Keynote 8, friedrich vollmar, ibm

© 2015 IBM Corporation 1


Industrie 4.0

Von der Vision zur Realisierung

GSE Jahrestagung Hamburg 12 Mai 2015

[email protected]

Updated Version 7-May-2015


The 2013 Vision Industrie 4.0

Industrie 4.0 is a customer led growth initiative

Convergence of

– Internet of People ,Internet of Things, Internet of Services

Available technology for vertical and horizontal communication

and cooperation in realtime between all participants.

ROI Expectations

– plus F2 Productivity

– minus F2 Resources.

Innovation

– Intelligent machines enable individualized products

– Value chains around individualized products = Lot size

1 for the price of a mass produced item

Real–time communication & collaboration between all

participants

– enables new value chains and

– new integrator less business models

2



Industrie 4.0 Driver: Exponential Growth Of IT Capabilities (F2 in 18 m)

1961: Apollo Control System (*)

– 4100 Integrated Circuits

– 1 K Byte Cache

– 12 K Byte ROM

– 1 Mhz clock

Connected to Houston Control

2014: Mid Class Car (**)

– 25plus embedded IT-Systems connected via bus

– 20 x Power of PC (quote: Winterkorn, CEO VW, Cebit 2014)

– Generates more than 3.6 GB system data per hour 1 MB/s

– 100 Mio ICs, 1MB cache , > 1 GHz clock – for each CPU!

Connected to the Internet, other cars & road side services

Price 400 K USD IT-HW Price 35K Euro incl Car + Car2Everything Communication

Source: AUTOSAR

(*) Source: Wikipedia (**) Source: AUTOSAR



20th century: the mass era

21st century: era of the “new individual”(*)

(*) “… a new awareness that I call psychological self-determination…”

Shoshana Zuboff, Charles Edward Wilson Professor of Business Administration, Harvard Business School

Industrie 4.0 Motivation: Customers Expect Uniqueness



Industrie 4.0 ROI: Modernize existing machinery in a sheet metal plant

Project Goals - Vertical integration of plant automation and

sensors with IT/ ERP System (in team with SAP)

- Horizontal IT based íntegration of existing machinery (in team with Siemens)

- Productivity increase plus F 1.x

- Resource input decrease minus F 1.x

5

© 2015 IBM Corporation 6 6

Serielle

Schnittstelle

Dateien (FTP, SFTP,

Verzeichnis) TCP/IP

PLS Ver-

packungs-

line

Waage

Disomat

Mess-

geräte

Durchlauf

-beize

Schub-

beize

Koppel-PC

Labor Glühe

Stored Procedures

DB Verbindung

PC für Waage

S7-Adapter

MQ

optional: Weiterleitung

für Benachrichtigung /

Weiterverarbeitung

Stored

Procedures

JDBC/ODBC

Daten-bank

Server

RFC (BAPI,

ALE)

ERP Server

ESB: Sichere und stabile Interoperabilität 0100101 0010101 0101001

01010101 01010101 111010101

0101010 1010101 1010101

0010100 1000010 1101010

0101010 1010101 1010100

0001101 1110101 0100010

10101010 1010101 1010101

Modernisation of sheet metal plant - IBM SOA ESB as backbone

6

+ Analytics +

Optimization


Industrie 4.0 Innovation: New Flexible Value Chains enabling “lot size 1”

The consumer interacts directly with shop floor – bypassing retail

– Enabler: Any lot size possible / unique personalized products

– Chances:

• Customer demand can be more precisely fulfilled. Cost saving & better ROI

• Additional differentiators, new offerings and enhanced extended customer relationship

– Examples: Fashion, Toys, e-engines, Furniture, Cars.

Friedrich Vollmar

Design

Production

Retail

Consumer

Design

Production Communication

Customer

Pay direct


1. Engineering & Software development Leading Edge Automotive System and Software Development for Robert Bosch GmbH

8

Continuous Engineering

Develop smarter products

MarketAnalytics

SystemVerification

SystemTest

SystemRequirements

SystemDesign

Deploymentto Mfg.

CustomerRequirements

Operations and Maintenance

Implementation

Agile SoftwareEngineering

ElectricalDesign

MechanicalDesign

Process & Data Mgmt.

