Unleashing the Potential of Industry 4 · Horizontal integration: Value added networks optimized in real time Confidential | RBAS/GM-VN I RBEI/EGB I Connected Industry | 04/10/2017

Confidential | RBEI/EDE I Connected Industry | 04/10/2017

© Robert Bosch Engineering and Business Solutions Private Limited 2017. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.1

Unleashing the Potential of Industry 4.0

Ankur Goyal – Head of Business

Development (Industry 4.0)

Digital Enterprise value chain

Confidential | RBAS/GM-VN I RBEI/EGB I Connected Industry | 04/10/2017


Digital

workplace

Digital

Engineering and

Manufacturing

Digital

Supply chain

Digital

Products, Services

and business

models

Digital

Customer and

channel

management

E-finance

Digital HR

Internal knowledge

sharing

Big data process

optimization

Predictive maintenance

Condition monitoring

Augmented reality

Integrated digital

engineering

Digital factory

Integrated planning and

execution

Logistics visibility

Procurement 4.0

Smart warehousing

Efficient spare parts

management

Autonomous and B2C

logistics

Prescriptive supply chain

analytics

Digitally enhanced

products

Intelligent and

connected products and

solutions

Automated and data-

based services

Digital business models

B2B2C customer

interaction

Digital customer

experience

Omni channel sales

integration

Omni channel marketing

Point-of-sale-driven

replenishment

Micro deliveries

Customer lifetime value

management

Technology, processes, organization

Digital Applications

Digital Enablers

Industry 4.0

Long road to Industry 4.0



Industry 1.0 Industry 2.0 Industry 3.0 Industry 4.0 Digital Ecosystem

The invention of

mechanical production

powered by water and

steam started the first

industrial revolution

Mass production, with

machines powered by

electricity and

combustion engines

Introduction of assembly

lines

Electronics, IT, and

industrial robotics for

advanced automation of

production processes

Electronics and IT (such as

computers) and the Internet

constitute the beginning of

the information age

Digital supply chain

Smart manufacturing

Digital products, services,

and business models

Data analytics and action as

a core competency

Flexible and integrated value

chain networks

Virtualized processes

Virtualized customer interface

Industry collaboration as a key

value driver

1800 1900 1970s 2015+ 2030+

Today

Industry 4.0 Dimensions



1

2

3

Horizontal integration: Value added networks optimized in real

time

Vertical integration: Business processes and technical

processes

Integrated life cycle management




1

2

3


time


processes


Horizontal integration: Value added networks optimized in real time



Integrated Planning and execution

Logistics Visibility

CustomerDistribution SiteProductionWarehouseSupplier

Procurement 4.0 Smart Warehousing Efficient spare parts management Autonomous and B2C Logistics

Prescriptive Supply Chain analytics

Smart supply chain enablers – Processes, Organisation, Skills, Performance Management, Partnering, Technology

External data

(eg. Weather,

social listening)




1

2

3


time


processes


Vertical Integration - Shop Floor to Top Floor



Technology stack level

Passive device level

Virtual marketplace2

Third party data

Enterprise level ERP system and PLM applications

Workcenter level

Supply chain applications, Asset

performance applications, process

control applications/MES, Big data &

advanced analytics applications

Software

-

Control device level

Device, machine & station control,

Big data & advanced analytics applica-

tions, HMI software, SCADA, Soft PLC

HMI, PLC, motion

controllers,

Field device level Field device applications

I/O (sensors, actuators),

drives, intelligent

mechanics, switches

Assembly lines

Mechanics, IMS

Hardware

"Connec-

ted World"

Integrated offerings

Ma

ch

inery

, s

ys

tem

s,

serv

ice

s

Au

tom

ati

on

so

luti

on

s a

nd

serv

ice

s

SW

/IT

in

teg

rati

on

EP

C1

Co

ntr

act

ma

nu

factu

rin

g

Secu

rity

off

eri

ng

s

Mo

du

le/s

ys

tem

1 Engineering – Procurement – Construction 2 Marketplace in the cloud to sell and distribute “industrial apps”

Intra-logisticsOperationsUpstream

logisticsDownstream

logistics

Demand

ManagementService

Management

Value Driven Smart Manufacturing




1

2

3


time


processes


Integrated Lifecycle Management



Value Driven Smart Manufacturing

Product Development Process

Manufacturing After Sales

Production

PlanningDesign

(func. & phys.)

