Introduction to Industrie 4.0 with SAP Connected Manufacturing Marcel Himburg (SAP University Competence Center) 13. February 2018

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1 Introduction to Industrie 4.0 with SAP Connected Manufacturing Marcel Himburg (SAP University Competence Center) 13. February 2018

2 Teaching material - Information i Teaching material - Version Version 1.4 Software used SAP ERP SAP ME/MII Model SAP Rapid Deployment Solution Prerequisites None 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 2

3 Module Information Authors The curriculum development was a joined project from SAP IBU Manufacturing, SAP UA, different SAP UA member schools (University of Arkansas, RWTH Aachen, Frankfurt University of Applied Sciences, DHBW Mosbach, Technische Universität Darmstadt, Joannuem University of Applied Sciences, Birmingham City University, Fudan University) and Festo. Target Audience Students who are studying Engineering, Business Management, or Computer Science 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 3

4 Module Information Learning Objectives What is Industrie 4.0 and Smart Factory? What is the core concept of SAP Connected Manufacturing? Which Industrie 4.0 Scenarios in the SAP University Alliances Program can be offered? 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 4

5 Agenda Industrie 4.0 Basics Enabling Technologies Smart Factory SAP Connected Manufacturing Basics Supported Industrie 4.0 Scenarios Practical Excercise What s Next Global Bike Integration fischertechnik Factory Simulation 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 5

Not limited to automation of a single production facility.

6 Industrie 4.0 Basics Characteristics Sub-category of the Internet of Things Industrie 4.0 has several names in different regions like Smart Manufacturing Industry+ etc. Not limited to automation of a single production facility. Possible integration across supply chain: material sourcing, warehousing, production, delivery Enables greater operational efficiency, responsive manufacturing, and improved report possibilities 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 6

industrial revolution On the basis of cyber-physical

1870 2 nd industrial revolution Through introduction of mass

industrial revolution Through application of electronic and

0 Degree of complexity 1 st industrial revolution Through

help of water and steam power Industry 1.

7 Industrie 4.0 Basics First programmable logic control system th industrial revolution On the basis of cyber-physical production systems (CPPS), merging of real and virtual worlds Industry 4.0 First mechanical weaving loom 1784 First assembly line nd industrial revolution Through introduction of mass production with the help of electrical energy 3 rd industrial revolution Through application of electronic and IT to further automate production Industry 3.0 Industry 2.0 Degree of complexity 1 st industrial revolution Through introduction of mechanical production facilities with the help of water and steam power Industry 1.0 End of 18 th century Beginning of 1870s of 19 th century Beginning of 1970s of 20 th century Today, 21 st century Source: Schlick et al. [2012] 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 7

8 Industrie 4.0 Basics To facing the growing complexity, manufacturers have to cope with the general global market trends Industrial production requirements are changing Automation Increasing product complexity and variety Mass Customization /Lot Size One Increasing speed of production and delivery Faster product lifecycles Increasing volumes of data and ability to get the right information in time Big Data Increasing scarcity of resources More efficiency Increasing pressure to manufacture at more competitive prices Growth of Manufacturing networks 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 8

9 Agenda Industrie 4.0 Basics Enabling Technologies Smart Factory SAP Connected Manufacturing Basics Supported Industrie 4.0 Scenarios Practical Excercise What s Next Global Bike Integration fischertechnik Factory Simulation 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 9

11 Industrie 4.0 Enabling Technologies Cyber-Physical Systems (CPS) CPS include computers, real-time capable sensors and actuators and link up the virtual with the physical environment. CPS are integrated into products, objects, buildings, transportation, medical processes, logistic processes, production facilities (Cyber-Physical Production Systems), etc. CPS are able to adapt to dynamic requirements and therefore are self-optimizing. This leads to automated and decentralized processes which can be combined to collaboration networks SAP SE / SAP UCC Magdeburg. All rights reserved. 11

12 Industrie 4.0 Enabling Technologies Cyber-Physical Production Systems (CPPS) Compromise of machines, product, objects, warehousing systems, and production facilities. Are capable to autonomously exchanging information, triggering actions and controlling each other Save and evaluate the data for modelling and analytics purposes Feature end-to-end vertical integration Inbound logistics Planning to production Marketing Outbound logistics Service 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 12

13 Industrie 4.0 Enabling Technologies Simulation 3-D simulations of products, materials, and production processes already established. Future simulations will enable companies to mirror the physical world in a virtual model incl. machines, products, and humans. This will enable testing and optimizing of shop floors in the virtual world before the physical set-up SAP SE / SAP UCC Magdeburg. All rights reserved. 13

