Industrie 4.0 : how digitalization revolutionizes the production chain

Transcription

1 Industrie 4.0 : how digitalization revolutionizes the production chain Prof. Dr. Dieter Wegener Head of External Cooperation, Siemens Corporate Technology Speaker ZVEI Management Team Industrie 4.0 Public Conference on Industrie 4.0, Silicon Valley, November 08 th, 28 ZVEI German Electrical and Electronic Manufacturers Association

2 The world is going digital in B2C new innovative business models are bringing about a change in user behavior Vom Buchladen zum ebook Vom Plattenladen zum Streaming Von den Gelben Seiten zum Marketplace Vom Taxi zum Ride Sharing Quelle: Siemens Slide 2

3 The new business model has been also launched in B2B Example: Proactive maintenance at Rolls Royce aircraft engines Mark Hillary Flickr Condition monitoring, proactive maintenance, "power-by-the-hour", as-a-service business model payment model based on flight hours New business model with Data Integration & Big Data Analytics Quelle: Slide 3

4 Overview 1 Digitalization of Economy 2 Initiative Industrie Industrie 4.0 operates in 3 dimensions 4 Example Smart Services in Smart Factory Slide 4

5 Digitalization of Economy is leading to a Connected World Slide 5

6 Two aspects at Digitalization of Economy - Industrie 4.0 is one Application Scenario Business THE INTERNET OF SERVICES Culture Cross-cutting themes which apply to all areas of demand Semantic technologies, operator models, cloud computing, operator platform for services Consumers (2) New Business through Smart Services => Digital Economy Industrie 4.0 CPS scenario Smart Factory + Smart Plant Energy CPS scenario Smart Grid Mobility CPS scenario Smart Mobility Health CPS scenario Smart Health Wohnen Home CPS Szenario Smart Home CPS scenario Smart Home Cross-cutting themes in cyber-physical systems which apply to all areas of demand Security, standards & norms, engineering, microelectronics & embedded software, training and continuing education (1) Digitalization of the Analogous Economy Quelle: Acatech / ZVEI THE INTERNET OF THINGS Slide 6

7 A Cyber-physical system (CPS) corresponds to a Digital Twin Cyber-physical system (CPS) Contains all the information about Physical production facility + Digital model software / IT mechanics electrics, electronics automation, HMI safety, security maintenance location, identity status SW version interfaces The digital model is always up-to-date and is expanded over the course of the entire lifecycle Product design Production planning Production engineering Production execution Services Source: Siemens AG Slide 7

8 Overview 1 Digitalization of Economy 2 Initiative Industrie Industrie 4.0 operates in 3 dimensions 4 Example Smart Services in Smart Factory Slide 8

9 ZVEI-Industrie 4.0 Management Team is the key stakeholder for Industrie 4.0 in Germany Slide 9

10 ZVEI-management-team Industrie 4.0 Exchange with the political Industrie 4.0 platform Slide 10

11 PLM Logistics ZVEI-management-team defines areas of activity for Industrie 4.0, viewed from the technical perspective Product development Interoperability Production Interoperability Service Value-added chain "Office floor" (machine-tobusiness) ERP MES "Shop floor" (machine-tomachine) Control Source: Siemens AG Slide 11

12 Energy Water & wastewater Chemicals Oil & gas Pulp & paper Metals & mining Pharmaceutical Glass Solar & solar Food & beverage Consumer products Marine Automotive Aerospace Machinery Electronics PLM Logistics ZVEI-management-team defines Industrie 4.0 -Component for different branches Produkt Development Inter- operability Production Inter- operability Service At the shop floor level take note of: Value-added Chain 1 High level of branch dependencies, detailed in norms & standards "Office Floor" (Machine-to- Business) ERP 2 Reference architecture dependent on use case MES "Shop Floor" (Machine-to- Machine) Control Process Hybrid Discrete Industrie 4.0 -Component = Cyber-physical system (CPS) Source: Siemens AG Different Use Cases Slide 12

13 Every Industrie 4.0 -Component will be developed based on the Reference-Architecture-Model RAMI 4.0 Industrie 4.0 -Component RAMI 4.0 Reference-Architecture-Model Industrie 4.0 Administration shell e.g. Machine Industrie compatible Communication Page 13 Slide 13

14 Communication Layer Possible Standards Communication OSI Schichten OPC-UA DDS, LWM2M, 7 Application 6 Presentation 5 Session 4 Transport 3 Network 2 Data Link UDP, TCP IP, IPsec Ethernet, WiFi, GSM/4G 1 Physical TSN, 5G Wired & Wireless Develop. Usage Production Usage Connected World Enterprise Work Center Station Control Device Field Device Product Page 14 Slide 14

15 Overview 1 Digitalization of Economy 2 Initiative Industrie Industrie 4.0 operates in 3 dimensions 4 Example Smart Services in Smart Factory Slide 15