Plant

Automation

Production

Execution

Maintenance

and Service

Quality and

Enhancements

Digital Twin of Product Digital Twin of Process Digital Twin of Performance

Integrated Data Model

Industry 4.0 design principles



Modularity

Interoperability

Decentralization

Virtualization

Service

Orientation

Ability of multiple systems with different hardware and software platforms, data structures, and

interfaces to exchange data with minimal loss of content and functionality

CPS and CPPS will take decisions on their own and autonomously without violating organisation goal.

Processes will adapt to individual product demands enabling custom products

Concept of digital twin in product design, engineering, production and lifecycle management enabling

proactive decision making

Factory based on Service-oriented Architecture renders manufacturing services to customers via IoS

Real time

CapabilityData collection and analysis performed in real time. Ability of the system to respond to changes,

such as changes in customer requirements or the status of the internal production system

Capability of system to be separated and combined easily on plug-and-play basis.

Modular systems are inherently scalable, allowing them to react to rapid changes in demand without

abandoning the initial investment

Industry 4.0 refers to convergence and application of nine digital industrial technologies



Source : BCG

Industry 4.0 complements actions of Lean implementation



Lean Tools

Kaizen (PDCA)

TPM

Standardization

Forms of waste

5S

TQM

Kanban

(JIT/Pull)

Takt Time

Value stream

mapping

Smoothing

Andon

Poke-Yoke

SMED

Real Time

capability

Decentralization

Modularity

Interoperability

Service

Orientation(SoA

and IoS)

Virtualization

I4.0 Design principles

Listening to

client

Anticipating

client’s

needs

Lean

Industry 4.0

Focussing

on value

adding

activities

Focussing

on value

adding

information

Make the

product flow

(Takt-time)

Make the

data flow

(Real-time)

Pull

Production

Pull

everything:

Production

and services

*Manufacturing as a service

MaaS*

Identifying

product

Identifying

processFactory

layout

Appropriate

strategy

Striving for

perfection

Continuous

Improvemen

t (Kaizen)

High Morale

Comprehensive framework for Industry 4.0 adoption



Advanced Robotic

Additive Manufacturing

Augmented Reality

Simulation

Vertical/ Horizontal

Integration

Industrial Internet

Cloud computing

Cyber security

Big Data and Analytics

Industry 4.0 Design Principles

(Real time, Modularity, Interoperability, Decentralization, Virtualization, Service Orientation)

Kaizen (PDCA)

TPM

Standardization

Forms of waste

5S

TQM

Kanban (JIT/Pull)

Takt Time

Value stream

mapping

Smoothing

Andon

Poke-Yoke

SMED

Predictive Maintenance

VR based training

RFID based WIP

tracking

OEE Monitoring

Dynamic production

scheduling

Early warning system

Digital supply chain

Intelligent supermarkets

Digital Maintenance

management

1) Anticipating client needs

2) Focussing on value adding

information and activities

3) Make the data

and product

flow

4) Pull production

and services

5) Strive for

perfection

Best and Traceable

Quality

Low Cost

Flexible lead time

Best safety

Industry 4.0 tech enablers Lean Tools Industry 4.0 enabled lean cycle Lean and Digital Enterprise

7 dimensions of EHS 4.0 framework



EHS 4.0

framework

Strategic | Opportunity to further elevate the business value of EHS

management

Systematic | Process standardization, harmonized systems, and

advanced analytics

Risk-based | Proactive processes for managing safety and

environmental risks, to predict and prevent adverse business impacts

Connected | Collaboration and communication to break down cross-

functional silos and provides process integration and decision-support

information from "shop floor to top floor“

Smart | Data-driven decision-making includes a sufficient volume of the

right types of data, and the application of advanced analytics technology

to extract actionable insights

Agile | Ability to successfully adapt to internal and external change, and

requires enterprise scalability and the capability to quickly create and

deploy new applications

Engaged | Motivated workforce collaborating to achieve organizational

objectives based on effective competency management and an

organizational culture of operational excellence

Integration of people, processes and technology

Environment, Health and Safety – Technology Enablers



Connected Worker – Smart Risk Management



AR/VR enabling Digital Transformation in Enterprise

AR/VR Solutions for Enterprise



Training Solutions Maintenance & Repair

Virtual Reality : Operator Training made simple

Augmented Reality: Explains complex

components in a realistic and simple manner.