14 Industrie 4.0 Enabling Technologies Horizontal and vertical Integration Vertical integration implies the connection between planning and scheduling, production management and execution, and low level PLC systems like (machine controllers, sensors, etc.) that exists within the company in order to deliver closed-loop integrated solution or landscape. Horizontal integration implies the connection between design, procurement, delivery, production, asset management, remote maintenance systems that may exist within one company or between different companies SAP SE / SAP UCC Magdeburg. All rights reserved. 14

15 Industrie 4.0 Enabling Technologies Cybersecurity Industrie 4.0 leads to increased connectivity and usage of standard communications protocols This requires protection of critical systems as cybersecurity threats increases dramatically. As a result, secure, reliable communications as well as sophisticated identity and access management of machines and users are essential. Source: BCG Perspective 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 15

16 Industrie 4.0 Enabling Technologies Cloud A form of standardized IT-based capability such as Internet-based services, software, or IT infrastructure offered by a service provider that is accessible via Internet protocols from any computer, is always available and scales automatically to adjust to demand, is either pay-per-use or advertising-based, has Web- or programmatic-based control interfaces, and enables full customer self-service. Three levels of Cloud Computing Software-as-a-Service (SaaS) Platform-as-a-Service (PaaS) Infrastructure-as-a-Service (IaaS) Source: Forrester 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 16

Industrie 4.0 Enabling Technologies Additive Manufacturing Additive Manufacturing (e.g. 3-D printing) is already used by companies to prototype and produce individual components.

17 Industrie 4.0 Enabling Technologies Additive Manufacturing Additive Manufacturing (e.g. 3-D printing) is already used by companies to prototype and produce individual components. In the future additive-manufacturing methods will be widely used to produce small batches of customized products that offer construction advantages, such as complex, lightweight designs. High-performance, decentralized additive manufacturing systems will reduce transport distances and stock on hand. Source: BCG Perspective 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 17

18 Industrie 4.0 Enabling Technologies Augmented Reality Augmented-reality-based systems are already supporting several services, such as selecting parts in a warehouse and sending repair instructions over mobile devices. In the future, augmented reality devices will provide workers with real-time information to improve decision making and work procedures such as workers may receive repair instructions on how to replace a particular part as they are looking at the actual system needing repair. Source: BCG Perspective 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 18

19 Industrie 4.0 Enabling Technologies Big data and Analytics The FOUR V s of Big Data are Volume, Variety, Velocity, and Veracity. Usage of analytical application enable companies to generate value from the available data. In an Industry 4.0 context, the collection and comprehensive evaluation of data from many different sources (production equipment and systems as well as enterprise- and customer-management systems) will become standard to support real-time decision making. Source: IBM; BCG Perspective 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 19

20 Agenda Industrie 4.0 Basics Enabling Technologies Smart Factory SAP Connected Manufacturing Basics Supported Industrie 4.0 Scenarios Practical Excercise What s Next Global Bike Integration fischertechnik Factory Simulation 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 20

21 Industrie 4.0 Smart Factory Definition The Future of Automated Manufacturing. The merging of the virtual and the physical worlds through cyber-physical systems and the resulting fusion of technical processes and business processes are leading the way to a new industrial age best defined by the Industrie 4.0 project's "smart factory" concept. Example for smart factory SAP SE / SAP UCC Magdeburg. All rights reserved. 21

22 Industrie 4.0 Smart Factory Characteristics The smart Factory should comprise of and is focused on creating intelligent processes, products, equipment and enable people to work in this environment (IT systems) All components (human beings, machines, products and objects), due to the built-in sensors, should communicate with each other as naturally as in a social network, without human intervention Nowadays sensor technologies become cheaper and more available. Thus, almost any process can now be measured 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 22

23 Industrie 4.0 Smart Factory Intelligent Machines and Processes Plant, equipment, tools, products/objects, databases and people are interconnected and continuously exchanging the information with each other. Every system is able to recognize its condition and publish that information so it and all other interoperating devices can take immediate and appropriate action SAP SE / SAP UCC Magdeburg. All rights reserved. 23

24 Industrie 4.0 Smart Factory Flexible and Reconfigurable Machinery and Work Stations easily upgradable and reconfigurable machine/cell/plants are important to achieving flexible and responsive manufacturing processes European Commission: FACTORIES OF THE FUTURE This includes : Development of embedded cognitive functions for supporting the use of machinery and robot systems Advanced sensing and perception, combined with robust behavior with respect to unforeseen changes Development of self-monitoring and self-healing capabilities of machinery 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 24

