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© FIR 2015
Prof. Dr.-Ing. Volker Stich Managing Director, FIR e.V. at RWTH Aachen Eindhoven, February 26th 2015
FACTORY OF THE FUTURE - Industrie 4.0
© FIR 2015
2
Introduction to Industrie 4.0 1
Agenda
The Aachen perspective on Industrie 4.0 2
Relevance of Industrie 4.0 in SME 3
Synopsis 4
© FIR 2015
3
Introduction to Industrie 4.0 1
Agenda
The Aachen perspective on Industrie 4.0 2
Relevance of Industrie 4.0 in SME 3
Synopsis 4
© FIR 2015
4
What is „Industrie 4.0“?
The striking name „Industrie 4.0“ is understood as the comprehensive inclusion of information and communication technology as well as the interconnection to an Internet of Things, services and data that enables a real-time capability of production systems.
Prof. Dr.-Ing. Dieter Spath
Source: BMBF, Spath (2013), Image: Festo
© FIR 2015
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Why do we need Industrie 4.0?
“The situation is not clear”
“The quantity of variables is increasing”
Average time between two passes
5,8 4,4 3,7
WC 1970
WC 1990
WC 2010
“The game becomes faster”
Daily routine Production
Source: Wjingaard & Schütze 2003; WZL-Project illustration; BMW Group & Renner 2007
>390 different job cards to manufacture a product
48% of all orders have more than one planed completion date
1,1
WC 2014
Variants at BMW Group over time
Del
iver
y Ti
me
[Day
s]
Significantly reduced delivery times (e.g. PVD-Coating)
Time
Pro
gram
rang
e
Time
© FIR 2015
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What is the intention of Industrie 4.0?
21. Cent. 18. Cent.
Price & Quality
& Flexibility & Time
& Deadline
Rep
etiti
vene
ss
Craftsmanship
Efficiency
1769 Steam engine
1908 Fordism
~1810 Interchangeability
from 1956
Toyota Production System
~1990 Lean Thinking
1930 - 1950
Quality awareness
1890 Scientific Management
Product variance
§ Standardized work § Time studies and
working standards § Worker/Management
Dichotomy
§ Any number, at different times, at different locations produced parts A need to fit any number, likewise produced parts B without a need to rework
§ Transition from craftsmanship to factory work
§ Use of machines
§ Value § Value stream § Flow § Pull § Perfection
§ Client contact § One-piece-flow § Zero-failure-principle § Kaizen
§ Quality control chat / Statistic process control
§ Ishikawa-Diagram § PDCA-procedure
§ Mass production § Flow-production § Tact § Complexity management
© FIR 2015
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What are essential distinguishing characteristics of the 4. industrial revolution
Industrie 4.0 drives the renunciation of Taylorism by complementary
automation processes at the interface of man-machine interaction
The “Company Organization 4.0” is characterized in terms of responsibility and remit by job enlargement and job
enrichment. Assistance systems helps to cope with greater responsibility.
21. Cent. 18. Cent.
Price & Quality
& Flexibility & Time
& Deadline
Rep
etiti
vene
ss
Craftsmanship
Efficiency
1769
Steam engine
1908 Fordism
~1810 Interchangeability
ab 1956 Toyota Production System
~1990 Lean Thinking
1930 - 1950
Quality awareness 1890 Scientific
Management
Product variance
© FIR 2015
8
Introduction to Industrie 4.0 1
Agenda
The Aachen perspective on Industrie 4.0 2
Relevance of Industrie 4.0 in SME 3
Synopsis 4
© FIR 2015
9
The increase of collaboration productivity enables a 50% reduction of development time, development- and manufacturing costs
IT Software: Truth IT Hardware: Speed cyber
physical Software
Hardware
Physical Systems: Automation
Business Communities
4. Industrial Revolution Collaboration productivity - Human / Human - Human / Machine - Machine / Machine
Social Behaviour: Cooperation
PLM-System
ERP-System
Local storage
Save in the cloud
High Speed Computing
Cognitive Systems Social Communities
© FIR 2015
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The increase of collaboration productivity enables a 50% reduction of development time, development- and manufacturing costs
IT Software: Truth 1. An entire PLM-System as a
„Single Source of Truth“
2. Use of “high-resolution” data from production
IT Hardware: Speed 3. Simulation-based decision
guidance
4. Cloud-based and real-time capable simulation
cyber
physical Software
Hardware
5. Intelligent and self-learning systems
6. Highly skilled employees as a key to success
Physical Systems: Automation
4. Industrielle Revolution
7. Disruptive network approach
8. Fast implementation by transparency and communication
4. Industrial Revolution Collaboration productivity - Human / Human - Human / Machine - Machine / Machine
Social Behavior: Cooperation
© FIR 2015
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1. An entire PLM-System as „Single Source of Truth“ for product an production-related data
Administration of Construction data
Administration of Product data PPC Formerly
Administration of Construction data
Administration of Product data PPC
PLM
As-is state
PPC
LF SOP KE
PLM/ PDM Ideal
Data transfer
© FIR 2015
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3. Simulation-based decision guidance for production to inrease decision quality
Source: Mercedes Benz, glasspilot, ProSense
“Will I hit the runway
on that trajectory?”
