Characteristics of the Chinese market and consequences for R+D and production

Transcription

1 Characteristics of the Chinese market and consequences for R+D and production Prof. Dr.-Ing. Jürgen Fleischer Shanghai, Oct. 27, 2017 wbk Institut für Produktionstechnik KIT Universität des Landes Baden-Württemberg und nationales Forschungszentrum in der Helmholtz-Gemeinschaft

2 "Local for Local" in the Chinese end-user market Overview of end-user market Key data of the Chinese market World's second largest economy (GDP) GDP growth rate 2016: 6.7% About 1.37 billion inhabitants 9.6 million square kilometers End-user market in China picture: Huawei P10 techcrunch.com Pull market with high customer expectations and strong competition Individualization degree strongly rising Product life cycles are accelerating Cost-conscious consumers also have high demands on technology Customers expect the latest technologies The Chinese market is developing its own innovations with a high variety of variants and high technical complexity Folie 2

3 Requirements for production systems in China Requirements for production systems Requirements Tailor-made production systems are intended to meet 100% customer requirements neither too much nor too little Demand for equipment from one source, but use of modules from different manufacturers (Germany, China,...) Fast configuration and commissioning also for inexperienced users Application of industry 4.0 technologies and local innovations for cost-efficient production with high variety of variants Enabler Industry 4.0 Technologies Bilder: cloudfront.net; brixzaun.com; freepik.com; depositphotos.com; 123rf.com; cadenas.de Folie 3

4 Requirements for production systems in China Sucess formula for the Chinese market Smart solutions for Chinese needs: Solutions instead of components Flexible and modular systems Enabler Industry 4.0 Technologies Innovations "local for local" Development on the pulse of users Speed instead of perfectionism Use of industry 4.0 Enablers for smart production solutions and local innovations enable success in the Chinese market pictures: cloudfront.net; brixzaun.com; freepik.com; depositphotos.com; 123rf.com; cadenas.de Folie 4

5 Demands for Turnkey Production Systems Market demands for Production Systems Why does the Chinese market require Turnkey Production Systems? Chinese consumer market: Pull market with extreme high consumer demands Individualization and short product lifecycles are increasing Consumer s cost sensitivity requires cost effective high variant production Current state Chinese production: Producers do not have the knowledge for product design, production system design and operation of the production system Sequential design of product (product manufacturer) and production system (production system manufacturer) Optimization of engineering and production can only achieved in an integrated approach along value stream Picture: zeit.de Chinese manufacturers need Turnkey Production Systems, consulting regarding production-oriented design and operation of the production system Folie 5

6 Demands for Turnkey Production Systems Market demands for Production Systems What are the needs for action? Fast set-up and commissioning of production systems especially for unexperienced manufacturers Parallel product-oriented consulting for shortening time to start of production (SOP) Use of Industry 4.0 enablers to achieve faster and cost effective production of high variant products Integrated approach along value stream for engineering and production Production system Design Set-up Product design Commisioning 1 year 2,5 Enablers: Certified modules unified interfaces platform Configurator for production system and businesss model Industry 4.0 technologies Product-oriented consulting Uniform networking structure Pictures: cloudfront.net; brixzaun.com; freepik.com; depositphotos.com; 123rf.com; cadenas.de Integrated Sino-German Industry 4.0 Factory Automation Platform is needed under participation of German and Chinese manufacturers, suppliers and academia Folie 6

7 Sino-German Industry 4.0 Factory Automation Plattform Preliminary work AMTC Bosch Rexroth, SCHUNK Demoline Description: Demonstration line for the production for batch size 1+ with i4.0 technologies Scope: Autonomous manufacturing with real time control Accelerated troubleshooting during production processes Networking of machines with OPC UA Smart automation of machines, operations and handling equipment Data collection during manufacturing to improve the global process Highly reduced inventory in the production Demoline built out of modules of several suplliers, still high effort for configuration and no yet Turnkey-Production-System. Underlying network structure for Turnkey partly established. Folie 7

8 Smart components for production systems in China Sensors and data interpretation for longer maintenance intervals Motivation Extension of maintenance intervals: Increased availability and service life of ball screw drives by means of lubricant requirement detection and adaptive lubrication. Approach Modeling the BSD-desired-state Measurement based determination of the BSDactual-state Development of a lubrication algorithm for dynamically changing operating conditions Use of inexpensive mass sensors Validation under realistic load scenarios Intelligent machine components adapt to the conditions of the user and prolong the maintenance intervals of the production machines. Folie 8

9 Smart components for production systems in China Intelligent components for innovative production systems Secure-Plug-and-Work (BMBF) Motivation and purpose Accelerated configuration and commissioning for the Chinese market requires selfdescribing components Commissioning of components in machine tools involves high manual work Configuration of components by manual Input during commissioning Configuration by pre-created archives, manual effort in planning Approach Expansion of the components with communication module Transfer of configuration data during installation No communication module Component transfers configuration data Result Faster start-of-production through self-describing, cross-linked components: Simplified configuration with self-describing components Avoiding input errors, shorter commissioning time Folie 9

