The three research partners Hahn-Schickard, Offenburg University of Applied Sciences and the FZI Research Center for Information Technology want to develop a simple, low-cost and risk-free toolbox of software and sensor technology for SMEs, which are often still sceptical about Industry 4.0, to make the benefits of networked production tangible. The special thing about this is that the actual production systems and machines remain unchanged and the production processes are not initially affected by the additional data acquisition.

Networked production would offer opportunities for process and cost optimization, particularly in terms of maintenance and production planning. However, small and medium-sized companies in particular fear high investment and conversion costs. The scientific project "Non-disruptive kit for the evaluation of Industry 4.0", NIKI 4.0 for short, enables companies to experience the benefits in their own real production and thus evaluate the requirements for a later migration in practice. The project uses common industry standards such as PROFIBUS and OPC UA. The display takes place via mobile devices and with augmented reality support. However, the system only provides information about machine statuses and does not intervene in the regulation and control of the systems.

The sensor information is particularly relevant in environmentally sensitive production processes or systems. Injection molding processes, for example, are prone to errors due to wind, draughts and fluctuations in ambient temperature. Thanks to the measurement and intelligent visualization with NIKI 4.0, skilled workers will in future be able to easily interpret disruptive air effects and indications of their source and derive the correct actions for troubleshooting.

The scientists are supported by a project committee. This is made up of 16 companies that are active in the subject areas covered by the project and mainly come from SMEs in Baden-Württemberg. The committee members advise the research institutes in all phases of the project with their knowledge of everyday production and contribute their case studies.

The partners reached the first project milestone on October 14, 2016: the requirements survey was completed and an initial, more detailed system architecture was implemented as a prototype. Together with the project support committee, further implementation was discussed on the basis of an initial demonstrator and the next five project phases were planned.