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KIT – University of the State of Baden-Wuerttemberg and National Research Center of the Helmholtz Association
wbk Institute of Production Science
www.wbk.kit.edu
Industrie 4.0 - industrial applications and guideline for implementationProf. Dr.-Ing. Jürgen FleischerInternational Conference on Sustainable Manufacturing ICSM 2015, 23.10.2015
Slide 203.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Summary5
Industrie 4.0: use case at AMTC4
Industrie 4.0: practical use cases3
Successful implementation of Industrie 4.02
Fourth industrial revolution1
Agenda
Slide 303.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Fourth industrial revolution
Approaches for Industrie 4.0- technologies:Integration of additional sensors and actuators on field level (more information and more influence on processes for new applications)
The fourth industrial revolution is called „Industrie 4.0“
Quelle: DFKI
Increased networking of physical components as well as focused collection of generated data (increased data availability by using the internet)Generation of information from data (services)Use of common standards for data exchange
An added value results form the intelligent use of the information made available.
weaving loom
assembly line
ProgrammableLogic Controller
Cyberphysicalsystems
1800 1900 1970 today time
com
plex
ity
Slide 403.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Fourth industrial revolution
Chances of the digital revolution in production
Real-time data availability in productionNetworking of all instances of supply chainsRealization of self controlled production environmentsEstablishing of new business models
Design principles for the fourth industrial revolution
InteroperabilityVirtualizationDecentralizationReal-Time CapabilityService OrientationModularity
Fourth industrial revolution
Source: Acatec - Umsetzungsempfehlung , Image: esntl.com, Siemens
Slide 503.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Fourth industrial revolution
Key enablers: Internet of Things and Cyber-physical Systems
Internet of ThingsPhysical objects (“things”) connected to the internetExchange of data from everywhereApproximately 14 billion connected devices worldwide by the end of year 2022
Cyber-physical SystemsPhysical object withan embedded communication unit,Information processing and data storageand Networking.
Source: Machina Research, 2014
Cyber-physical System
CPU Data Physicalobject Communication
unit
Slide 603.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Fourth industrial revolution
ServiceDevelopment of business activities by providing ServicesE.g.: Condition Monitoring
ConnectivityNetwork and middleware and communication platforms . E.g. Connection between production systems
Devices / SystemsDevice with integrated processing of sensor data. E.g. Adaptive systems, smart grippers
Sensors / Actuatorsimpact on processes or control of processes.E.g. Temperature sensor
Industrie 4.0 pyramid
Connectivity
Devices / Systems
Sensors / Actuators
Service
Established players:
Slide 703.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Fourth industrial revolution
Physicalize the CyberApproach of the information driven companies. Information companies
Cyberize the PhysicalApproach of the hardware driven companies. Production companies
Industrie 4.0 development directions
Connectivity
Devices / Systems
Sensors / Actuators
Service
Development directions:
Information companies
Production companies
Source: Lee
Slide 803.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrial Internet ConsortiumBottom up: Use Case first
Fast implementationDevelopment of quasi-standards
Industrie 4.0
Plattform Industrie 4.0Top Down: Standardization first
Political frameworkCollaboration in industrial consortiaBetter standardization
Approaches to introduce the 4th industrial revolution
Quelle : Plattform Industrie 4.0
A optimal implementation of Industrie 4.0 can be realized by fast implementation of use cases and simultaneous standardization.
Slide 903.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Summary5
Industrie 4.0: use case at AMTC4
Industrie 4.0: practical use cases3
Successful implementation of Industrie 4.02
Fourth industrial revolution1
Agenda
Slide 1003.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Successful implementation of Industrie 4.0
Challenge Industrie 4.0:Industrie 4.0 is no „Value“ by itself!Enabler for new:
Products, Processes and Services
Potential of Industrie 4.0:Better fulfillment of customer needs
Increase in sales!Improvement of processes
Reduction of production costs!
Challenge and Potential
Images: diepresse.com
You cannot buy Industrie 4.0, you must work for it!
