The BaSyx open source platform has been applied to several industrial set-ups. One of the first applications is a product line with configuration capabilities at runtime. The support of changing plant configurations is a substantial contribution of Industrie 4.0.
The focus of the initial application in the case study and its evaluation is the changeability of a plant enabled by horizontal integration of the devices in an Industrie 4.0 context. The set-up incorporates the following aspects of a product line:
- Different products
- Ability to change products
- Multiple devices
- Different devices
- Configurable devices
By using multiple and different devices in the evaluation use case, the complete manufacturing process is simulated, covering the following devices:
- Warehouse: Item source
- Mill: Processing station
- Packaging station: Item sink
- Transport device: Transport between devices
The plant setup uses two warehouses and two mills to be able to simulate the concurrent processing of multiple workpieces. The manufacturing of a product follows a predefined pattern.
First, a raw workpiece is retrieved from an arbitrary warehouse. This workpiece then is processed in one or multiple mills. Each of this mills can provide multiple manufacturing capabilities depending on the tools installed. It is possible to add or remove mills. Additionally, the mills can be configured in regard to the installed tools. By adding or removing tools, the manufacturing capabilities of the devices can be changed. Finally, the workpiece is packaged using a packaging station. To move the workpiece between different stations a transport device is used.
To be able to provide a real hands-on experience of Industrie 4.0 enabled plant changeability, the simulation is connected to real model devices. These devices are placed on top of a table with a tabletop consisting of a TV screen with touch capabilities. This touch screen can be used to control the plant, order products and configure the different devices.
The development of the use case and the demonstrator is driven by a set of user stories and evaluation scenarios. The starting point is the central user story of plant changeability, which includes changing the devices of a plant, the device configuration, or the orders themselves. This process should happen without any need for manual reconfiguration of the plant to integrate these changes. Based on the user stories a set of evaluation scenarios has been derived.
- Scenario 1: Pipelining of Products
- Changing the production capabilities to react to changing orders enables a more efficient manufacturing process. The goal is to reduce the resulting downtime by changing the production capabilities to the minimum.
- Scenario 2: Fully Parallelized Production
- In order to reduce further the downtime of the system caused by changing orders, a more enhanced set-up with redundant production capabilities was designed and evaluated.
- Scenario 3: Changing Product On-The-Fly
- The time frame for reaction on change request for the production process shall be reduced to a minimum. Therefore, the support for the on-the-fly change request for the product that is currently being produced is designed. The change request should require as little effort as possible to allow an economic viable production of vastly different products
- Scenario 4: Mitigation of Device Failures
- A smart factory shall mitigate device failures. By continuous monitoring of plant and device properties of critical situations are detected. The plant shall conduct a reasonable failure reaction with low impact and interference.
- Scenario 5: Mitigation of Tool Failures
- Similarly to a device in the previous scenario, a tool or service can fail. The system should be able to detect a faulty tool or service and removes or deactivates it on the device. This scenario evaluates the capabilities of the system to handle such a tool failure.
The text has been taken and adapted from 
- Schnicke, Frank: Evaluation of Industrie 4.0 Middleware Communication, Master's Thesis, Technical University of Kaiserslautern, Germany, 2018
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