IBM Continuous Engineering Solutionfor Systems and Software Engineering

Open Lifecycle Integration

Quality Requirements

Architecture, Design and Development

Systems and SoftwareEngineering

Change/ Configuration Management

Best Practices and Services

Bosch example:

Car Instrument Cluster Demo

Increase re-use of software

Automate dashboards

Get real-time project status information

Full data traceability and query capabilities

Continuously plan, design,

implement and build the product

software in an iterative, taylored and

ASPICE compliant process

Connect and manage all data across

the development lifecycle

+

IBM Rational

Collaborative

Lifecycle Management


2. Production & Integration Shopfloor Integration based on Industrie 4.0 principles and standard SOA software 2015

HMI / Worker assistance (assembly instructions,

„pick-by-light“, digital reflection)

Plug&Play, flexible uniform shopfloor

(re-)-configuration

Illustration of material

handling and withdrawal,

pull rope, screwdriver

Real-time data capture and machine parameter control

+

9

IBM BPM with real-

time machine SCADA

visualization

IBM Integr. Bus

Manufact. Pack + S7

Adapter, MQTT &

WSRR


Straigth from Software to Product New value chains around 3 D printing

10

Erstes Triebwerk aus 3D-Drucker •

• AERO Telegraph Donnerstag, 26. Februar 2015 - 17:22 Laura

Frommberg

http://www.aerotelegraph.com/erstes-triebwerk-3d-druck-universitaet-

australien

Ein Jahr lang haben die Forscher der australischen Monash University

gemeinsam mit der Deakin University und der Commonwealth Scientific

and Industrial Research Organisation am Projekt gearbeitet. Jetzt

präsentieren sie das Ergebnis - und beeindrucken eine ganze Branche.

Sie haben das erste Triebwerk entwickelt, dass komplett aus einem 3D-

Drucker stammt - und das zweite gleich auch noch.

Angefangen hat alles, als der Triebwerkhersteller Safran

Ihnen zwei ältere Flugmotoren zur Verfügung stellte.

Mit ihnen kann man etwa einen Falcon-20-Jet antreiben.

Diese haben die Forscher nun nachgedruckt.

Mit dem Ergebnis sind sie mehr als zufrieden. Offenbar nicht nur sie:

Auch Airbus und Boeing zeigen bereits Interesse an der Technologie.

Tests in den kommenden Jahren

Forschern gelingt weltweit erster 3D-Druck eines

vollfunktionsfähigen Flugzeugtriebwerks

Von: Michael Kammler in Technik 26. Februar 2015 um

12:07 0

DMG MORI hat eine neue Maschine entwickelt, die

unter anderem auch in der Werkstatt von Iron Man ein

Plätzchen finden dürfte. Zudem ist es Forschern unter

der Leitung von Prof. Xinhua Wu gelungen, weltweit das

erste Flugzeugtriebwerk mit einem 3D-Drucker zu

drucken.

http://www.aerotelegraph.com/erstes-triebwerk-3d-druck-universitaet-australien?format=email

http://www.aerotelegraph.com/4846

http://www.aerotelegraph.com/4846

http://www.trendsderzukunft.de/author/michael/

http://www.trendsderzukunft.de/category/technik/

http://www.trendsderzukunft.de/forschern-gelingt-weltweit-erster-3d-druck-eines-vollfunktionsfaehigen-flugzeugtriebwerks/2015/02/26/#respond



What is missing? The IoT assessment of Gartner (*)

Gartner Hype Cycle for Internet of Things July 2014

Concerns / Issues

– Who owns the data ?

– Customer relationship

• With whom does the customer actually

want the relationship?

– Standards. Missing or too many diverse

or even conflicting

– IoT security lags behind IoT technology

• Things interfere with public safety

– Integrate Legacy Artifacts

– Get IT and OT to cooperate

(OT = operation technology)

We are here

(*) Source: Gartner, July 2014



The 5 Dimensions of Industrie 4.0

Industrie 4.0 demands cross-branches, cross-company, public-private teamwork

Moving forward in all 5 dimensions will make Industrie 4.0 become reality

User Acceptance Usability

ROI

Demand

Legacy Integration Different lifecycles

of IT and Things

Standardization of communication and cooperation -

Protocols, ConnectionPlatform,

Semantics

Legal Framework Security + Safety

Secure, trusted solid Infrastructur

Ownership of data + liabilities

Governance + legal approvement

IT / IoT Technology

Enables new opportunities for innovation

and industrial capabilities


Public Private Partnership to Enable Industrie 4.0 secure integrator-less value chains

Politics starting to take action

– Digitale Agenda in Germany

– Digital Europe

Modify Legal Framework to enable usage of New Technologies

– Example autonomous driving. Technology is nearly there, the legal framework is missing

Legal Framework for digital business and new value chains.

– M2M Machines act in business context - / ordering, contracting /

Shared Infrastructure (digital marketplace / shared dataspace ) incl. legal framework

– Infrastructure to enable secure integrator - less value chains

13


The central service platform of Industrie 4.0

Connects all participants

Assures trusted identity and

secure communication

Filter fraud and verifies

transactions. Acts as digital

market place.