25 Industrie 4.0 Smart Factory Intelligent Machines and Processes Systems are intelligent enough not only to rule, control and monitor the production execution process and collecting production data, but also do some realtime analytics based on the collected data, and provide aid to the workers in real-time, for example Process-oriented simulation and visualization Human-oriented interfaces for workers Equipment data from the shop floor is available in the Manufacturing Execution System (MES) and can be accessed by various systems etc SAP SE / SAP UCC Magdeburg. All rights reserved. 25

26 Industrie 4.0 Smart Factory Equipment can be connected to electronic devices or networks via different protocols such as Bluetooth, HTTP, OPC, NFC, Wi-Fi, 3G, etc SAP SE / SAP UCC Magdeburg. All rights reserved. 26

27 Industrie 4.0 Smart Factory Intelligent and configurable Products The intelligent product: Supports the manufacturing process Provides details on its production history Shares the information with other systems for better planning Resource utilization Full product information is important to have, that other systems can request and benefit from this info. Information exchange realized by labels, sensors or RFID chips built onto the product or product carrier. This identification is maintained in the MES SAP SE / SAP UCC Magdeburg. All rights reserved. 27

28 Industrie 4.0 Smart Factory By simple barcode scanning or reading the information from the RFID chip, we can get all necessary information about a product or a process from the MES SAP SE / SAP UCC Magdeburg. All rights reserved. 28

29 Industrie 4.0 Smart Factory Automated and Connected Automated and connected equipment ask or can be asked (active) about: Its status and about the readiness of tools to produce the next order The time required to calibrate the tools. Various systems (for example, production system) to provide order or material information, parameters or maintenance details SAP SE / SAP UCC Magdeburg. All rights reserved. 29

30 Industrie 4.0 Smart Factory Automated and Connected Automated and connected equipment notify or can be notified (passive) about: Its own status. Current status information like the level of water, amount of oil, etc and send this information over the internet to responsible people or systems. Self-track the deviations in the work of its tools and if the deviation is reaching a certain limit send a signal to replace the tool SAP SE / SAP UCC Magdeburg. All rights reserved. 30

31 Industrie 4.0 Smart Factory Well-prepared and Technology enabled Worker The collaboration between factory workers and robots will be crucial for successful manufacturing. Factory workers will be soon knowledge-workers Human-centricity will be needed in factories of the future in order to increase flexibility, agility, and competitiveness. Routine tasks as well as hard manual work will be taken over by machines 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 31

32 Industrie 4.0 Smart Factory Robots will be no longer locked in their work cells, but co-operate with each other and/or with humans. New production planning should consider the hybrid approach, where several robots or human and robots are integrated in the production chain and work jointly together. For example, an object (product being produced) can be directly transferred from the robot body to the hands of the human SAP SE / SAP UCC Magdeburg. All rights reserved. 32

Industrie 4.0 Smart Factory Well-prepared and Technology enabled Worker Complex, experience-based tasks and decisions will still reside by humans.

33 Industrie 4.0 Smart Factory Well-prepared and Technology enabled Worker Complex, experience-based tasks and decisions will still reside by humans. Workers will be enabled to focus on creative and value-added activities. Smart assistance systems will allow older workers to extend their working lives and remain productive for longer SAP SE / SAP UCC Magdeburg. All rights reserved. 33

34 Industrie 4.0 Smart Factory Advanced Analytics and Modeling The increase of connected equipment leads to huge increase of data created by these connected things. In the context of Industrie 4.0 the biggest application area of the created data is within the context of predictive maintenance. To gain the right information out of the data, analytic models are key. Creating those models involves selecting the right data sets, algorithms and variables and the right techniques to format data for a particular problem SAP SE / SAP UCC Magdeburg. All rights reserved. 34

35 Industrie 4.0 Smart Factory Analyses can be divided into 5 groups Trends What are the trends in the data for example, what is the predicted life span of components? Relationships What are the main influencers of, for example, machine breakdown? Asset lifetimes? Segments Are there any clear segments or groups in the data for example, machine performance (startup, normal running, behavior prior to a failure). Associations What are the correlations in the data? Are machine performance degradation or failures related? Anomalies What anomalies or unusual values might exist? Are they errors or real changes in, for example, sensor behavior? 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 35

36 Agenda Industrie 4.0 Basics Enabling Technologies Smart Factory SAP Connected Manufacturing Basics Supported Industrie 4.0 Scenarios Practical Excercise What s Next Global Bike Integration fischertechnik Factory Simulation 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 36

Live response in production planning and scheduling for high flexibility with last minute demand changes 4. Direct replenishment, Outsourcing 5.

