Real-Time IoT-Based Production Planning and Control of Industrial Robots in an Automated Cyber-Physical Production System Under Dynamic Conditions: Lessons Learned from a Make-to-Order Usage Case

Industry 4.0, IoT, and cyber-physical production systems (CPPSs) are regarded as a key factor for manufacturing companies to become more efficient, flexible, and responsive to market changes. However, all but real-time bidirectional communication between shop floor cyber-physical systems (CPSs) and IoT-based production planning and control (PPC) in a cloud environment become especially challenging regarding the de facto state of technology, as we indicate. Many CPS/CPPS projects fail in industrial practice. We describe the design and implementation of a highly automated CPPS in a real-time make-to-order usage case for the production of prescription lenses based on an environment that requires real-time communication if it is to work. We use the project experiences to explain the lessons learned and derive a holistic approach to IoT-PPC CPS and CPPS design and implementation.