Contact coordinates:


University of Ljubljana

Faculty of Mechanical Engineering (FME)

Laboratory LASIM

Askerceva 6

SI-1000 Ljubljana

Slovenija


Tel.: +386 (0)1 4771 726

        +386 (0)1 4771 760

Fax: +386 (0)1 4771 434

        +386 (0)1 4771 761


E-mail: niko.herakovic@fs.uni-lj.si

Smart Factory Research and Demonstration Center

Innovation excellence

FOCUS AREAS

Focuse areas Smart factories 

UL FME LASIM (University of Ljubljana, Faculty of Mechanical Engineering, laboratory LASIM) expresses the innovation excellence through the fundamental R&D activities as well as applied research in different areas related to the factories of the future (FoF) and its key enablers. We are particular focused on intelligent manufacturing systems, automation, robotics as well as new control methods, algorithms and strategies. All the new technologies, mainly focused on the use of I4.0 principles are first analysed and validated in the laboratory environment and further on implemented into the real industrial environment and tested in the real industrial applications. The main R&I areas are:

  • Smart factories and new innovative architecture models for distributed systems, development of transformation strategies from traditional towards smart factories.
  • Digitalization of real manufacturing processes by using new innovative approaches for visualization.
  • Modelling, simulation and optimization focused on production logistics and material/information flow, handling and transport systems, assembly processes, real-time simulation and optimization, dynamic production planning and optimization.
  • Digital twins and digital agents for different types of production (production processes, logistics, data analytics, AI-based decision/ control algorithms). A Digital Twin enables real-time monitoring, predictive maintenance, and process optimization by collecting and analysing production data. It improves quality control by detecting defects early and adjusting parameters dynamically. Integrated with ERP/MES, it optimizes production planning and resource allocation.
  • Agile production systems, new concepts of self-configurable systems and production lines capable to reconfigure according to the changes of products and orders.
  • Distributed CPS systems and Edge Computing in complex network of production processes and systems, logistic systems.
  • 5G for manufacturing, testing of public and private network principles, communication, data transfer and real-time control.
  • DIGITAL LEAN approach: integration of traditional lean strategies in combination with digitalization and AI-approach of manufacturing systems and processes, Factories of the future, Smart factories.
  • Smart robotics in combination with machine vision for flexible/agile production process.
  • Human-robot interaction and cooperation (industrial robots and cobots).
  • RFID technology for human/object recognition and tracking.
  • Advanced manual assembly in combination with collaborative robotics.
  • Development of smart product management systems capable to set the assembly process based on knowing the 3D model and the structure of the product, integration into ERP, MES that fulfil the entire product value chain (LPM – LEAN Production Management). LPM and the Digital Twin enable advanced process control by integrating MES, ERP, and production machines through industrial communication protocols. The system uses digital agents and AI-based optimization to conduct real-time decision-making and process optimisation.
  • VR and AR technology integration and use in the manufacturing systems.
  • Smart hydraulics and pneumatics with the focus on local intelligence for data analytics, real-time control and prediction of systems behaviour using the ML approaches.

 

Main scientific and professional interest

In general, the core research and development areas of the LASIM laboratory and thus also of the experimental environment are:

  • I4.0 and I5.0 technology in the field of manufacturing technologies.
  • Smart factories / Factories of the Future and in particular architectural models for the development of smart factories.
  • Distributed cyber-physical systems and Edge Computing, smart products.
  • Digitalization of manufacturing processes, digital platforms and digital twins/digital agents.
  • Use of VR and AR technology in production systems.
  • Modelling, simulation and optimization of logistics and material/information flow in manufacturing processes, real time simulation and optimization.
  • Product management in assembly processes involving the entire value chain.
  • Smart control and advanced algorithms with AI integration (prediction, decision-making strategies).
  • Smart manual assembly work stations, collaborative robots (human-robot collaboration).
  • Advanced tracking of products and people in production (RFID, smart watches,…).
  • I4.0 oriented communication protocols, connectivity of distributed systems, networking.
  • Advanced manufacturing approaches such as DIGITAL LEAN, AGILE manufacturing systems.
  • Industrial Robotics, automation, smart robotic tools and sensors.
  • Machine vision systems.
  • Advanced hydraulics and pneumatics with the focus on piezo technology.
  • Piezo actuators for the use in robotics and other handling and assembly systems.