Must be democratic –

monopole will not be broadly

accepted

E.g. SWIFT / Cooporative /

Open Standards


Plattform Industrie 4.0 Defined Reference Architecture Industrie 4.0

New Challenges

All Layers connected with / connected World/

Products stay connected after leaving plant

Facts

Industrie 4.0 needs real-time processes

Industrie 4.0 needs 100% security

Strong growth of computing power & communication

– In production & engineering

– Products

– Aftersales

– New business models with connected

products

15


Plattform Industrie 4.0 Defined Reference Architecture: Industrie 4.0 Component

Internal

Control(s) S 1 A x

Internal

communication

Application A Industrie 4.0

Component Internet

Control

subsystem(s)

SOA Administration shell Defines services provided and requested by this component

ESB as Service

Repository

• Protected kernel

• Service offerings at interface,

based on Standards

• Life cycle independence

= prepared for future

integration of

legacy systems

Industrie 4.0 Component =

Any kind of intelligent /Thing/



Outlook


IBM Confidential | Do Not Distribute © 2014 IBM Corporation 18

Minister Siegnar Gabriel , Germany on Hannover Fair April 2015

Forcast Industrie 4.0 in Germany

• Invest Industry in Industrie 4.0 2016-2020 30 B Euro p.a

• Based on 1.6 T Euro BIP Germany from industrial sector

– + 3.5 % Growth = 48 B Euro p.a

– - 3.5 % Cost = 48 B Euro p.a

– EU estimated 4-5 Times German invest and ROI

EU view

– Growth + Re-Industrialization with Industrie 4.0

– Lot size enables EU to compete in markets with higher scale of economics (China, NA ) on level playing field

– Industrie 4.0 will come anyway. Be early, be first ==> Same invest , better ROI

– Unified legal framework for Digital Europe as base for Industrie 4.0.

Germany is anchor point for 44 % of all industrial value chains.

Market Industrie 4.0



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IT Technology : Two alternative Architectures for Industrie 4.0 + technology of both alternatives available from IBM and demonstrated on HMI + different business value chains . Any interconnected hybrid possible

IOT Cloud Commercial Apps

Shared data Technical Apps

Analytics

s A M C

Value

S M C

SOA

ESB

SOA SOA

Integration Peer to peer

Value

Integration thru Cloud Service

Friedrich Vollmar

Commercial Apps Shared Data

Analytics


Plattform Industrie 4.0 defined Reference Architecture Industrie 4.0 . Who will manage the Overall Corporate - IT and - Network ??

New Challenges

All Layers connected with / connected World/

Products stay connected after leaving plant

Facts

Computepower Car = 20 X Thinkpad

Computepower Plant = xx classic IT

Industrie 4.0 needs 100% security

Strong growth of computepower + communication

– In Production + Engineering

– Products

– Aftersales

– New business models with connected

products

20

Interconnected Product

Basis for new value chains

Engineering + Plant

From island

to

Interconnected


Software will connect everything Software will bring different industries into functional overlaps and competition

Friedrich Vollmar

Software

Entertainment-

electronic

Automotive

Retail

Telecommunication

Machine Builder

Chemie/ Pharma

Financial-

Services

Electronic

IT - Industry

IT-Services

Agriculture

Chance

Alliances

Risk


/ Software ist .... das neue Rad der Industrie/

Dr. Elmar Degenhart CEO Continental ( FAZ 06-03-15)

/ Nowadays, a small team of talented programmer

can change the world /

Marissa Mayer CEO Yahoo 2013

( as response to the question how to revitalize Yahoo )

/ Make sure it is Your team ……….. /

Fritz Vollmar IBM HMI 2015

Friedrich Vollmar



. Industrie 4.0 Represents Massive Opportunities Let’s get it done together !!! Packen wir es an !!!

Thank you for your attention

Legal Framework

Security + Safety Right of Ownweship + Liabilities

Governance + certification + approval

Reliable, secure network

IT Technology

Enables innovations and

new value chains

User Acceptance

Value

ROI

Legacy Connection

Standards For communication, cooperation,

services


– Growth + Re-Industrialization based on Industrie 4.0

– Lot size 1

• Fits to the diverse local markets in EU and individualized demands of EU customer

• Enables EU to compete in markets with higher scale of economics (China, NA ) on level playing field

• First industries in successfull implementation process ( f.e Automotive)

– Industrie 4.0 will come anyway. Be early, be first ==> Same invest , better ROI

– Proven legal framework to be extended to digital world ( Digital Europe, Digital Marketplace ...etc )

– Expected WW growing demand for individualized products can position Europe in a leadership position

==> Industrie 4.0 has the potential

- to leave Europe lagging behind

+ to transform Europe into a leading economy + society of the 21 century.

Chances & opportunities for Europe in Industrie 4.0

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