As the world market leader for pharmaceutical packaging systems, Uhlmann Pac-Systeme GmbH & Co. KG shapes the fourth industrial revolution in its sector. Recently, Uhlmann has started a collaboration with Computer Scientist from Ulm University in the areas of data analytics and process management. Both scientists from the Institute of Databases and Information Systems (DBIS) and DBIS students have contributed their expertise to this project. In September 2017, the long-term collaboration was expanded in the common research colloquium “Digitization for Pharmaceutical Packaging” during which first project results and future project goals were discussed.
More than 8000 machines from Uhlmann are used in more than 80 countries worldwide to package blisters, bottles and cartons. In this process, tablets are packed in blisters, blisters in folding boxes, folding boxes in cartons, and, finally, cartons on pallets. During packaging, the numerous sensors and actuators of the machines, which are networked in a packaging line, produce huge amounts of raw data in a millisecond cycle. In turn, this raises the challenge of utilizing the flood of production and sensor data (“Big Data”) for deriving accurate business information. In this context, the Computer Scientists of the Institute of Databases and Information Systems (DBIS) from Ulm University come into play: „DBIS has an excellent track record in business process automation and knows how to digitize the processes along a packaging line. When executing the processes during production, big event streams and large amounts of data are produced, which need to be interpreted in the respective process context – an area in which DBIS is among the world-leading research institutes“ explains DBIS director Prof. Dr. Manfred Reichert.
Enabling digital services based on intelligent data analyses
A typical Industry 4.0 scenario is condition monitoring: Through the intelligent analysis of sensor and machine data, the accuracy and efficiency of a machine can be monitored in real-time and potential problems be discovered in advance. For example, the DBIS experts were already able to show that specific analyses of motor current data allow detecting potential problems with the engine sprockets more than 400 hours in advance. As a next step, machine learning techniques will be applied to realize next generation predictive maintenance services.
Based on such data analyses and supported by the Computer Scientists from Ulm University, Uhlmann is developing customized products and services for its customers. For globally acting pharmaceutical companies, for which an around-the-clock operation is crucial, the demands for packaging lines differ significantly from the ones of highly specialized, regional pharmaceutical companies. Furthermore, digital services (e.g., predictive maintenance) based on the real-time analyses of machine data are increasingly demanded by customers. In this context, privacy and security issues need to be addressed as well.
Other digital services, into whose development the Computer Science experts and students from Ulm University have been also involved, include machine data visualization and product process documentation (i.e., track and trace). Legal regulations oblige pharmaceutical companies to mark each folding box and to monitor the logistics chain completely. This way, counterfeit drugs shall be avoided. In the area of human machine interaction, the Computer Scientists are further developing interaction concepts for augmented reality glasses („HoloLens“), which, in combination with process management technology, shall enable improved maintenance and support processes.
DBIS Students contribute to the project
The contact with Uhlmann was made through a former DBIS student one year ago. After their first meeting, Uhlmann and DBIS concluded a strategic cooperation agreement and started the third-party funded project CaPE (Context-adaptive Process Execution in Industrial Environments). Uhlmann funds one PhD student in this project. „We were able to support Uhlmann with our expertise in the field of condition monitoring and identified additional fields of development“ explains Klaus Kammerer, a DBIS PhD student working in the project and staying for several days per week at Uhlmann in Laupheim. There, he gains deep insights into pharmaceutical packaging processes and supervises several students working in the project. A framework for the real-time analysis of machine streaming data, which was developed by DBIS students, is already in use.
„We are always interested in identifying killer applications for the technologies developed in our research projects. The exchange with a regional industrial partner like Uhlmann provides deep insights into practical demands and real-world challenges“ emphasizes Professor Reichert. On the other hand, Uhlmann is convinced of the long-term collaboration with Ulm University: „The cooperation with experts and students from Ulm University complements our competencies in an optimal way. The cooperation not only allows us to benefit from the unique knowledge of the academic experts, but also gives us the opportunity to get into touch with motivated students who might be interested in working for Uhlmann after their graduation“ explains Jörg Riekenbrauck, Head of Advance Development at Uhlmann.
Research colloquium in Laupheim
In the first joint research colloquium of the two partners, which took place at Uhlmann’s headquarter in Laupheim at 26 September 2017, around 35 experts from both industry and science, participated. Following a presentation of the current development status at Uhlmann, researchers from the Universities of Ulm and Magdeburg presented their results in areas like data analytics, process management, man machine interaction, and IT infrastructure for Industry 4.0. The next challenges: How can the sensor data produced by packacking machines worldwide be analysed and stored in the cloud and how can analysis results be utilized to optimize production and service processes? How will users interact with machines in future? These and other subjects were discussed during the colloquium. Further research colloquia will follow.
For their students, DBIS additionally provides a miniature factory that makes them acquaint with with the digitization of factories and their processes.
About the background
In the context of Industry 4.0, the Institute of Databases and Information Systems is involved in several research projects: In a joint project with the University of Applied Sciences Ulm and Reutlingen, DBIS researchers are working on technology solutions for digitizing logistics processes. Recently, the postgraduate school „Cognitive Computing in Socio-Technical -Systems“ was established by Ulm University and the University of Applied Sciences Ulm. Prof. Reichert is one of the two chairman of this school. The focus of this school is on the development of intelligent technical systems, which allow for the support of technical processes in the era of Industry 4.0.