Modular production using hierarchical planning and a generic OPC UA skills concept

In response to the growing global demand for customized and sustainable aircraft with shorter lead times, this research aims to enhance flexibility and automation in aircraft production. The study focuses on integrating hierarchical process planning with machine skills and simulation to streamline the final assembly phase, where numerous components and modules are combined. Existing research highlights challenges in coordinating module production across various locations, emphasizing the need for cost-effective and adaptable systems to manage demand fluctuations and supply chain disruptions.This study presents a novel approach by expanding the concept of machine skills to include prediction skills, enabling pre-execution, simulation-based outcome estimation for informed decision-making and resource optimisation. The proposed methodology involves a minimal demonstration scenario featuring a warehouse, preassembly stations, a final assembly station, and flexible intralogistics with automated guided vehicles (AGVs), all connected through standardized OPC UA interfaces. This setup serves as a use case to illustrate the application of a generic software architecture and standardised modeling for task-specific skill combinations. By addressing hierarchical planning tasks supported by simulation and standardized interfaces, the research provides a framework for adaptive process orchestration and flexible logistics. The results show a significant improvement in the flexibility and efficiency of production process planning and execution, which has practical implications for the further development of aircraft manufacturing processes.