37 SAP Connected Manufacturing - Basics End-to-End Business Process and Business Partner Integration 1. Top Floor to Shop Floor 2. E-Commerce integration: Sales order entry with configuration and personalization for individualized products 3. Live response in production planning and scheduling for high flexibility with last minute demand changes 4. Direct replenishment, Outsourcing 5. Manufacturing execution with orchestration of the automation layer in lot size of 1 6. Machine-to-machine communication Complementary video: Insight-to-Action based on machine & business data for high transparency SAP SE / SAP UCC Magdeburg. All rights reserved. 37

40 SAP Connected Manufacturing - Basics Communication between MES System and Machine Synchronous Service Calls with Response Evaluation A physical event e.g. raw material arrives on conveyor belt at the drilling machine initiates the communication Machine can t proceed operation without information from MES The machine (data source/automation layer) pulls required data from MES layer e.g. a drilling coordinate for the current material Gateway manages the service call that was initiated by the machine and ensures that the service response is written back to the machine 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 40

41 Agenda Industrie 4.0 Basics Enabling Technologies Smart Factory SAP Connected Manufacturing Basics Scenarios Practical Excercise What s Next Global Bike Integration fischertechnik Factory Simulation 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 41

SAP Connected Manufacturing - Scenarios Open Integrated Factory Generation 2016 EN: https://youtu.be/zxnei7doquk DE: https://youtu.

43 SAP Connected Manufacturing - Scenarios Open Integrated Factory Generation 2016/2017 Lot Size 1 and High Speed Production Controlled by SAP Flexible Production Orchestration Smart combination of Global & Local Intelligence Service Calls down to PLC 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 43

45 SAP Connected Manufacturing - Scenarios Open Integrated Factory Generation 2015 combined with a FESTO plant a) Get information from SAP ME (material, next routing step) write data to RFID chip b) Read RFID chip, ask SAP ME for drilling parameter write RFID chip after drilling c) Read RFID chip, ask SAP ME for components for assembly process and SAP ME validates assembly process after finishing write result to RFID chip d) Camera checks the product, compares its result with parameter from SAP ME and SPA ME provides next routing step, dependent on the result e) Using of SAP ME Touch POD* and getting 2D/3D visual aids to identify and repair the problem f) Manual back-loading step g) Read RFID chip, ask SAP ME for packaging information displayed through POD* * = Production Operator Dashboard 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 45

0 Infrastructure Run the full process from production planning to manufacturing on the shop floor Industrie 4.

46 SAP Connected Manufacturing Scenarios (Teaching Scenario) Teaching Scenario Industrie 4.0 landscape based on the SAP Open Integrated Factory 2015 Simulated shop floor with supported curriculum Industrie 4.0 Slide Deck Industrie 4.0 Infrastructure Run the full process from production planning to manufacturing on the shop floor Industrie 4.0 Case Study SAP ERP Client 100 Client 200 SAP NetWeaver JAVA with ME/MII SAP NetWeaver Instance... Site 1000 Site 1200 SAP ME SAP MII SAPMEINT Pco/Kepware SAP Plant Connectivity Agent / Simulator 1000 Agent / Simulator Client 210 Site 1210 Agent / Simulator 1210 SAP UCC Magdeburg Database Instance Database Instance Database Instance KEPServerEX (Kepware OPC-Server) SAP ME WIP Schema SAPMEINT Schema Channel / Device 1000 Channel / Device 1200 Database SAP Netweaver Schema SAP ME ODS Schema... Channel / Device 1210 For detailed infrastructure information, please get in contact with your local UCC/ACC! 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 46

SAP Connected Manufacturing Scenarios (Teaching Scenario) Solution Activities SAP ERP 1 Create planned independent requirement 2 MRP run 3 Planned order conversion 4 Release production order 10 Check

47 SAP Connected Manufacturing Scenarios (Teaching Scenario) Solution Activities SAP ERP 1 Create planned independent requirement 2 MRP run 3 Planned order conversion 4 Release production order 10 Check production order status SAP MII Transfer production order to ME SAP ME 5 Create shop order 6 Release shop order 7 Open line monitor Smart Factory Line Monitor 8 Select and run SFC < Visualization of production process < SAP PCo Smart Factory Line Monitor Data Transfer Kepware -Server KEPServerEX (OPC Server) Executing SFC Order confirmation 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 47