 

Main services

  • Education of future engineers – pedagogic, programme: graduate, master degree, PhD
  • Assistance and training for SMEs through workshops – use of demonstration center of smart factory, learning by doing.
  • Consultancy for the SMEs in the area of factory of future
  • Developing, testing and demonstration of the latest manufacturing technologies in the laboratory environment, knowledge and results transfer into the real industrial environment (SMEs pilot lines, scalable to production lines).
  • Designing the manufacturing processes in digital environment (digital twins, production simulation in advance) in the early development stage – low-cost phase before high cost investment.
  • Human skills and competences development – factories of future, smart manufacturing.

 

Significant infrastructure and equipment, Digital Factories

UL, FS, LASIM has all the necessary facilities for implementing the R&D activities, from human resources, to software and hardware. Beside R&D activities, we are specialized for trainings and education of human resources in the field of advanced manufacturing and smart automation. The main infrastructure of the laboratory presents Smart Factory Demo Lab and Agile Production and Logistic Demo Lab, where the new developed technologies can be tested, validated and prepared for the integration into the real industrial environment.

DF1 (Digital/didactic factory 1) - Smart Factory Demo Lab

The demo center is developed and built according to the principles of Industry 4.0 (I4.0) and provides the possibilities for basic and applied research of all key technologies I4.0 and logistics. The equipment includes a modern self-configurable production line, two industrial robots, one collaborative robot, automated smart rack warehouse, smart hydraulic servo press with integrated modular intelligent tools supported with digital twin technology to perform AGILE forming processes, machine vision technology on different locations, RFID technology and traceability, cloud technologies, 5G technology and edge computing, BIG Data technology (data capturing, processing and transferring and real-time data processing), digital twin’s technology of processes and digital agents (AI) at different levels (global, local, etc.), distributed production systems technology, VR and AR, smart and self-adaptive and self-configurable manual assembly workstation with LPM (LEAN Production Management system to cover the entire product life cycle and production value chain) system, supported by visualization, etc.

demo_center_1

Figure: Smart Factory Demo Lab - digital twin technology integrated into production system VIDEO.  

Key equipment and subsystems:

  • Assembly production line, controlled by Beckhoff controller, with 6 automatic assembly stations (RPI for EDGE, NFC for ID, LAN/WiFi for OPC UA) with integrated local intelligent.
  • Automated warehouse of base parts and finished products (RPI for EDGE, NFC for ID, LAN/WiFi for OPC UA).
  • 2x robotic cells, industrial robot MOTOAN HP6 and P20 with 4 KOSMEK tool changers (grippers: finger grippers, vacuum grippers).
  • Handling devices as cyber-physical systems for pick and place operations in combination with machine vision and RFID tracking system integrated in assembly production line with 6 assembly workstations.
  • 1x collaborative robot Franka Emika.
  • Smart manual assembly workstation with collaborative robot (integration of I4.0 technologies, integration of product management system to perform visualization, RPI for EDGE, NFC for ID, LAN/WiFi for OPC UA).
  • Advanced production management systems to cover the entire value chain from supply to end users - LPM – LEAN Production Management Software connects all manufacturing process services (from engineering, supply, warehouse, assembly, logistics and management) and connect them to manual assembly process stations and enables digital LEAN optimised assembly process: assembly material preparation, digital assembly instructions, online and real-time error solving, timing of assembly processes, project status overviews, etc.
  • 3D printer (PLA, ABS) used to perform products prototyping and production of new personalized products.
  • 3x Machine vision system (safety, quality control, stock/warehouse part detection).
  • ZED 2i Stereo Camera with polarizer (2.1mm) - Depth Sensing,120° Wide-Angle FOV, Built-in Next-Gen IMU, Gyroscope, Barometer & Magnetometer; Software (ZED Explorer, ZED Sensor Viewer, ZED Diagnostics, ZED Depth Viewer, ZED SDK + pyzed.
  • Pneumatic systems for assembly and handling, robotics. Robotic grippers.
  • Servo hydraulic press with different tooling for forming processes.
  • AR and VR equipment as supporting technique incorporated into the smart manufacturing (Meta 2 glasses to perform augmented reality in different areas of production line and individual manufacturing machines, Oculus Rift used to visualize the objects (systems, production lines, factories) in the development phase and later (Digital Twin in VR for customers that need better visualization of planned on current production line).
  • AR glasses (mainly used for digital instruction visualization for guiding the workers in manual assembly processes).
  • Smart hydraulic press with integrated modular intelligent tools supported with digital twin technology to perform AGILE manufacturing processes, digital twin for automatic programming of forming cycles based on input data of production plan and product/press/tooling characteristics, expert systems for prediction of hydraulic press behaviour.
  • Smart hydraulic actuators with integrated sensors controlled with digital piezo valves.
  • Smart control and visualization platform (Siemens Plant Simulation, ThingsBoard, Siemens Teamcenter with integrated Digital Twin, SCADA and distributed Plug&Produce manufacturing nodes that together form complete distributed model.

