1. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Industry 4.0 by Tekniker/ES and Brockhaus Group 2. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Who we are: A partnership between 2 companies: Tekniker / Basque country, Spain and Brockhaus Consulting Expertise in the field of: Software Development and Software Architecture MES Systems (also in automotive sector) Data Acquisition and Analysis in the field of predictive maintenance 3. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt What does industry 4.0 mean to us (and to our customers) 4. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Industry 4.0 The 4th industrial revolution The focus for machine building industry might/must shift from hardware to information and information processing lets say: software. --- Prof. Dr. Detlef Zhlke / DFKI (Saarbrcken) 5. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Industry 4.0 The 4th industrial revolution Industrial Revolution 1.0 Beginning in the UK in the late 18th century, leads to machine manufacture with the introduction of mechanical production methods. Industrial Revolution 2.0 At the start of the 20th century, mass industrial production in which assembly line and factory principles of products for mass consumption. At the start of the 1970s, the deployment of electronics and IT in industrial processes led to optimized and automated production. 6. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Industry 4.0 The 4th industrial revolution Industrial Revolution 3.0 Continuation of the automation of production processes, human responsibilities being overtaken by machines. Industrial Revolution 4.0 Over the next decade the fourth industrial revolution will usher in an age of "decentralized" production. Industry 4.0 is made possible by smart objects, autonomous products and decision-making processes which manage manufacturing and production networks in close-to-real-time. 7. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Industry 4.0 Value proposition of industry 4.0 Increase agility and flexibility in production process. Individualize smallest volumes to a high degree of productivity. Optimizes multi-variant series production. React faster on changing market requirements. 8. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Industry 4.0 What means industry 4.0 to us? Data is important to increase production quality, storage capabilities improve drastically with NoSQL databases. New technologies provide improved control over your production processes; e.g. optimize maintenances times / down times by prognosis of upcoming failure of equipment. New technologies allow different way to interact, e.g. mobile devices for operating, supervising and collaboration New standards like OPC UA and OPC / Java allow to close technological gaps between shop floor and business-oriented applications 9. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt The current approach What means industry 4.0 to us? 10. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Industry 4.0 What means industry 4.0 to us? Operate equipment by means of mobile devices (with respect to actual position of operator) 11. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Industry 4.0 What means industry 4.0 to us? Supervise equipment by means of OPC integration and interaction through SCADA system on mobile devices 12. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Industry 4.0 What means industry 4.0 to us? Visualize additional data (KPI, technical documentation, ) of equipment by means of QR code and devices like google Glass (or similar) currently under development! 13. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Industry 4.0 What means industry 4.0 to us? Analyse sensor data for purposes like predictive maintenance, trends and quality reports There is a lot of information in production plants: From several sensors already installed From the control parameters Right now a lot of that information is not used, just a small part is used. currently under development using NoSQL / Big Data databases and statistical frameworks like weka or Apache Mahout / Spark 14. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Reference projects 15. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Windmill Park 3. ANOMALY PREDICTION AND DETECTION 2. MODELLING e.g. temperature 1. CLUSTERING, e.x. based on wind turbine performance Groups of wind turbines with similar performance Temperature modeling and prediction based on SCADA dataset, under normal operating conditions. e.g. Generator/Gearbox: bearings temperature Wind farm anomaly detection based on those temperatures related to the failure: e.g: bearing temperature monitoring Too high % of deviation on temperature X regarding baseline (the farm, the model). Dangerous for the Generator performance. Client: INGETEAM Analyzing current sensor values for modeling and predictive maintenance 16. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt Machine tool Models Nominal conditions Failure A Failure B Vector Clustering Feature selection Frequency Domain: - Power bandwith - Spectral lines Time domain RMS Curtosis Machine2Fingerprint Machine1Fingerprint MachineNFingerprint Currentand Power Monitoring Othersensors monitoring Pattern recognition Prediction/ Prognosis Realtime monitoring Model based analysis Automatic learning Motorize internal signal (like electric consumption) for predict fails in heads and lineal guides. 17. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt 17 MES System for Automotive Supplier Architectural lead on ISA 95 compliant MES System realized with Java EE The existing solution came to an end in terms of maintainability and technologies. The customer asked for a modern solution catering all needs. Training internal teams Defining the a new architecture Implementation lead Staffing of development teams Implemented for: Honda / Ohio Volkswagen / Wolfsburg Ford / China, Thailand, Turkey and India Consulting/ Development Training / Coaching Research / Academia 18. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt 18 MES System for Film-stretching industry Architectural lead on ISA 95 compliant MES System realized with Java EE and Big Data The existing solution was build by different vendors and not according to modern requirements. The new solution should be re-build based upon standards like ISA 95 and latest technologies. Training of internal teams Defining the a new architecture Implementation lead of distributed teams in Germany and Romania Staffing of development teams Consulting/ Development Training / Coaching Research / Academia 19. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt 19 Software Architecture: Review Architectural review of the application related to planning the production of the powertrain components of a car manufacturer in Germany The existing solution was older than 16 years, maintenance and improvement were almost impossible due to technical debts. Evaluating the existing architecture Identification of problematic hot spots Defining an optimization strategy Developing the new reference architecture Consulting/ Development Training / Coaching Research / Academia 20. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt 20 eConvey: Operating and supervising conveyors Implementing a new, mobile solution for operating and supervising conveyors in the automotive sector (mass production) The existing solution was operated by 250+ touch screens, the mobile solution was developed to replace several of these. Based upon direct OPC interaction the solution allows: to operate the conveyors (< 5 ms latency), to localize the operator (Bluetooth LE), to vizualize the current state of the conveyor(s) by means of a VISU to retrieve additional information by QR-Codes Consulting/ Development Training / Coaching Research / Academia 21. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt 21 Capturing and analyzing production data Production data and Big Data Storages in production lines within the automotive industries The master thesis of Steffen Templin was done in collaboration of Drr Systems, University of Siegen and Brockhaus Group. Real-time Consulting/ Development Training / Coaching Research / Academia 22. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt 22 Master Thesis: Industry 4.0, CEP and Big Data Joint Master Thesis in the field of Complex Event Processing and Big Data Storages in production lines within the automotive industries The master thesis of Steffen Templin was done in collaboration of Drr Systems, University of Siegen and Brockhaus Group. Real-time analysis of complex events from several streams / sensors in production processes Storing large amounts of sensor data in NoSQL datastores Prototypical implementation using OpenSource technologies (WSO2 CEP / ESB, MongoDB) Consulting/ Development Training / Coaching Research / Academia 23. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt 23 Persons in charge Prof. Dr. Ing. Thomas Barth - Studiengangleiter RFH Kln - Prof. Dr. Julian Reichwald - Schwerpunkt Industrie 4.0 DHBW Mannheim - Miguel Perez - Projektleitung Industrie 4.0 - Enrique Plaza Soria - Big Data und Machine Learning - Matthias Bohnen - Geschftsfhrung Brockhaus Gruppe - 24. Copyright by Brockhaus GmbH, alle Rechte reserviert, unautorisierte Vervielfltigung untersagt 24 Enough propaganda ... Contact information: Brockhaus Consulting GmbH Gustav Stresemann Ring 1 D - 65189 Wiesbaden Germany Fon: +49-611-97774-332 Fax: +49-611-97774-432 Web: www.brockhaus-gruppe.de Mail: office@brockhaus-gruppe.de