DIY Training Platform & Authoring Tool

Maintenance Service Manual

Maintenance & Repair

Dial an Expert – Step by step guidance from an

expert to fix a complex machinery

Improves Retention &

Recall

Assessment Module to

measure the performance

Dial an Expert with

annotations for easy

understanding

Easy Maintenance functions

with step by step guide




Immersive Virtual Reality powered hands on learning

VR platforms enabled high fidelity immersion into Virtual worlds.

Customer Benefits

Hands on experience (similar to a real

world)

No need to halt the production line

No need to tamper process for

Troubleshooting

Expert dependency is reduced




Augmented Reality powered training tool

At Bosch we use AR powered training tool to train engineers on latest technologies

Customer Benefits

Self learning Apps on Consumer smart phones

Dependency on expert reduced

24/7 Availability

Consistent training across the organization

FINAL-AR-KOR.mp4

FINAL-AR-KOR.mp4




Key Challenges for Maintenance & Repair

Expert Cost

Machine

Downtime

Effective

Maintenance

High

Travelling cost

of Experts

Downtime of

Machinery

impacting

production

Skilled experts

not available for

efficient

maintenance




AR powered Dial an Expert (Mobile-Mobile Standard Solution)

AR powered training tool to train engineers on latest technologies

Customer Benefits

Affordable solution

Mass market

No special devices required

Annotations for easy understanding

Dial an Expert

Case Study #2: I4.0 in a box for SME segment



Machine and Production Analytics

Bosch Energy

Signature Analyzer

Bosch Mechanical

Signature Analyzer

Backup

Generator

Asset-lite model (Pay-per use)

Retrofit and non-intrusive

Rapid deployment (1-2 weeks)Grid

Bosch Machine

Controller Analyzer

GS

M/G

PR

S

GS

M/G

PR

S

GS

M/G

PR

S

Key Features

Machine OEE & Industry Benchmarks

Production Part OEE

Productivity Improvement Analytics

Machine Capacity Utilization

Production and Capacity planning

Bosch

Energy

Analytics

Active

Time

Power

On/OffMachine

Productivity

Power Quality

ConsumptionProduction

Count

MTBF /

MTTF

Machine OEE

Dashboard and Analytics

Bosch India Journey



I4.0 movement in India

9 Legal Entities

18 Manufacturing Plants

30,500 employees

>4000 Sales outlets

>1500 suppliers

Digital Immersion:

Build ‘Digital Culture’

– skill building for new

age

Reimagine CIP &

Lean processes for

digital world

Closer to consumer:

Let’s build B2B2C

mind set

I40 Solutions

contextualized to

India

Long-term vision and

roadmap

Building

infrastructure & Data

strategy for future

Business outcome

led use-case

implementation

Agile execution

Bosch in IndiaI40 for India: Key building blocks

Building a ‘Digital Culture’

‘Hyper-Local’

solutions

Long-term vision &

Agile execution

Fostering Eco-

system

Collaboration with

CII for I40 academy

Affordable solutions

for SME

Start-up

engagement

program (DNA)

Bosch Connected Industry



Nexeed Portfolio

Nexeed Open IntegrationHarmonization solution of different software systems and applications for production and logistics.

Integration of Bosch Connected Industry solutions, Bosch solutions and third-party solutions.

Nexeed Connected Manufacturing Nexeed Connected Logistics

Nexeed

Manufacturing

Execution Nexeed

Manufacturing

Transparency Kit

Nexeed

Automation

Nexeed

Production

Performance

Manager

Nexeed

Remote Shopfloor

Access

Nexeed

Data Analytics

Nexeed

Device Portal

Nexeed

Track & Trace

Nexeed

Intralogistics ExecutionNexeed

Maintenance

Support System

LET`S SHAPE THE FUTURE WITH INDUSTRY 4.0

LET`S SHAPE THE FUTURE WITH INDUSTRY 4.0

Documents

Unleashing the Potential of Industry 4 · Horizontal integration: Value added networks optimized in real time Confidential | RBAS/GM-VN I RBEI/EGB I Connected Industry | 04/10/2017