 

Testing services offered for digital and green technologies

Smart Factory Design Principles: Development, testing, and validation of new architectural models for the Factories of the Future (LASFA – LASIM Smart Factory Architecture) suitable for the Edge Computing approach and the integration over LAN, WiFi and 5G technology; Development, testing, and validation of new distributed production system concepts (Edge Computing); Development of digitalisation of legacy software to work in connected production systems of Smart Factories.

Connectivity, Communication, and Data Transfer Approaches: Design, test, and validation of communication and data transfer in production and logistics processes, in combination with LAN, WiFi and 5G technology; Testing, validation and integration of communication protocols (OPC UA, Modbus, MQTT, EtherCAT, AMQP, CoAP,...); Design, test, and validation of communication and data transfer in production and logistics processes, in combination with LAN, WiFi and 5G technology; Testing, validation and integration of communication protocols (OPC UA, Modbus, MQTT, EtherCAT, AMQP, CoAP,...).

Digitalization, Digital Twins Development, and Visualization:Development, testing, and validation of AI in digital twins of manufacturing processes including logistics; Development, testing, and validation of AI-based algorithms in relation to digital twins and digital agents; Development of Digital Twins with AI for real-time worker guidance and work activities distribution; HMI/GUI design and development to achieve efficient process monitoring.

Description of the support offered to manufacturing companies before, during and after the testing phase

The process for companies to access the testing facilities: Our services are available within a controlled laboratory environment located in University of Ljubljana, Faculty of Mechanical Engineering, laboratory LASIM, Aškerčeva 6, 1000 Ljubljana, Slovenia. Companies interested in utilizing our facilities should contact us via email (niko.herakovic@fs.uni-lj.si or marko.simic@fs.uni-lj.si), specifying their area of interest. A tailored workshop or testing session will then be organized to meet their specific needs.

How the center support companies throughout the testing process? The center provides comprehensive support throughout the testing process, starting with a live presentation and demonstration of the relevant technologies. Depending on the service, we also offer in-depth analysis of parameter adjustments and technology configurations for a deeper understanding. Compatibility with the company's processes is assessed, and we can collaborate on the integration of technologies and solutions as a final step.

Are there opportunities for companies to consult with technical experts? Consultation is possible and is internally organized during an all areas with different experts that work in laboratory LASIM.

Networking events available for companies to connect with potential partners or clients: We organize the annual ASM Conference (posvet-asm.si), which attracts over 150 partners, offering valuable networking opportunities. Additionally, other events are regularly posted on the event schedule available on the LASIM website (https://web.fs.uni-lj.si/lasim/index.php?page=home), providing further platforms for companies to connect with potential partners or clients.

SUCCESS STORIES AND CASE STUDIES

YASKAWA Europe Robotics d.o.o. significantly benefited from the implementation of our Digital Twin and Visualization solutions in two key areas. Through targeted education on Digital Twin usage, followed by the development of a tailored Digital Twin for planning a new robot production facility, the company achieved a remarkable 60% reduction in the required factory floor space, compared to facilities in Japan with similar production rates. This optimization also resulted in multimillion-euro savings on factory construction costs. The Digital Twin served as a comprehensive tool for optimizing the entire value chain, from Just-In-Time (JIT) parts ordering, warehouse sizing, CNC scheduling, and manual assembly line integration, to painting and testing processes.

