Safety-critical automation often requires redundancy to enable reliable system operation. In the context of integrating sensors into such systems, the one-out-of-two (1oo2) sensor architecture is one of the common used methods used to ensure the reliability and traceability of sensor readings. In taking such an approach, readings from two redundant sensors are continuously checked and compared. As soon as the discrepancy between two redundant lines deviates by a certain threshold, the 1oo2 voter (comparator) assumes that there is a fault in the system and immediately activates the safe state. In this work, we propose a novel fault prognosis algorithm based on the discrepancy signal. We analyzed the discrepancy changes in the 1oo2 sensor configuration caused by degradation processes. Several publicly available databases were checked, and the discrepancy between redundant sensors was analyzed. An initial analysis showed that the discrepancy between sensor values changes (increases or decreases) over time. To detect an increase or decrease in discrepancy data, two trend detection methods are suggested, and the evaluation of their performance is presented. Moreover, several models were trained on the discrepancy data. The models were then compared to determine which of the models can be best used to describe the dynamics of the discrepancy changes. In addition, the best-fitting models were used to predict the future behavior of the discrepancy and to detect if, and when, the discrepancy in sensor readings will reach a critical point. Based on the prediction of the failure date, the customer can schedule the maintenance system accordingly and prevent its entry into the safe state—or being shut down.

Globalization in the field of industry is fostering the need for cognitive production systems. To implement modern concepts that enable tools and systems for such a cognitive production system, several challenges on the shop floor level must first be resolved. This paper discusses the implementation of selected cognitive technologies on a real industrial case-study of a construction machine manufacturer. The partner company works on the concept of mass customization but utilizes manual labour for the high-variety assembly stations or lines. Sensing and guidance devices are used to provide information to the worker and also retrieve and monitor the working, with respecting data privacy policies. Next, a specified process of data contextualization, visual analytics, and causal discovery is used to extract useful information from the retrieved data via sensors. Communications and safety systems are explained further to complete the loop of implementation of cognitive entities on a manual assembly line. This deepened involvement of cognitive technologies are human-centered, rather than automated systems. The explained cognitive technologies enhance human interaction with the processes and ease the production methods. These concepts form a quintessential vision for an effective assembly line. This paper revolutionizes the existing industry 4.0 with an even-intensified human–machine interaction and moving towards cognitivity.