16 Industrie 4.0 impacts on every company in 3 dimensions Smart Services Smart Factory Smart Plant Smart Products Quelle: ZVEI nach PwC Slide 16

17 Siemens approach for Smart Products is the Digital Twin Smart Products Quelle: ZVEI nach PwC Slide 17

18 "Virtual machine" Increase in productivity through simulation of the production process Digital "twin" Simulated manufacture of a workpiece Determination of production times. 10% increase in productivity in day-to-day operations and time savings of up to 80% during setup/configuration of the real machine. Unrestricted Siemens AG 28 Slide 18

19 Siemens approach for Smart Factory / Smart Plant is the Digital Enterprise Smart Factory Smart Plant Quelle: ZVEI nach PwC Slide 19

20 Example for a Smart Factory : Digital Factory of SIEMENS in Amberg, Germany XhnERtyMGm_YA&feature=share&index=5 Smart Factory Smart Plant Quelle: ZVEI nach PwC Slide 20

21 The digital twin is the heart of the smart factory Plant simulation adds value Volvo as an example Benefits Virtual model Personnel deployment planning Definition of multidisciplinary work packages Visualization of construction status Planning of mechanical finishing Definition of work packages for finishing/commissioning Library of industry-specific checklists Movie: Volvo Cars Group Unrestricted Siemens AG 28 Slide 21

22 From our leading position in automation, we re driving digitalization of our business and the entire industry for the process and discrete industries Comprehensive portfolio for Industrie 4.0 Digital Enterprise Digital Enterprise Industrie 4.0 from Siemens Industrial software and automation EDA Software Industrial communication CAE software e.g. flow dynamics Industrial security Totally Integrated Automation (TIA)/ No. 1 in automation D simulation e.g. reinforcement simulation PLM Software Cooperation with Bentley Systems 27 Industrial services MindSphere the cloud-based, open operating system for the Internet of Things Unrestricted Siemens AG 28 Slide 22

23 The Digital Enterprise for the discrete and process industries brings the virtual and real worlds together Digital Enterprise Discrete industry Process industry Product design Production planning Production engin. Production execution Service Product design Process design Engineering Operation Service Optimizing the entire value chain Industrial software and automation portfolio Industrial communication From Integrated Engineering to Integrated Operation Industrial security Industrial services Unrestricted Siemens AG 28 Slide 23

24 Full consistency between virtual and real production world from digital model to real production Production/ planning Production engineering Production Services Real world Product design Virtual world Supplier Unrestricted Siemens AG 28 Slide 24

25 Simulation and the Digital Twin Basis for continuous improvement Digital Twin Product Digital Twin Production Digital Twin Performance Insights from performance with MindSphere Virtual product Verification Specification Virtual production Validation Commissioning Real production Automation Ideal delivery Real product Continuous improvement Collaboration platform: Teamcenter Unrestricted Siemens AG 28 Prof. Dr. Dieter Wegener I Meeting with Siemens Canada DF/PD, October 25 th, 28 Slide 25

26 Digital Twin meets Additive Manufacturing and example Unrestricted Siemens AG 28 Prof. Dr. Dieter Wegener I Meeting with Siemens Canada DF/PD, October 25 th, 28 Slide 26

27 Digital Twin meets Additive Manufacturing and example Digital Twin Product Digital Twin Production Digital Twin Performance Virtual production Real production Automation Real product Unrestricted Siemens AG 28 Prof. Dr. Dieter Wegener I Meeting with Siemens Canada DF/PD, October 25 th, 28 Slide 27

28 Digital Twin meets Additive Manufacturing and example Digital Twin Product Digital Twin Production Digital Twin Performance Real production Automation Real product Unrestricted Siemens AG 28 Prof. Dr. Dieter Wegener I Meeting with Siemens Canada DF/PD, October 25 th, 28 Slide 28

29 Digital Twin meets Additive Manufacturing and example Digital Twin Product Digital Twin Production Digital Twin Performance Real product Unrestricted Siemens AG 28 Prof. Dr. Dieter Wegener I Meeting with Siemens Canada DF/PD, October 25 th, 28 Slide 29

30 Additive Manufacturing Towards an integrated design and production 50% of initial designs are unprintable, 30% need complete rework Design Software Simulation Software Print Preparation Software Production Software Disconnected software Multiple file conversions Out of control workflow Conventional thinking Unrestricted Siemens AG 28 Prof. Dr. Dieter Wegener I Meeting with Siemens Canada DF/PD, October 25 th, 28 Slide 30

31 Generative Design Example: High-temperature burner system Unrestricted Siemens AG 28 Prof. Dr. Dieter Wegener I Meeting with Siemens Canada DF/PD, October 25 th, 28 Slide 31