Additionally, similar Digital Twin solutions have been successfully implemented in other companies, including Krka d.d. (warehouse layout optimization), ECOLAB d.o.o., SCANIA, IMP Armature d.o.o. and many others.

The developed LPM system, which can be tested in our laboratory, seamlessly connects the development department with the production line by restructuring the 3D product model into an assembly-focused structure tailored for manual worker guidance. This system has been successfully implemented at Yaskawa Ristro d.o.o., where it has become a critical tool for guiding assembly workers and preparing required materials in advance. The LPM system has reduced robot cell assembly and testing time by 40%, while also enabling the company to achieve near 100% traceability across manual assembly stations.

An advanced Digital Twin system with AI for real-time worker guidance was developed for Adria Dom d.o.o. This solution integrates ERP data and worker availability to dynamically plan the manual assembly of mobile homes. Leveraging advanced IT connectivity, the system connects the ERP, Digital Twin, and smartwatches with a visualization app, ensuring seamless communication across all platforms. The assembly plan is updated every three minutes based on real-time data from completed processes, worker expertise, and other operational metrics. Workers use smartwatches to log in, receive current tasks, and send updates upon task completion, enhancing efficiency and workflow management. Similar Digital Twin for planning without smart watches was implemented in company IMP Armature d.o.o.

DF2 (Digital/didactic factory 2) - Agile production and logistic Demo Lab

An agile, modular production line enables fast and easy reconfiguration through plug-and-play and self-recognition capabilities. It consists of mobile production modules, including AGVs and AMRs, each functioning as a Cyber-Physical Production System (CPPS) with integrated local digital twins, EDGE technology, and connectivity.

The modules interact based on input factors—such as energy, data, resources, materials, and technological constraints—and output factors—such as products, semi-finished goods, data, assets, and waste. Connected modules form flexible production processes that are controlled through a combination of local and global digital twins, merging global orchestration with local edge computing.

In the DF2 setup, eight different production modules are used for assembly, handling, warehousing, quality control, and material tracking. The system supports the analysis of different material and information flows by enabling reconfigurable layouts and varying sequences of production modules.

DC2_Layout picture DC2_Plant simulation

Figure: Modular production for agile production processes (8-camera view of production layout).

Concept DC2 

Figure: Production modules recognition by machine vision system and creation of virtual models. 

More than 20 production modules (8 different types) are used to form different production layouts for different processes (based on different products and production plan):

  • Module 1: Detection and sorting of colored pieces on the conveyor belt, equipment provided: mini robot Dobot, optical sensor.
  • Module 2: DOBOT C3 collaborative robot, equipment provided: robot attachment to a small table, DOBOT C3.
  • Module 3: Robotic component warehouse, equipment provided: 1x rail, 1x small robot, 1x color sensor, cubes of different colors.
  • Module 4: Machine vision system for color perception and piece orientation.
  • Module 5: Robotic cell for assembly, robotic vision.
  • Module 6: Robotic cell for laser engraving.
  • Module 7: AGV – Automatic guided vehicles used for internal logistics between modular production stations.
  • Module 8: AMR - Autonomous Mobile Robot used for internal logistics between modular production stations.

 

Testing services offered for digital and green technologies

Smart modular self-aware and self-recognition production lines: Designing, testing, and validation of new modular production lines, analysing and evaluation of plug-and-produce principles, analysing and evaluation of different recognition principles (recognition of production modules location and orientation in production hall). Designing the global Administrative shells for production modules (characteristics, attributes, cloud data preparation, connectivity, error handling and maintenance). Development, testing, and validation of new distributed production system concepts (Edge Computing). Designing the Administrative shells for different production modules (digitalization, attributes and characteristics definition, designing the information structure). Testing and integration of AMR (Autonomous Mobile Robots) developed inhouse (using development hardware and ROS architecture) and finished industrial solutions with aim to test different sensors for detecting AMR orientation, track planning and obstacle avoidance and positioning. The mentioned services are performed in laboratory environment, the research results are available for demonstration.
 