Smart Factory Line Monitor Simulation of the Open Integrated

48 SAP Connected Manufacturing Scenarios (Teaching Scenario) Open Integrated Factory Generation 2015 combined with a FESTO plant Smart Factory Line Monitor Simulation of the Open Integrated Factory 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 48

49 SAP Connected Manufacturing Scenarios (Research Scenario) Research Scenario Exclusive Industrie 4.0 landscape Integration of existing machines, e.g. from Festo, Bosch Rexroth, and others Industrie 4.0 Slide Deck Industrie 4.0 Infrastructure Shopfloor at the university Implement your own scenario, based on your needs and machines Pre-configured connection between SAP ME/MII and SAP ERP Shopfloor at the university SAP ERP Client 100 Client SAP NetWeaver JAVA with ME/MII SAP NetWeaver Instance SAP ME SAP MII SAPMEINT Client 300 Site 3000 SAP UCC Magdeburg Database Instance Database Instance Database Instance SAP ME WIP Schema SAPMEINT Schema Database SAP Netweaver Schema SAP ME ODS Schema For detailed infrastructure information, please get in contact with your local UCC/ACC! 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 49

50 Agenda Industrie 4.0 Basics Enabling Technologies Smart Factory SAP Connected Manufacturing Basics Supported Industrie 4.0 Scenarios Practical Excercise What s Next Global Bike Integration fischertechnik Factory Simulation 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 50

51 Practical Excercise Introduction to Industrie 4.0 Case Study Get a look in the Teaching Scenario and the Case Study You get access to an SAP ERP client and SAP ME/MII with a Smart Factory Line Monitor More details in the Case Study Questions are welcome at any time SAP SE / SAP UCC Magdeburg. All rights reserved. 51

52 Agenda Industrie 4.0 Basics Enabling Technologies Smart Factory SAP Connected Manufacturing Basics Supported Industrie 4.0 Scenarios Practical Excercise What s Next Global Bike Integration fischertechnik Factory Simulation 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 52

the Industrie 4.0 Teaching Szenario with any SAP ERP GBI client It will be able to bundle the Industrie 4.

53 What s Next - Global Bike Integration Integration into the Global Bike scenario Didactic, by extending the case studies Technically, by connecting ME/MII to an ERP GBI client Modularization and Integration You can combine the Industrie 4.0 Teaching Szenario with any SAP ERP GBI client It will be able to bundle the Industrie 4.0 Teaching Szenario with the IoT-Curriculum SAP Leonardo Curriculum 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 53

54 Agenda Industrie 4.0 Basics Enabling Technologies Smart Factory SAP Connected Manufacturing Basics Supported Industrie 4.0 Scenarios Practical Excercise What s Next Global Bike Integration fischertechnik Factory Simulation 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 54

55 What s Next - fischertechnik Factory Simulation fischertechnik Factory Simulation 9V Creating a physical and portable teaching case Simulation of a complete production process High-bay warehouse Vacuum gripper Multi processing station with oven Sorting line with detection Connectable with SAP ME & MII Integrated into the Global Bike Use Case Easy, out-of-the-box setup and also reversible SAP SE / SAP UCC Magdeburg. All rights reserved. 55

What s Next - fischertechnik Factory Simulation fischertechnik Factory Simulation 24V Creating a portable and low-budget research case Same Factory Simulation but without any fischertechnik

56 What s Next - fischertechnik Factory Simulation fischertechnik Factory Simulation 24V Creating a portable and low-budget research case Same Factory Simulation but without any fischertechnik Controller Controlled by Programm Logistic Controller (PLC) like any other industry production plant Also possible to connect with SAP ME & MII through SAP PCo by using OPC UA protocol Need to be implemented ideally for student projects 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 56

58 Thank you! Industrie 4.0 General contact

59 Sources By Dickdavid own work, CC BY-SA 3.0, By TMP-Mediagroup of German - Transferred from de.wikipedia to Commons using the CommonsHelper., CC BY-SA 2.0 de, By fischertechnik own work, By fischertechnik own work, FT_Fabrik_Simulation_24V.jpg 2017 SAP SE / SAP UCC Magdeburg. All rights reserved. 59

Smart Factory The Heart of the Digital Transformation Era

Smart Factory The Heart of the Digital Transformation Era Dr. Jörg Pirron PROTEMA Consulting Services, Germany 2017 Epicor Software Corporation PROTEMA It is personalities, not principles that move the