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Autonomous Factories 4.0:
Industrial Use Cases and the Role of AI
Prof. Dr. Oscar Lazaro (Innovalia) – [email protected]
Smart Factory Conference 2019, Athens, 12th February 2019
Innovalia GroupDigital Transformation (DTx)
Digital Innovation Hubs
(DIH)
Digital Maturity
Quality Control Products &
Services
Zero Defect Manufacturing
Platforms
HMI
Cybersecurity
Software Quality & Safety
International
SOLUTIONS FOR EVERY SECTOR
Products
Systems Sensors Software Accessories
More performanceLower cost
Systems
Horizontal Arm Systems Bridge type Systems Gantry Systems Portable Systems
Optical sensors
High Speed Scanning
Obtain high accuracy 3D pointclouds of your parts for reverse engineering, virtual metrology and automatic inspection.
OptiScan 1040-L OptiScan 1015-L / HR
MEASURING SOFTWARE FOR PRODUCT
QUALITY CONTROL IN LABS AND PRODUCTION LINES
ACCREDITED BY:
Captures and analyzes point cloudsallowing the inspection and
measurement of any type of part
Machine Check
BETTER ADAPTATION TO OUR MACHINES
HIGHER USABILITY
HIGHER MEASUREMENTS ACCURACY
HIGHER SAVINGS ON NON QUALITY
Use your machine to its fullest
Accessories More
performanceLower cost
Checking fixtures Positioners Calibration Tools
Accessories YOU can make it WE can hold it
Coordination
Big Data Infrastructure
Factory 4.0 Big Data Expertise
Big Data Tools & Smart Machines
Lighthouse Factories 4.0
Replication Factories 4.0
Open Communities
Scientific Management & Digital Transformation
Certification & Standards
Autonomous Factory 4.0
Factory 4.0
Bayer Pharmaceuticals Division (Garbagnate, Italy): digitaltwin-based scheduling programme for quality-control lab.Bosch Automotive (Wuxi, China): Advanced data analyticsare helping the company to “deeply understand andeliminate output losses, simulate and optimise processsettings, and predict machine interruptions before theyoccur”.Haier (Qingdao, China): ‘Order-to-make’ masscustomisation platform and a remote, AI-supportedintelligent cloud platform for predictive maintenance.Johnson & Johnson DePuy Synthes (Cork, Ireland): IoTtechnology to create digital twins of physical assets foradvanced machine insights, lower operating costs, andmachine downtime reductions.
Phoenix Contact (Bad Pyrmont/Blomberg, Germany): ‘Customer-driven digital twinning’ has involved creating digital copies of eachcustomer’s specifications, cutting production times by 30 percent.Proctor & Gamble (Rakona, Czech Republic): The factory hasdeveloped a Web-based analytics model for supply chainimprovements, speeding up time to market, and increasinginventory efficiency and customer satisfaction.Schneider Electric (Le Vaudreuil, France): Operators haveincreased visibility into operations, maintenance, and energy use,leading to energy cost reductions of 10 percent and maintenancecost reductions of 30 percent.Siemens Industrial Automation Products (Chengdu, China): Anew platform for flexible production takes customer orders andimmediately allocates resources and schedules production time,leading to 100 percent compliance and 100 percent traceability.Fast Radius/UPS (Chicago, US): Industrial-grade 3D printing ishelping to tackle demand for fast-turnaround times and masscustomisation of products, while a centralised, proprietaryoperating system drives real-time analytics and orchestratesdesign, production, and global fulfilment.
Europe leads the world’ssmartest factories (5 +2 / 9)
By 2020, 75% of
enterprise and ISV
development will include
cognitive/AI or machine
learning functionality
including all business
analytics tools
By 2020, 40% of All Digital Transformation Initiatives, and 100% of All Effective IoT Efforts,
Will Be Supported by Cognitive/AI Capabilities
Factory 4.0 –Impatc of Data-driven AI Transformation
Smart Factory
Digital Factory
Autonomous Factory
A Vision for the Autonomous Factory 4.0
The Industry 4.0 digital platform stars are……
The advantage of being digital, is that we can always play not to be, however being the opposite is completely impossible……………….. the manufacturing process and the business value
Industry 4.0 Business Value
Industry 4.0 manufacturing processes
Adding software to a broken process doesn't make you digital. The biggest challenge is reimagining the process, not writing software.
