Effective Digitization in Brownfield Factories : A conceptualized model for technology transfer to brownfield production factories through smart factory lab

Abstract: The exploration of Smart Factories and Industry 4.0 technologies has indeed sparked curiosity and interest in the industrial world. The potential of these advancements to revolutionize manufacturing processes, enhance efficiency, and drive innovation is immense. However, there is a gap in research when it comes to the practical implementation of these advanced technologies in real-world production settings, especially in already established factories so-called Brownfield Factories. This thesis work was conducted within one such brownfield factory to comprehend the tangible challenges associated with transferring smart technologies. Within this specific company, a laboratory had already been established for testing novel smart technologies in the context of production and logistics. The aim in companies is to test smart technologies in a controlled environment without causing any disruption to the ongoing profit-generating production processes. This laboratory setup also serves the additional purpose of educating the personnel within traditional production facilities about the upcoming smart technologies in the market. The Lab showcases the potential of new and emerging technologies in addressing long-standing issues with a fresh perspective, thereby inspiring innovation. The central approach of this thesis revolves around the establishment of a standardized laboratory work process through which smart technology can be tested in a structured way. In this context, an illustrative example of a technology, namely "Virtual Training for Assembly Operators," was chosen as a case study to explore and comprehend the challenges associated with technology transfer. This case study also played a pivotal role in assessing the credibility of the standard technology transfer model formulated within the company. Notably, it was deduced that knowledge and competence are two key obstacles impeding the smooth transfer of technology. Building upon the insights garnered from the case study on virtual training technology and drawing from interviews with engineers and managers employed at the case company, a refined technology transfer process named the "Smart Factory Lab Process" was developed. This process aims to enable the effective transfer of smart technologies, informed by the lessons learned from the practical application of technology in real-world scenarios.