INDUSTRIE 4.0: CHALLENGES AND CONCEPTS...Saudi Arabia Ranking of Nations Developing countries are gaining on industrialized countries Top 15 manufactu-ring countries, ranked by global

© Fraunhofer IPA, IFF University of Stuttgart

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INDUSTRIE 4.0: CHALLENGES AND CONCEPTS

Michael LickefettMay, 2018


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The Fraunhofer-GesellschaftResearch for the Market

Applied research of direct utility to the economy and to the benefit of society

Fraunhofer innovations:

LED

Mp3Biosensors

Service robotMultimedia phones

3D at home

Institutes and independent research units: 67

Annual research budget in billion €: 2.3

Staff 23,000


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Fraunhofer IPA as a technology consultant and innovation driver

Third-largest institute of the Fraunhofer-Gesellschaft; based in Stuttgart

1,000 employees I 73.4 million euros operating budget I 22.3 million euros industrial revenues

Expertise in manufacturing engineering and automation since 1959

Note: key figures for 2015


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Fraunhofer IPA as a partner of the industry

Over 1,000 projects with industrial customers per year

Goal: to improve the competitiveness of manufacturing companies with a focus on the strategic cornerstones of mass sustainability and mass personalization


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Fraunhofer IPA with an international network

Field offices and subsidiaries in Germany, Austria and Hungary

Fraunhofer Project Center for Electroactive Polymers at AIST Kansai in Japan

One third of all projects outside Germany


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Technical equipment and laboratoriesIn tune with the times

Cleanrooms & cleanliness rooms

Application Center Industrie 4.0

Robotics experimentation area

Production laboratory

Coating technology center

Factory planning cockpit

Biomanufacturinglaboratory

Motion laboratory

Electroplating laboratory Intervention room

BioPoLis

Synthesis & reactor park


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Business units and field of workAn interdisciplinary organization

Director Prof. Dr.-Ing. Thomas Bauernhansl


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Überschrift KapitelInternational comparison −the race has begun


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1990 2000 2010 2017

1. United States United States United States China

2. Japan Japan China United States

3. Germany China India India

4. France Germany Japan Japan

5. Italy France Germany Germany

6. United Kingdom India Russia Russia

7. China United Kingdom Brazil Indonesia

8. Brazil Italy France Brazil

9. India Brazil United Kingdom United Kingdom

10. Mexico Russia Italy France

11. Spain Mexico Indonesia Mexico

12. Canada Indonesia Mexico Italy

13. Indonesia Spain Spain Turkey

14. South Korea Canada South Korea South Korea

15. Australia South Korea Canada Saudi Arabia

Ranking of NationsDeveloping countries are gaining on industrialized countries

Top 15 manufactu-ring countries, ranked by global share of nominal gross value added of production (purchasing power parity)

Quelle: International Monetary Fund, abgerufen am 30. April 2017 (englisch), Report for Selected Countries and Subjects (BIP nach Kaufkraftparität). Abgerufen am 2. Februar 2018 (amerikanisches Englisch). Report for Selected Countries and Subjects (BIP-Veränderung zum Vorjahr). Abgerufen am 3. Februar 2018 (amerikanisches Englisch).


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Manufacturing cost index 2014Manufacturing cost converge - globally and timely

Quelle: Boston Consulting Group 2014

+20 %

-20 %


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The Digital World of Today and TomorrowInternet of Everything

source: The Internet of Things, MIT Technology Review, statista, cisco

Access-Economy – Holistic global integration as base for new business ecosystems

More than 3 billion people used the internet in 2015.

25 billion things were connected in 2015 via internet. In 2020 the number is expected to rise up to 50 billion.

Internet services are uncounted. Example: Apple Apple store: > 1 million apps were downloaded more than 75 billion times

New economic activities arise:

Shared economy

Prosumer

Industrie 4.0

…


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Areas of Industrie 4.0 implementationEnterprise of the future

Realtime Information

Connectivity

New Businessmodels

I 4.0

PersonalizedProducts

Smart Production

Industrie 4.0 has the target to …

…. create dynamic, realtimeoptimized, self organizing inter-company Value Networks,

realize individual customerdemands

at a cost level of massproduction.

In Anlehnung an: Plattform Industrie 4.0 (2014) Industrie 4.0 – Whitepaper FuE-Themen


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http://www.a1blog.net/wp-content/uploads/2011/10/systeme.jpg

New ecosystems −networking and shared economy


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IoT and IIoT Platform ProviderCloud-based platforms as backbone of Manufacturing Ecosystems

Consumers,Business and IT Manufacturing, Production

GE PREDIX


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Structure of ecosystems Integrated design from Front to Back End

Back End Front EndFocus Value Adding

Focus Market Position

Ecosystem

XProsumer

Manufacturing Network

Factory

Value Adding System


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Since beginning of 2015 tailor-made gripper can be ordered from Schunk by CAD file of the object to be handled.

