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Digitalization:
Transformation in the Consumer Space …
… to
e-books
… to ride-
sharing
From the
book store
…
… to streaming
From the
record store
…
From
taxis …
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… is happening even more powerfully in our Industrial Space
… to distributed
power
generation
… to data driven
maintenance
From
centralized …
… to virtual
collaboration
From paper
based design
…
From manual
checks …
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The Internet of Things:
Driving the Digital Revolution, everywhere
Internet of Things
Energy
Smart grid
Infrastructure
Smart mobility
Healthcare
Smart health
Buildings
Smart buildings
Living
Smart home
Logistics
Smart logistics
Cities
Smart cities
+ Efficiency
+ Productivity
+ Capacity
+ Shorter time
to market
+ Resilience
+ Flexibility
Customer
benefitsManufacturing
Industrie 4.0
Smart factory
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Industrie 4.0:
The Vision of the Future of Manufacturing
1st industrial
Revolution
Water and
steam
2nd industrial
Revolution
Electricity, mass
production
3th industrial
Revolution
Automation
4th industrial
Revolution
Digitalization
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Industrie 4.0:
The Vision of the Future of Manufacturing
Digital Enterprise Technologies
Big Data and analytics
Augmented reality
Additive
manufacturing e.g.
3D
printing
Cloud
Cyber
security
Industrial
Internet
(network of integrated
sensors)
Horizontal/
vertical
software
integration
Simulation
Autonomous
robots
PLM = Product Lifecycle Management; MES = Manufacturing Execution System;
TIA = Totally Integrated Automation
ZVEI Movie
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From B2B to C2B –
An Ecosystem for Individualized Customization
Real
World
SuppliersVirtual World
Design and
Engineering
Production/
AssemblyService
Digital Enterprise
Digital
Enterprise
Ecosystem
Individualized
Customization
From Business-to-Business to Customer-to-Business
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Integration and Digitalization of the Supply Chain
in the Electronic Works Amberg
Production-Planning
Production-Engineering
Production-Execution Services
Product-Design
Product-
Design
Production-
Planning
Production-
Engineering
Production-
Execution
Services
Teamcenter
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Teamcenter
Innovation in Action - with 3D-Simulation
Design and Optimization of our SIMATIC S7-1500 with NX
Product-
Design
Production-
Planning
Production-
Engineering
Production-
Execution
Services
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Teamcenter
Innovation in Action - with 3D-Simulation
during Product Design
Product-
Design
Production-
Planning
Production-
Engineering
Production-
Execution
Services
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Teamcenter
Innovation in Action - with 3D-Simulation
during Product Design
Product-
Design
Production-
Planning
Production-
Engineering
Production-
Execution
Services
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Teamcenter
Innovation in Action - with 3D-Simulation
during Production Planning
Product-
Design
Production-
Planning
Production-
Engineering
Production-
Execution
Services
Simulation of the injection molding
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Teamcenter
Innovation in Action - with 3D-Simulation
during Production Planning with Tecnomatix
Product-
Design
Production-
Planning
Production-
Engineering
Production-
Execution
Services
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Teamcenter
Innovation in Action - Mechatronic Engineering and Virtual Ramp-Off
during Production Engineering
Product-
Design
Production-
Planning
Production-
Engineering
Production-
Execution
Services
Digital Twin
of the SIMATIC S7-1500
Automated Engineering:
PLC-Code generation
from NX to the TIA Portal
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Teamcenter
Innovation in Action - Efficient Engineering of all Automation Components
during Production Engineering with Totally Integrated Automation (TIA) Portal
Product-
Design
Production-
Planning
Production-
Engineering
Production-
Execution
Services
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Teamcenter
Innovation in Action - Control of the Production in Electronic Works Amberg
with SIMATIC IT und SIMATIC PLCs
Product-
Design
Production-
Planning
Production-
Engineering
Production-
Execution
Services
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Teamcenter
Innovation in Action - Analyzation und Optimization of Energy Consumption
with SIMATIC B.Data
Produkt-
design
Produktions-
planung
Produktions-
Engineering
Produktions-
ausführung
Services
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Actual situation regarding Smart Factories
The majority of companies can
neither monitor operations in real
or near time nor adapt processes
quickly
The majority of manufacturing
companies do not make use of the
vast amount of data that is
generated in their organization
Only 48% of manufacturing
companies have implemented digital
platforms that span across
organizational boundaries
Only 54% of manufacturing
companies have yet automated
their core processes
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Actual perception regarding the need of Smart Factories
Over 75% of manufacturing
companies believe that the Digital
Enterprise will help leveraging their
competitive position!