“Terrain vision“
System
”What is the distance behind my car?“ Rear view camera
“What potentials can I realized by better steering decisions?“ Potential- & „What-if“- simulation
Sophisticated decision guidance, self-optimization and simulation “conquer” the production
Intelligent dicision guidance in daily routine Intelligent dicision guidance in production
© FIR 2015
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6. High-skilled employees are a key to success
We need to utilize the competencies we have within this country. However, if we want to use the highly-skilled education, we need to reject from Taylorism. We need to move to a holistic
employee responsibility (Hr. Wiedemann, Technikvorstand Fa. Rational)
Intuitive surfaces for complex applications
Interactive visualizations
Fast Problem solving
Employees as decisions makers
Source: Ortlinghaus, WZL
© FIR 2015
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8. Fast implementation by transparency and communication
Promote exchange between employees
Openness
Break up with hierarchical structures
Bring your own device
Higher transparency facilitates employees to quickly improve complex production processes. Thereby the productivity rises within the entire company!
Source: Ortlinghaus, WZL
© FIR 2015
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Introduction to Industrie 4.0 1
Agenda
The Aachen perspective on Industrie 4.0 2
Relevance of Industrie 4.0 in SME 3
Synopsis 4
© FIR 2015
16
In SME and particular in production, a variety of areas for improvement can be identified Examples of medium-sized mechanical engineering companies
Source: WZL Project illustration 2011/2012
>10 orders on average are located before the machine – corresponding with a workload of 4 days
days of possessing time are needed for an order to pass the production. The average is 32,5 days 2-250
48% of all orders have more than one completion date
of working time are used for non value-adding activities by employees of production scheduling department 50%
>390 different job cards to manufacture a product
© FIR 2015
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The preconditions in order to implement Industrie 4.0 in SME are not set yet
“Everything is possible“ is not relevant in practice
n 57% of the companies use a written documentation of their stock- and movement data
n 17% of the companies do not acquire data
IT-Infrastructur1 Lack of information3 Willingness to invest2
Yes, I know about Industrie 4.0
No, I don‘t know about Industrie 4.0
Source: 1) Schuh (2013): Produktion am Standort Deutschland (n=84); 2) VDI Nachrichten (2014); Fraunhofer IML; 3) techconsult GmbH (2013): Fertigung Mittestand D/A/CH (n=900)
How can solution approaches of Industrie 4.0 be adapted and transferred to SME?