Reduction of purchase time and high benefit for the customer by integrating him into the design process

Communication via Online-Platform

Manufacturing with 3D-Printing by partner company „Materialise“

[Schunk GmbH; Materialise]

Schunk eGRIPBusinessmodel-Innovation

SchunkProduct Design

Platform

MaterialiseManufacturing

Customer


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Personalized Products


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Change of Product ArchitectureThe ability to manage complexity effectively becomes a key competitive advantage

sources: Wildemann, H.: Wachstumsorientiertes Kundenbeziehungsmanagement statt König-Kunde-Prinzip; Seemann, T.: Einfach produktiver werden –complexity im Unternehmen senken; Bildquellen: apple.de

degree of integration

simple

cyber-physical

mechanical

mechatronical complicated

complex

degree of personalization

Minimal complexity, maximum personalization and economies of scale

Customer is part of the personalization process and pays for it

Innovation focus: eco-system, user-friendliness, design

Success factor: openness

standard mass

products

individualized regionalized,personalized


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Überschrift KapitelDigital Shadow − element of Smart Factory


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Our future scenario of shop floor productionDecentralized self-organization of smart factories in real-time

Cyber-physical systems (e.g. machines, facilities)

Have an identity

Communicate with each other and their environment

Configurate themselves (Plug and Produce)

Store information

Have easy-to-use human – machine interfaces

Decentralized self-organization in real-

time

New big customer order: Additional shift on Saturday

necessary

I´ve to leave early. Who can

operate my orders?

In two hours I have to be delivered!

Capacity is fully-booked till Friday

Saturday I won´t be able

to work

I will be able to work on Saturday

Hooper will be empty soon, please refill!


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Mobile Robots refill assembly areas and return empty boxes.

Mobile Robots with sufficient capacity move through the supermarket and put goods in the boxes.

Use of Robotic CPS in intralogisticsMobile assistant within the low-wage sector

1. Mobile manipulation (omnidirectional)

2. Storage facility

3. Ability to grasp container

4. 3D Environment sensing (stereo vision, 3D sensor)

5. Can be used without any fence in an industrial environment

1

2

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5


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source: IPA

Robots will be mobile, flexible and safeExample: SEW Eurodrive – freely navigating DTS (carries the robot for bin picking)

KUKA Agilus

Bin withcut-pieces

Mobile platform −Inductive powertransmission

3D-camera systemensenso N20

Magnetic gripper

Cut-pieces

Point cloud


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source: audi-mediaservices.com

All Objects in a Factory will be Mobile as Far as PossibleExample: Audi R8 – freely navigating AGV (navigation as a service)


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Each object in the factory becomes smartiBin − Intelligent bins order their fillings autonomous

Based on: Fraunhofer IML, Prof. Dr. Michael ten Hompel

The quantity can be obtained via the built-in camera,

the information will then be transmitted to the other IT-systems (e.g. ERP)

http://www.wuerthindustri.no/web/en/wuerthindustrie/cteile_management/kanban/ibin_intelligenterbehaelter/ibin.php


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Previous IT-Architectures dissolveWithin the cloud: from the pyramid to the network

Previous

Historical precise hierarchical structured model

Future

Service orientation

broad service orientation (XaaS)

Service orientated IT-Architecture (SoA)

Dehierarchization

Dissolution of hierarchal structures

New functions based on services

App-ization

App-development by end user

Simulation in real-time

Open standardization

Efficiency benefits/ synergies by IT-Clouds

Focus on information/ semantics

ERP: Enterprise-Resource-Planning; MES: Manufacturing Execution System; QC: Quality Control; CAx: Computer-Aided x

QC


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Legend:

S Service

AS Aggregated Service

IS Integration Service

CS Cloud Service

CPS Cyber-Physical-System

mOS Manufacturing Operating System

Fraunhofer IPA Cloud-Architecture for Industry 4.0Virtual Fort Knox: supported, secure Cloud Platform

http://www.google.com/url?sa=i&rct=j&q=virtual+fort+knox&source=images&cd=&cad=rja&docid=ASmU0VFBAIjFMM&tbnid=oSHM8wPcPOZT6M:&ved=0CAUQjRw&url=http://www.flexis.com/de/news/flexis-auf-der-hannover-messe.html&ei=5z7kUZqUIYHVPPnCgfgN&bvm=bv.48705608,d.ZWU&psig=AFQjCNHnGGPD_IY8wEV-Twud-mJObWXg_g&ust=1373999196536674