Slide 1103.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
New ideas Product
and Process
Successful implementation of Industrie 4.0
How can Industrie 4.0 improve your profit?
Industrie 4.0 filtering process
Market needs? New Products
Efficient productionProduct/ Service
1
You can generate new product and service ideas in a systematic process based to your companies competencies.
Product/ Service
3
Product/ Service
4
Product/ Service
2
Product/ Service
2
Product/ Service
2
Images: onlinemarktplatz.de, consulting-spirit-solutions.com
Market Potential
Our competencies? Relating to Industrie 4.0
Industrie 4.0 pyramid
Resources / Strengths
Filtering process
Slide 1203.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Successful implementation of Industrie 4.0
Assessment of the market needs.Example: Product with add-on functionality
Market Potential
Market needs? New Products
Efficient production
Market Potential
Images: preparebrandingstrategy.com
Basis
ExcitementPerformance
satisfied
dissatisfied
not fulfilled well fulfilled
Product
Product with Add-On
Slide 1303.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Successful implementation of Industrie 4.0
Assessment of the competences related to Industrie 4.0.
Resources / Strengths
Our competencies? Relating to Industrie 4.0
Industrie 4.0 pyramid
Resources / Strengths
Low
Medium
High
Integration of sensors
Processing of data
Communication (Machine to Machine)
IT supported Services
Product
Data collection
Communication in production (M2M)
Vertically communication
Human Machine Interfaces
Production
Low
Medium
High
Low
Medium
High
Example:
Slide 1403.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Successful implementation of Industrie 4.0
Filtering process for new product ideas
Product/ Service
1
Product/ Service
3
Product/ Service
4
Filtering process Market potential
Resources / Strengths
low
high
low high
Product/ Service
3
Product/ Service
1
QuestionMarks
Cash Cows
Poor Dogs
Stars
Prod./Ser 2
This process ensures the optimal order of innovations regarding Industrie 4.0.
Slide 1503.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Summary5
Industrie 4.0: use case at AMTC4
Industrie 4.0: practical use cases3
Successful implementation of Industrie 4.02
Fourth industrial revolution1
Agenda
Slide 1603.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrie 4.0: practical use cases
Implementation in a smart factory:Assembly line for over 200 versions of hydraulic valvesManufactured products are equipped with RFID-chips for identificationBased on the current product, individual work instructions are displayed to the assembly operator
Added value:The complexity of a high product variety becomes manageable for the operatorHigh productivity despite small batch sizes and large numbers of product variants
Smart Factory: Bosch Rexroth Assembly Line in Homburg
Source: Rexroth
Slide 1703.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrie 4.0: practical use cases
Product:Uniform man-machine interface for machine toolsIntegrated management, documentation and visualization of job-, process- and machine-data
Added value of the product: Time saving through direct access of relevant dataHigh user friendlinessPremium price for the machine manufacturerTime saving for the machine user
Machine Tools in a Smart Factory: DMG Celos
Source: DMG Mori Seiki AG
Slide 1803.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrie 4.0: practical use cases
Product:Signal converters which are able to continuously receive signals and information of production systems and transmit them to networks (PCs, machine control) via Modbus/TCP
Added value of the product:Base-component for possible Industrie 4.0 applicationsQuick and simplified diagnosis within the networkAccelerated troubleshooting during production processesInternet-capable by the use of TCP/IP
Base Components in a Smart Factory: Signal Converters with TCP/IP
Source: Weidmüller Interface GmbH & Co. KG
Slide 1903.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrie 4.0: practical use cases
The ball screw of a machine tool sends data of it’s use and integrated sensors to the cloud
Analysis strategies for the data are provided by the manufacturerMaintenance requests are triggered out of the cloud
Predictive Maintenance in a Smart factory
Images: MAG, Steinmeyer
Component manufacturer
Ball screw data
Analysis strategiesData cloud
MaintenancerequestSystem operator
Slide 2003.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrie 4.0: practical use cases
Product:Adapter for communication between sensors and mobile devices (tablets, smartphones) Safety aspect: The new Bluetooth capability has no influence on the function of the sensor or it‘s communication with the machine control
Added value of the product:Enabler for an in-line sensor managementSimplified commissioning, diagnosis and troubleshooting for the operator
In-line Sensor Management in Smart Factories: Pepperl+Fuchs SmartBridge
Source: Pepperl + Fuchs
Slide 2103.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrie 4.0: practical use cases
Product:An airplane engine is provided to the customer; the manufacturer carries out monitoring, maintenance and repairs throughout the lifetime of the engineThe Engine remains property of Rolls RoyceAirlines pay for the function of the engine
Added value of the product:Reduction of financial risks for the airlineCost of operations become projectableOperational availability can be increasedProduct improvements can be implemented more directly
New Business Models and Maintenance: Rolls Royce Total Care
Source: Rolls-Royce plc
Slide 2203.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrie 4.0: practical use cases
Self-organizing, adaptive logisticsTraceability with CPS:
Information of the position of every load carrier
LogisticsExposure of weak spots in supply chainsFast derivation of emergency strategies
Intra logisticsPaperless logisticsEfficient handling
Smart Supply Chains
Source: Daimler
Logistics supported with Internet of Things services to save money and increase efficiency.