Factories 4.0 – Industrial manufacturing process evolution
Factories 4.0 – Industrial manufacturing process evolution
Plug & ProduceModular Assembly Cells
AutonomousTransportation & Logistics
Mass customisationFlexible operations Components move
Machines moveProducts move
Safe human-robot collaboration
Digital twin – Real factorysynchronised operations
Human-robots-machines come together as needed for mission-oriented tasks
Real-time digital and physical actuation
Continuous Production Planning Adaptation for Zero Defect Manufacturing
Human in the loop - Augmented Virtual Decision Support
Factories 4.0 – Industrial manufacturing process evolution
Factories 4.0 – Industrial manufacturing process evolution
75%Reduce time to
production decision
90%Reduce time to set
quality controls
Factories 4.0 – Industrial manufacturing process evolution
• 185-200 new references per year.
• 500-600 references are in production simultaneously.
• Checking fixture development cost: 5.000 € (simplest) -25.000-30.000 € (most complex). → Average cost: 12.000 €.
• Checking fixtures have to be available in the productionplant during the production life of the part, usually about 4years.
Cost
Measurement process is manual,done by quality engineers andmanually-uploaded on PC.
Until quality ok, productionbatch not valid.
Time
Quality
Factories 4.0 – Industrial manufacturing process evolution
Business Objective BPI resultsCost reduction for checking
fixtures 25%
Total Costs reduction 40%Measurement time reduction in
development phase 90%
Measurement time reduction in production phase 75%
Reduced requirement of skilled works on non-value adding
operations50-75%
Storage and easy access of historical values 90%
Increase of available shop floor surface (fixtures) 50-75%
Factories 4.0 – Industrial manufacturing process evolution
Factories 4.0 – Industrial manufacturing process evolution
Factory 4.0 Architecture
Reference Architecture for Manufacturing Industry 4.0 (RAMI 4.0)
Smart production
Smart supply chain
Smart product
From Industry 4.0 towards data-driven AI operations
Industry 4.0 Big DataTransformation
99%Manufacturing Data Value is Lost
Link between Platforms & Things
Industrial Data Space: Data sovereignty for data-driven AI services
95+Companies & Organisations
18+Countries
40+Use
Cases
1Ecosystem
=
IDSA Members
Reference national IDS contact points
Industrial Data Space: Data sovereignty for data-driven AI services
FIWARE for Smart Industry: Building the right industrial context for smart services with OSS.
Industrial Data Space Foundations
Data Access & Usage Control
Same Rules Certification
Factory 4.0 migration pathways: How do we get there?
Digital Migration Paths for Factories 4.0
Autonomous Factories 4.0 Transformation: Digital Capabilities
Autonomous Factories 4.0 Transformation Pathway
20%
2
9
50K€InvestmentAverage digital transformationproject investment goes from 50K€to 100K€.
DurationOver 60% of enterprises consider theoptimum I4.0 project durationbetween 9 and 12 months
ROI55% of enterprises expect a ROI ofIndustry 4.0 actions below 2 years
CompetitivenessProductivity improvements20%.