© FIR 2015
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By connecting operational objects and information technologies Industrie 4.0 enables Smart Products, Smart Data und Smart Services
Source: Smart Service Welt - Umsetzungsempfehlungen für das Zukunftsprojekt Internetbasierte Dienste für die Wirtschaft
Container Documents Identification Localization
Smart Data
Smart Products
Smart Services
Operational objects Information technology
Sensors Actuators Work pieces Machines
Staff Communication Information processing Tools
© FIR 2015
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Already today adapted solutions for SME are existing in order to implement Industrie 4.0
Tomorrow Today
Intelligent tools
Self-controlling products
Smart Products
Real-time optimized production
IT-supported material posting Smart Data
Simplified maintenance
Flexible material staging
Smart Services
© FIR 2015
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Smart Products From intelligent tools to self-controlling products
n Automated tool crib
n Optimized tool planning by recording tool idle time
n Automatic request to supplier, if tools are needed
n Communication between product and production plant
n Storage fo all necessary information on one chip on the product
n Self-controlling product throughout the whole production
Image source: Gühring, mymüsli
Tomorrow Today
© FIR 2015
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Smart Products From intelligent tools to self-controlling products
n Communication between product and production line, - plant
n All necessary information stored on a chip right on the product
n Self-controlling product throughout the entire production
Tomorrow Today
Image source: Gühring, mymüsli
n Automated tool crib
n Optimized tool planning by recording tool idle time
n Automatic request to supplier, if tools are needed
© FIR 2015
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Smart Data From IT-supported material posting to real-time-optimized production
n Supporting posting of material withdrawal from stock by sensors
n Material tracking throughout production by sensors at work places
n Simulation of production scenarios on basis of gathered data
n Testing of “What- if“ scenarios in order to analyze different scenarios
n Improve production control by deriving relevant fields of actions
Image source: inotec, ProSense
Tomorrow Today
© FIR 2015
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Smart Data From IT-supported material posting to real-time-optimized production
n Simulation of production scenarios on basis of gathered data
n Testing of “What- if“ scenarios in order to analyze different scenarios
n Improve production control by deriving relevant fields of actions
Tomorrow Today
Image source: inotec, ProSense
n Supporting posting of material withdrawal from stock by sensors
n Material tracking throughout production by sensors at work places
© FIR 2015
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Smart Services From flexible material staging to simplified maintenance
n Improving of internal logistics
n Determination of material requirements and request times at work places, based on production planning data
n Calculation of departure time and “Milkrun” routing
n Simplification of maintenance by using Augmented Reality
n Target/actual comparison permits a quick fault detection, fast debugging and reduction of machine downtimes.
Image source: Liebherr, Kinrig
Tomorrow Today
© FIR 2015
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Smart Services From flexible material staging to simplified maintenance
n Improving of internal logistics
n Determination of material requirements and request times at work places, based on production planning data
n Calculation of departure time and “Milkrun” routing
n Simplification of maintenance by using Augmented Reality
n Target/actual comparison permits a quick fault detection, fast debugging and reduction of machine downtimes.
Image source: Liebherr, Kinrig
Tomorrow Today
© FIR 2015
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A variety of Digital Manufacturing initiatives are already launched on country and EU level
Source: European Commission
© FIR 2015
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The Industrie 4.0 “Readiness” across Europe varies; Frontrunners are Germany, Ireland, Austria and Sweden
Source: Roland Berger (2014)
© FIR 2015
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Introduction to Industrie 4.0 1
Agenda
The Aachen perspective on Industrie 4.0 2
Relevance of Industrie 4.0 in SME 3
Synopsis 4
© FIR 2015
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Industrie 4.0 - How we make it happen at the RWTH Aachen Campus Cluster Logistik
Increased significance Automated calculation of transition times
Staging area 2
RFID - Sensor
Consistent communication Adaptive assembly instructions
Reliable forecast Situational capacity planning
Better comprehension PPC based analysis of gathered data
Simulation of possible alter- native actions
Overview of production capacities
Visualization of gathered data (As-is status) Simulative Determination of Controlling optimum
PLM - based worker guidance
Staging area 1
© FIR 2015
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Synopsis
Industrie 4.0… … is the inclusion of information and communication
technology and their interconnection to an „Internet of Things“,
… offers great potential by combining information in an appropriate context,
… enables the increase of collaboration productivity in order to increase competitiveness,
… enables Smart Products, Smart Data and Smart Services,
… needs to be adapted to the requirements of SME.
© FIR 2015
31
Thank you for kind your attention
Prof. Dr.-Ing. Volker Stich Managing Director
Telefon: +49 (0)241 477 05-100 Fax: +49 (0)241 477 05-199 E-Mail: [email protected]