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Wenn Maschine 7564 = „Störung Mechanik“dann Benachrichtige

„N. Hofer“

Wenn BestandProdukt 7815 < 12 Stck

dann Generiere BestellauftragProdukt 7815: 12 Stck

ERP

Rules

Actuator

Sensor

If Machine7564=„mechanical Failure“,

then inform „N. Hofer“

If stock product 7815<12 pcs, then create new order

product 7815:12

Sense&ActRule based approach for production and logistics management

Features Simple way to define own/individual

rules for interlinking the production entities

Monitoring of sensor values Automatic triggering of predefined

actions

Benefits Flexible interlinking / integration Simple adaptation to company specific

requirements and situations Enables rule based production Flexible/ transformable production IT


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Sense&ActDecentralized configuration of rules by users –Central contextual system optimization

If Machine 7542 is down…

…create a maintenance order!

…send Email to Ms. N. Hofer!

…then that (Act)!If this (Sense)…


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Instant MES-Apps

Master data AppAdministration of resources (e.g. machines, workers, work processing sheets,…)

Tracking AppProduct traceability on Shopfloor (e.g. batch, machine, worker via NFC)

Tracking AppProduct traceability on Shopfloor (e.g. batch, machine, worker via NFC)


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KPI App − Key Performance Indicators

Process planning and monitoring

Active involvement for remote and self-control of manufacturing processes

User friendly (simple, fast and dynamic) operation by Drag & Drop

Individual configuration of KPI charts

Storage of templates for predefined situations

Integration of different databases and decentralized data provision

ComparisonAs is / Should be

Configuration


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Sensor data

Work data

Analysis, simulation, evaluation

Taking measures

Localization system

Meta modelInformation

modelDesign task

Fields of application Factory operation Maintenance Factory planning

Data pool

Physical factoryContext data offactory objects: type place state time relations storage systems, transport systems, machines, parts, material, tools, products, workers, assembly line

Near real-timefactory model

Objectives Support for people

and machines “Real-time“

production system

Time

Product dataFactory structure data

Infrastructure dataProcess data

Resource dataMotion data

Digital shadow

Digital Shadow of ProductionEmulating models to ensure ”one peace flow”

http://images.google.de/imgres?imgurl=http://www.inidia.de/globus_mittlerer_osten_puretec.gif&imgrefurl=http://www.inidia.de/globus.htm&h=600&w=600&sz=45&tbnid=vK3qB6LopJJT0M:&tbnh=133&tbnw=133&hl=de&start=18&prev=/images?q=globus&svnum=10&hl=de&lr=lang_de&client=firefox-a&rls=org.mozilla:de:official&sa=N


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Augmented Reality

Description of components and machinesPersonnel training using context-based descriptions and tutorials

Support by error diagnostics Linking between components and control elements

Assistance by maintenance activitiesAutomated maintenance protocols Sensor evaluation

Remote assistant on plant levelImage transmission from tablet to smartphones


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Cyber physical production supportAdaptive assembly workplace

Flexible, intuitive and personalized support in the assembly of complex products

Pick-by-Light-System for supporting workers and capturing the correct material

Put-to-Light-System for visualizing and control the correct product part position

Flexible connection to material supply by variable height and position of the rear port

Fault-free assembly and simultaneouslythe least effort for learning the assembly operations


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Mixed Reality - a new way of „scale 1:1“ training andplanning


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Automated Detection of Dependencies Between processes and deriving optimization potential

Through

“minimally invasive“ process monitoringvia camera without elaborate system integration

feature-based configuration and recognition of conditions in the videos via adaptive evaluation algorithms

Benefits

near real-time process analysis with direct assignment of the cause for loss

detection and quantitative evaluation of potential for process optimization

permanent transparency through forwardingerrors and machine condition to operators and planers


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Business potential of Industry 4.0Experts expect an increase in performance of 30–50 % on value added

Pilot project of Bosch in which thewhole shipping process of the in-plant logistics centre was redesigned in a Industy 4.0 project.

-10 %Milkruns

+10 %Produc-tivity

-30 %reduce of

stock

Potential benefits

Quelle: IPA/Bauernhansl, Bosch


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Michael Lickefett

Head of department Factory Planning and Production ManagementCoordinator China Activities

Phone +49 711 970-1993Mobile +49 171 4450121

[email protected]

Thank you for your attention.

Documents

INDUSTRIE 4.0: CHALLENGES AND CONCEPTS...Saudi Arabia Ranking of Nations Developing countries are gaining on industrialized countries Top 15 manufactu-ring countries, ranked by global