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Raphael Wagner, M.Sc.

Research Associate
department: Production Systems
office hours: To be agreed
room: Geb. 50.36, F 003
phone: +49 1523 9502627
Raphael WagnerXgc9∂kit edu

76131 Karlsruhe
Kaiserstraße 12

Raphael Wagner, M.Sc.

Area of Research:

  • Quality Assurance in the field of micro production
  • Quality control cycles for economic production of high precision products
  • Data Analytics for process optimization
  • Development of “Industrie 4.0” strategies


General Tasks:

  • Coordination of lecture...
    • Quality Management at Hector School
    • Learning Factory Scalable Automation
    • Working Methods in Mechanical Engineering at Carl Benz School
    • Integrative Strategies in Production and Development of High Performance Cars (ISS)




Test benches:


Dissertation: Quality control by means of functional models to meet high quality requirements


Curriculum Vitae:

since 05/2016 Research Associate at the Institute of Production Science (wbk) at Karlsruhe Institute of Technology (KIT)
2010 - 2016 Study of Mechanical Engineering at Karlsruhe Institute of Technology (KIT)



[ 1 ] Wagner, R.; Häfner, B. & Lanza, G. (2016), "Paarungsstrategien für hochpräzise Produkte*", wt Werkstatttechnik online, no. 12, pp. 804-808. [08.12.16].
Steigende Anforderungen an die Produktqualität stellen Unternehmen vor die Herausforderung, günstige Produkte nahe der technologischen Fertigungsgrenzen zu produzieren. Die Paarung von Montagekomponenten mit angepassten Produktionsstrategien bietet in diesem Umfeld mögliche Lösungsansätze. Neue Informations- und Kommunikationstechnologien im Kontext von Industrie 4.0 eröffnen hierfür neuartige Möglichkeiten.

[ 2 ] Wagner, R.; Kuhnle, A. & Lanza, G. (2017), "Optimising Matching Strategies for High Precision Products by Functional Models and Machine Learning Algorithms ". WGP-Jahreskongress, eds. Schmitt, R. & Schuh, G., pp. 1-9.
Companies are confronted with increasing product quality requirements to manufacture high quality products, close to technological limits, in a cost-effective way. Matching of assembly components offers an approach to cope with this challenge by means of adapted production strategies. To satisfy and optimize precise functionality requirements a model that integrates process variation and functionality is applied to enhance existing matching strategies. This paper demonstrates the implementation of functional models within production strategies for fuel injector systems. The injector system must fulfil high requirements regarding the functionality, i.e. providing a homogeneous fuel mixture at a constant level. To enhance matching strategies and the functional models for the assembled components, a machine learning algorithm will be applied. This model is utilized to determine and quantify a model for the functional relation between pre-process variations and product functionality and to optimize matching strategies by selecting the relevant features.

[ 3 ] Haefner, B.; Biehler, M.; Wagner, R. & Lanza, G. (2018), "Meta-Model Based on Artificial Neural Networks for Tooth Root Stress Analysis of Micro-Gears". Procedia CIRP 75, eds. Elsevier, pp. 155-160.
Micro-transmissions, consisting of micro-gears with a module <200µm, are used in manifold industrial applications, e.g. the medical industry. Due to the technological limits of their manufacturing processes, micro-gears show large shape deviations compared to their size, which significantly influence their lifetime. Thus, for micro-gears a model has been developed to enable a prognosis of their lifetime based on areal measurements of the gear geometry, finite elements simulations as well as lifetime experiments. To significantly reduce the amount of experiments, existing prior knowledge is additionally used as input to the lifetime model by means of Bayesian statistics. To enable a time-efficient application of the model for industrial series production, in this article the application of a machine learning approach based on artificial neural networks is investigated. The uncertainty of the model is evaluated according to the principles of the Guide to the Expression of Uncertainty in Measurement (GUM).

[ 4 ] Wagner, R.; Haefner, B. & Lanza, G. (2018), "Function-Oriented Quality Control Strategies for High Precision Products". Procedia CIRP 75, eds. Elsevier, pp. 57-62.
Companies are confronted with increasing product quality requirements to manufacture high quality products, close to technological limits, in an economic way. The implementation of adaptive quality control strategies (QCS) in production offers an approach to cope with this challenge. In this paper, new function-oriented QCS by means of selectively assembling multiple components are demonstrated based on a functional product model. The implementation of QCS for fuel injector systems, which must fulfil narrow tolerances regarding the product’s functionality, show benefits in quality and cost-effectiveness. In the approach a functional model of the product and a simulation of the production system are implemented.

[ 5 ] Wagner, R.; Schleich, B.; Haefner, B.; Kuhnle, A.; Wartzack, S. & Lanza, G. (2019), "Challenges and Potentials of Digital Twins and Industry 4.0 in Product Design and Production for High Performance Products". Procedia CIRP, eds. Elsevier, pp. 88-93.
Digital twins offer great opportunities in various domains of the product engineering process. However, current approaches to the use of digital twins only focus on different separated disciplines. In contrast to that, it is expected that the holistic use of digital twin models in product development and production will dominate future product generations, because they allow to create high-performance products competitively. This paper explores important challenges and future potentials of digital twins and Industry 4.0 for the seamless integration of product specification and production. In this regard, approaches of linking digital twins to other domains open up new possibilities in tolerance allocation and production integration. Thereby, the most efficient product specifications in technical and economic terms are achieved for the manufacturer. In addition, the connectivity of Industry 4.0 broadens the scope and enables the evaluation of alternative approaches in production planning and control. Approaches at the organizational level, product functions with specifications beyond the technological limits and production control strategies (e.g. order dispatching) ensure high performance operations. Simulations with a digital production twin with integrated digital product twin allow early estimations even before the actual ramp-up of the product. The future challenge addressed in this paper is to define a consistent framework for the holistic use of digital twins in the entire product development process, which requires the integration of product designers and production planner concepts.

[ 6 ] Silbernagel, R.; Wagner, R.; Häfner, B. & Lanza, G. (2019), "Qualitätsregelstrategien in Wertschöpfungsnetzwerken", wt-online, vol. 109, pp. 802-806.
In Zeiten der Globalisierung und Digitalisierung führen Silodenken und Protektionismus zu Wettbewerbsnachteilen aller Partner eines Wertschöpfungsnetzwerkes. Ineffizienzen zeigen sich zum Beispiel durch hohen Ausschuss und geringe Margen der Zulieferer für die Produktion hochpräziser Produkte. Der Beitrag zeigt auf, wie Kollaboration in der Supply Chain mit unternehmensübergreifenden Qualitätsregelstrategien zur Steigerung der Qualität und Senkung der Qualitätskosten beiträgt.