous works, are presented with are
or will be in the future of interest for TECIS.
After a short introduction in the fundamentals of Production
4.0 an outlook on further developments – Production 5.0
(6.0) – is given. This subject is currently influenced by a
overwhelming digitalization.
According to the scope of TECIS special emphasis is on
assembly and disassembly automation 4.0 not only because
of the replacement of “low cost” working places which yields
to social problems.
On common workplaces because of human – robot
collaboration ethical problems arises.
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