Connectivity, Communication, and Data Transfer Approaches: Development, testing, and validation of connectivity, communication and data transfer in production and logistics processes. Designing, testing, and validation of communication protocols (OPC UA, MQTT, Modbus, ...). Designing, testing, and validation of HMIs, visualization and monitoring principles. The services are performed in laboratory environment, the research results are available for demonstration. 
 
Digitalization, Digital Twins Development, and Visualization: Development, testing, and validation of AI in digital twins of logistics processes. Development, testing, and validation of AI-based digital agents. Development, testing, and validation of AI-based algorithms in relation to digital twins. HMI design and development to achieve efficient process monitoring. Daily energy consumption forecasting, real-time visualization, forecasting daily or even yearly energy consumption, optimizing energy procurement by enabling the purchase of the exact required amount in advance, thus reducing costs. The services are performed in laboratory environment, the research results are available for demonstration.

 

Description of the support offered to manufacturing companies before, during and after the testing phase

The process for companies to access the testing facilities: Our services are available within a controlled laboratory environment located at University of Ljubljana, Faculty of Mechanical Engineering, laboratory LASIM, Aškerčeva 6, 1000 Ljubljana, Slovenia. Companies interested in utilizing our facilities should contact us via email (niko.herakovic@fs.uni-lj.si or marko.simic@fs.uni-lj.si), specifying their area of interest. A tailored workshop or testing session will then be organized to meet their specific needs. Online access point is currently under preparation.

How the center support companies throughout the testing process? The center provides comprehensive support throughout the testing process, starting with a live presentation and demonstration of the relevant technologies. Depending on the service, we also offer in-depth analysis of parameter adjustments and technology configurations for a deeper understanding. Compatibility with the company's processes is assessed, and we can collaborate on the integration of technologies and solutions as a final step.

Are there opportunities for companies to consult with technical experts? Consultation is possible and is internally organized during an all areas with different experts that work in laboratory LASIM.

Networking events available for companies to connect with potential partners or clients. We organize the annual ASM Conference (posvet-asm.si), which attracts over 150 partners, offering valuable networking opportunities. Additionally, other events are regularly posted on the event schedule available on the LASIM website (https://web.fs.uni-lj.si/lasim/index.php?page=home), providing further platforms for companies to connect with potential partners or clients.

SUCCESS STORIES AND CASE STUDIES

Based on the connectivity and visualization technologies developed within the DF2 project, we successfully integrated a daily energy consumption forecasting and metering system for IMP Armature d.o.o. The existing Digital Twin, used for production planning, was enhanced with energy consumption data from production machines, enabling precise energy usage calculations at 15-minute intervals. The machines were upgraded with energy consumption measurement devices, and the developed platform collects this data using MQTT and REST API communication protocols. This system provides real-time visualization, allowing the company to forecast daily or even yearly energy consumption, optimizing energy procurement by enabling the purchase of the exact required amount in advance, thus reducing costs.

Other equipment and software

HPC - high performance computer system to perform advanced simulation and real time optimization.
Siemens Plant Simulation – development of 2D and 3D digital models of the production lines and factories in order to simulate and optimize production process, material flow and logistics.
Siemens Process Simulate - modelling, simulation and visualization of manufacturing processes in combination with VR.
Visual Components – manufacturing simulation software for designing and simulation of factories.
Siemens Teamcenter – PLM-product lifecycle management.
GUI ThingsBoard platform – Open-source IoT platform (HMI/GUI development, real-time control, monitoring, visualization).
Beckhoff TwinCAT – PLC GUI, Windows based solution for PLC controllers.
VR/AR Unity engine – development tool for GUI development and animations of the systems.
MathLab, Simulink, Phython, C++ - programming, development of advanced control and decision-making algorithms.
NI LabVIEW software and hardware equipment – programming, experimental testing, GUI development in laboratory environment, test before invest, technology demonstration.
SolidWorks 3D CAD – digitalization of production systems and processes, pre-animation of production processes, 3D modelling of the components and systems, simple FEM analysis, simple CFD analysis.
DSHplus – modelling and simulation of pneumatic and hydraulic components and systems, hydraulic and pneumatic systems and processes optimization using what if scenarios and optimization methods.

 

 

Laboratorij LASIM