Slide 2303.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrie 4.0: practical use cases
Product:Small parts container with built-in camera to monitor its filling levelAutonomous triggering of re-orders through the system Real-time control of the supply chain
Added value of the product:New business segment for the manufacturer of small parts: Optimization of the customer‘s supply chain High supply reliability combined with low inventory levelsStrong customer relationships through the use of a closed system
Intelligent Inventory in a Smart Supply Chain: Würth iBin
Source: Würth
Slide 2403.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Summary5
Industrie 4.0: use case at AMTC4
Industrie 4.0: practical use cases3
Successful implementation of Industrie 4.02
Fourth industrial revolution1
Agenda
Slide 2503.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrie 4.0: use case at AMTC
Showcase for Smart Automation: Valve manufacturing with Industry 4.0
Product:Hydraulic Valve manufacturing with Industry 4.0
Added value of the product:Autonomous manufacturing with real time controlNo inventory in the productionQuick and simplified diagnosis within the networkAccelerated troubleshooting during production processesInternet-capable by the use of TCP/IP
VisionExtension to other product variant
Slide 2603.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Industrie 4.0: use case at AMTC
Showcase for Smart Automation: Valve manufacturing with Industry 4.0
Turning
Milling andhoning
Clampedvalve block
Valve spool Additional parts
RFID
Zero point clamping
Cloud
LogisticWork piece carrier
Control
Conveyor
Assembly& QA
valve block
Valve spool
Additional parts
Slide 2703.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Summary5
Industrie 4.0: use case at AMTC4
Industrie 4.0: practical use cases3
Successful implementation of Industrie 4.02
Fourth industrial revolution1
Agenda
Slide 2803.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Summary
Changes through Industrie 4.0Future products and production systems get communication abilitiesSensors and actors extend access to the physical worldServices improve product functionalities
Industrie 4.0
Source: Plattform Industrie 4.0
Industrie 4.0-technologiesMany necessary technologies are already availableAn added value is generated through the intelligent combination of different technologies; only implemented use cases can demonstrate true values
You cannot buy Industrie 4.0!The successful implementation of Industrie 4.0 is a processStart with the company’s know how and needsImplement the most obvious applications firstLearn with application!
Slide 2903.11.2015
© wbk Institute of Production ScienceProf. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze
Prof. Dr.-Ing. Jürgen Fleischer
Head of InstituteKaiserstr. 12, 76131 KarlsruheTel.: +49 721 608 [email protected]
Thank you!
![17.06 - Technische Universität München1]:accessed 27th January 2016) ... My Joghurt–accepted Industrie4.0 demonstrator Demonstrator:](https://img.pdfslide.us/doc/110x75/5ab574077f8b9ab7638cc5ad/1706-technische-universitt-mnchen-1-accessed-27th-january-2016-my-joghurtaccepted.jpg)