32 Generative Design Example: High-temperature burner system Conventional design Generative design 50% less parts Length: 3.4 m Reduced length: 1.7 m Unrestricted Siemens AG 28 Prof. Dr. Dieter Wegener I Meeting with Siemens Canada DF/PD, October 25 th, 28 Slide 32

33 Siemens approach for Smart Services based on Mindsphere Smart services Quelle: ZVEI nach PwC Slide 33

34 MindSphere The cloud-based, open operating system for the Internet of Things from Siemens MindApps Apps from OEMs, from end customers, from partners and from Siemens Transparency in plants and analytical insight (e.g. fleet management) MindSphere MindSphere Open interface for developing customer-specific apps Different cloud infrastructures: SAP, AtoS, Microsoft Azure as public or private clouds or on the premises (planned) MindConnect Open standards for connectivity, e.g. OPC UA Plug & play connection of Siemens and third-party products Secure and encrypted data communication Unrestricted Siemens AG 28 Slide 34

35 MindSphere applications A comprehensive ecosystem with strong partners Our partners Consulting/strategic partners Connectivity partners MindSphere The cloud-based, open IoT operating system Application developers Technology providers System integrators IaaS providers Unrestricted Siemens AG 28 Slide 35

36 Condition monitoring of machine tools with MindSphere Gebr. Heller Maschinenfabrik GmbH Heller offers its own condition monitoring app: Heller Services Interface Gebr. Heller Maschinenfabrik GmbH Leading supplier of CNC machining centers and flexible production systems Siemens Solutions Complete automation and drive technology MindSphere platform Benefits Global access to data (connectivity over the cloud) Increased productivity, quality and availability for the end customer New business model for collaboration with the end customer Photo: Gebr. Heller Maschinenfabrik GmbH Unrestricted Siemens AG 28 Slide Slide 36 36

37 Cloud connectivity at the customer s request Calvatis GmbH uses new business models with MindSphere Photos: Calvatis GmbH Calvatis GmbH Manufacturer of industrial cleaning machines and cleaning agents for the F&B industry Siemens Solutions MindSphere Connects the cleaning machines to the cloud via MindConnect Nano Visualizes the data Facilitates performance management and predictive maintenance Benefits Meets explicit end customer demand Permits new digital services and business models Vision: Pay-per-use business models Unrestricted Siemens AG Slide Slide 37 37

38 M&A of mendix : It will be become much easier for our customers and for ourselves to write Mindapps Unrestricted Siemens AG 28 Slide 38

39 Overview 1 Digitalization of Economy 2 Initiative Industrie Industrie 4.0 operates in 3 dimensions 4 Example Smart Services in Smart Factory Unrestricted Siemens AG 28 Slide 39

40 Example Smart Services in Smart Factory Smart Services Smart Factory Smart Plant Quelle: ZVEI nach PwC Slide 40

41 Structure of a Smart Factory evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 41

42 Structure of a Smart Factory Station 1 Cover Depot White & Red Feeding Station Transition belt Station 2 Sorting Station Cover Depot Blue & Red evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 42

43 Structure of a Smart Factory Station 1 Station 2 Transition belt Feeding Station Sorting Station evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 43

44 Structure of a Smart Factory SIMATIC S F-3PN/DP evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 44

45 Structure of a Smart Factory NX11 for Design evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 45

46 Structure of a Smart Factory NX11 MCD evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar NX MCD (Mechatronics Concept Designer): Digitaler Zwilling für Mechatronisches Engineering und Virtuelle Inbetriebnahme im Maschinenbau Slide 46

47 Structure of a Smart Factory SIMIT evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Simulation SIMIT: Simulationssoftware von SiEMENS Automatisierungssystemen Slide 47

48 Original Behaviour Feeding Station Processing time Sorting Station Processing time evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 48

49 Siemens approach for Smart Services based on Mindsphere Smart services Quelle: ZVEI nach PwC Slide 49

50 Expansion of a Smart Factory with Smart Services MindConnect Nano SIMATIC S F-3PN/DP evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 50

51 Expansion of a Smart Factory with Smart Services MindSphere Feedback Used MindSphere APIs Customer Application SOA UI Controller Learner Operation Planning Time Series Processor Used MindSphere Services Rabbit MQ Mongo DB evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 51

52 Optimized Behaviour with Smart Services Feeding Station (original) Feeding Station (optimized) Sorting Station (original) Processing time Sorting Station (optimized) Processing time evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 52

53 T#iming-Vergleiche, Optimierungskurven Video Splitscreen sollte ca.20 sek dauern evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 53

54 Summary Original Optimized Feeder Feeder Sorter Sorter Efficiency Increase 31,4% evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 54

55 Summary Investments Original Optimized Hardware Mindconnect Nano Software Cloud Integration Simulation License App Development break-even within first year evosoft GmbH 28 Smart Plant / Smart Services Unrestricted / Frei verwendbar Slide 55

56 Thank you for your attention! Any questions? Slide 56