Digital Transformation Project Profile
A Digital Shopfloor Alliance for Factory 4.0 Transformation
Low Deployment Cost
Fast Return of Investments
Easy Configuration & Operation
Reliable Solutions
Incremental deployment
Open Systems
Digital Shopfloor Alliance Value Proposition
Autonomous Factory 4.0 Services Framework
3 Types of knowledge generation
Edge control,streamperception& actuation
Smartmemory
Augmented interaction &planning
Factory 4.0Big Data
Pilots
FACTORIES 4.0
TextileCeramicsElevation / AERO
3 Replication
Automotive (6)Machine Tool (2)White Goods & Appliances (2)
10 Lighthouse
BIG DATA BUSINESS
PROCESSES
40 12OPEN BIG DATA
PIPELINESPROOFS OF
CONCEPT (POC)
High Added Value Products
Smart Connected Shaver
(Electric) ConnectedCar
Smart Washing Machine
Machine Tool & Automation
Manufacturing Processes 4.0
ZDM (Hot) Stamping& Hydro-forming
Autonomous Assembly Islands
Light metal Casting
Predictive Maintenance Service
Augmented Manual Assembly
AdaptiveWelding
Mass-manufacturingInjection Molding 4.0
Spare Part CustomerService Management
High-precisionLot-size-1 Machining
Autonomous (Intra) logistics & warehouse
High Performance Big Data Algorithms & Platforms
Hybrid Twin Engineering Analytics
Edge-poweredEngineering Analytics
Distributed Production Scheduling
3D Industrial Lake Visual Production Analytics
Rule-based Fault Detection & Prediction
In-memory Demand Forecasting
Data Lake Operational Analytics
IoT StreamOperational Analytics
Hybrid Predictive Production Planning
Real-time SimulationBased Planning
61 www.qu4lity-project.eu
AI for Autonomous Zero Defect Manufacturing
One Day at theM3 Digital Factory
One Day at the M3 Digital Factory
TIME SAVINGERROR
MINIMIZATIONTRACEABILITY
One Day at the M3 Digital Factory
Product Designer
Thomas
Model Based Design
QIFSTEP 242…..CATIA
One Day at the M3 Digital Factory
Industrialization Prototypes
Mats
HIGH DEFINITION
FASTFLEXIBILITY
One Day at the M3 Digital Factory
ColormapPart 034834-20180614
One Day at the M3 Digital Factory
One Day at the M3 Digital Factory
CNC Production
Irina
IN-PROCESSINTEGRATION
PROGRAMABLE
One Day at the M3 Digital Factory
CNC Production
Irina
MH Check
One Day at the M3 Digital Factory
In-machine metrology
One Day at the M3 Digital Factory
One Day at the M3 Digital Factory
Quality Control
Leo y Lily
DATA QUALITYCERTIFICATIONPRODUCTIVITY
One Day at the M3 Digital Factory
hybridOptiscan + TouchPTB-NIST CertificationMulti-CAD/Multi-alignmentOff-line programmingVirtual MetrolologyGD&TSimulationQIF – DMISReporting flexibilityAutomation
One Day at the M3 Digital Factory
Process Engineers
Amelia y Harry
RELIABILITYTIME SAVING
SERVICE
One Day at the M3 Digital Factory
Fixture Tech
One Day at the M3 Digital Factory
Production Engineer
Olivia
PROCESS VISIBILITY
EASY TO USEDECISION SUPPORT
One Day at the M3 Digital Factory
Olivia
Production EngineerOlivia
analytics
One Day at the M3 Digital Factory
ElisabethProduction
Maintenance
Carlos
BIG DATAREAL TIME
CONNECTIVITY
One Day at the M3 Digital Factory
ElisabethProduction Maintenance
Carlos
Monitoring
One Day at the M3 Digital Factory
Product Manager
Alice
SECURITYVERSATILITY
COMMUNICATION
One Day at the M3 Digital Factory
Workspace
One Day at the M3 Digital Factory
One Day at the M3 Digital Factory
academy
One Day at the M3 Digital Factory
85
M3 Digital Factory Academy
The advantage of being intelligent, is that we can always play stupid, however being the opposite is completely impossible
The advantage of being digital, is that we can always play not to be, however being the opposite is completely impossible
Thanks!Oscar Lazaro (Innovalia)[email protected]
www.boost40.euboost4_0
www.linkedin.com/groups/12075988
Any questions?