Technologies that enable employees to
work and cooperate from any location
will be a massive advantage for our
operations !
Using analytic models to transform
data into valuable insights will boost
significant operational efficiency!
Data driven business excellence is
crucial to improve operational
processes
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The Answer to the Question:
„How can I become a smart factory?“
Automation
Line Design• Smart Line Concepts
• Automated Production
• Industrial Engineering
• Plug & Communicate Specification
Digitalization
Plane Design• Digital Lifecycle Readiness
• Horizontal and Vertical Integration
• Identification and History for all Elements
• Smart Data Management
Point Design• Manual/ LCA Production
• Standardized Work Instructions
• Ergonomic Workstation Design
• Focus on Tact Time
Organization
….stepwise – the Amberg way
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The Answer to the Question:
„Why should I become a smart factory?“
Interpretation -AbilityPattern RecognitionMeasure -Ability
Information Gathering
Prognostication -AbilityStabilization
Decision -AbilityAdaptation
REALITY PLANINGSIMULATION
… to increase “-abilities”!
Reactive Proactive
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Va
ria
nc
e o
f W
ork
Co
nte
nt
Variance of Work Sequence
observe – categorize – analyze – react
• Cause & Effect Relation direct or static
• Eliminate Non Value Add
12
3
A
BC
1 32
12
3
A
BC
Design Paradigm for Production SystemsSimple or Complex ?
Simple
Less Complicated
Less Complicated
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Va
ria
nc
e o
f W
ork
Co
nte
nt
Variance of Work Sequence
Design Paradigm for Digital Production SystemsSimple or Complex ? Reactive, Proactive or Prevention?
Complicated & Complex Production System
observe –analyze – (trial and error – analyze) – predict - prevent
• Cause & Effect Relation static or dynamic
• Eliminate Non Value Added Variability
12
3
A
BC
Z
12
3
A
BC
Z
a
b
C
a = A(t)
Data Driven Business Excellence
simulate
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Industrial Data Management ExampleLogistic Management / Energy Management with SIMATIC
Field/ Control Level Operator Level Operator Level Management Level
Automation-Ability
… of Logistic Systems
Interpretation-Ability
…of Logistic Systems
Prognostication-Ability
… of Logistic behavior
Decision-Ability
… Logistic Planning
S7-1200, S7-1500, S7-300,
ET200S SP; Basic Panels, Comfort
Panel, …
Plant Simulation PreactorWinCC
Observe Analyze Predict Prevent
Field Level Control Level Operator Level Management Level
Measure-Ability
… of Energy data
Interpretation-Ability
…of Energy consumption
Prognostication-Ability
…of Energy hot spots
Decision-Ability
… Energy management
ET200-Energy meter, SIRIUS
SIMOCODE, SENTRON PAC, …
Energy Box
S7-1200, S7-1500, S7-300
Basic Panels, Comfort Panel, … SIMATIC WinCC V7, PCS7,
SIMATIC powerrate
PROFIenergy
TIA Portal
WinCC V12, STEP7 V12
SIMATIC B.Data (On-Site)
Energy Analytics (als Managed
Service)
S7-300, S7-400, Industrial PC
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Challenges and Requirements
who define the design elements for our smart factory of the future !
+
Challenges Requirements
… of production systems and
facility
modularity
… of shop floor, facility, equipment
& workforce
scalable
… open media structure net with
no gaps incl. WiFi & data net
compatible
CA B
… through neutral standard
parameters & interfaces
universal
… of equipment and material
mobility
… common collaboration platform with
state-of-the-art security
secure data management
… through big data and business
intelligence
data analytics
… standard communication protocols
plug & produce
… access any data point
(horizontal/vertical)
grid data integration
… information, data and analytic
access from anywhere
cloud base
Vision: Full Agility of Digital Production Systems/ Network
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Electronic Works Amberg
Digitalization enables High Performance
SIMATICSPS - Speicherprogrammierbare
Steuerungen
DP - Dezentrale Peripherie
HMI - Human Machine Interface
~1 SIMATIC-Product per Secund
24 hours between Order and Receiving at Customer
>1200 Product Variants in Teamcenter
~9fold Increase of Production Volume
<11 dpm, Quality Level >99,9989%
Velocity
Flexibility
Efficiency
Quality
4th industrial
Revolution
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Thank you for your [email protected]
Vice President Manufacturing DF FA MF
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