10 Sino-German Industry 4.0 Factory Automation Plattform I4TP Market demands for Production Systems How can I4TP solve this problem? Enablers: Tools Enabler i4.turnkey Intelligent modules and embedded systems with unified and validated interfaces (software and communication) i4.design Product-oriented counseling for cost-efficient manufacturing using Industrie 4.0 enablers i4.business Tools and methods for configuration of a suitable business model for the operation of the turnkeyproduction-system i4.collaboration Common collaboration platform with integrated and tested trust-levels, processes and role models i4.demo-validation-center Distributed centers for validation, verification and show case I4TP can increase production and market share for both sides and strengthen the Sino- German cooperation within production equipment and manufacturing Folie 10

11 Sino-German Industry 4.0 Factory Automation Platform i4.turnkey Enabling Turnkey Production Systems Modularization, Configuration, Interfaces, Intelligent modules Research need i4.turnkey: How can Turnkey Industrie 4.0 production systems be designed and implemented quickly in a structured manner under the local prevailing requirements and boundary conditions with the involvement of German and Chinese partners for the efficient production of (smart) products? Expected results: Generation of a unified architecture of the Factory Automation Platform Unified networking structure, unified interfaces and description language Digital-Module-Models (virtual image) of the real module comprising interfaces, description language and behavior Partners: Intelligent validated and verified modules out of I4TP platform Configuration Embedded systems enabling the communication and data acquisition in the intelligent modules Impulses for standardization of Industry 4.0 technologies and method in the Sino-German context Pictures: Puzzle icon, Marta Ambrosetti; CNC icon, jon trillana; thenounproject.com i4.turnkey: Validated intelligent modules for Turnkey-Production-Systems Folie 11

12 Sino-German Industry 4.0 Factory Automation Platform i4.design Enabling I4.0 Product Design Process Adapted and targeted guidance in product design Research need i4.design: How can a (smart) product be developed or designed so that the potential of available industry 4.0 production systems (high flexibility, variant diversity, lot sizes, quality,...) can be efficiently and effectively used - Design for Industry 4.0? Partners: Expected results: Product-design process-model defining interaction between the stakeholder during product development process Methods for deduction of Industrie 4.0 functionalities for efficient production within the product Methods for linking the development activities during product and production-system development Methods for continuous validation of products and product properties using Industrie 4.0 functions Pictures: i4.design: Product-oriented consultation and processes for efficient development Folie 12

13 Sino-German Industry 4.0 Factory Automation Platform i4.demo-validation-center Enabling Validation Validation of intelligent modules Research need i4.demo-validation-center: Which functions and interfaces in the produced products and the modules of the production system are required to meet the requirements of industry 4.0? Partners: Expected results: Set-up of unified procedures for validation of intelligent modules Demo-Validation-Center in Germany (e.g. KIT) and China (e.g. AMTC) for validation and verification of the intelligent modules Test-area for the product to be manufactured Showcase demonstrating the potentials of Industry 4.0 Infrastructure for further cooperation Learning factory for Industry 4.0 i4. Demo-Validation-Center: Validation area, show case and infrastructure Folie 13

14 Sino-German Industry 4.0 Factory Automation Platform i4.businesss Enabling Business Models for Turnkey Optimized business models for a Turnkey Production System Research Need i4.businesss: How can these Turnkey Industry 4.0 Production Systems be implemented, operated, optimized for efficiency and evaluated? Which business model is adapted to the product and the customer? Partners: Expected results: Methods for dedicated compilation of Chinese market requirements regarding turnkey production systems Configuration of business models for turnkey production systems for sourcing and operation System and approach for targeted selection of the business models (e.g. pay per use) taking into account manufacturer of the products and supplier the supplier of the turnkey production system Pay per use Sourcing Financing Leasing Ownership Value Pictures: i4.businesss: Customized business models for sourcing and operation Folie 14

15 Sino-German Industry 4.0 Factory Automation Platform i4.collaboration Enabling I4.0 Collaboration for Turnkey Cross company and cross national collaboration with trust levels Research need i4.collaboration: How can the cooperation between users, suppliers and research partners be sustained and what further research needs can be addressed in conjunction with the platform and which business models for the turnkey production system are economically meaningful? Partners: Expected results: Defined and tested interfaces within the product and production system development process Defined and tested role and trust levels for effective collaboration enabling secure, effective collaboration with integrated know-how conservation Identified and defined flow of information and data Pictures: i4.collaboration: Defined, tested and trusted collaboration in cross national projects Folie 15

16 Summary Sino German Industry 4.0 Factory Automation Platform (I4TP) Summary I4TP addresses the: Increasing complexity of the Production System Higher technical and economic risks for system integrators due to the integration of multiple manufacturers Product-oriented consulting to optimize product and the business model for the Production Systems Status: Well structured and outlined concept / research proposal for a joint research project addressing the needs of the Chinese and German market Strong commitment of the industrial partners based on Letter of Intent (Germany: 2.4 Mio EUR, China: 20 Mio. RMB, 2.7 Mio. EUR) Success factor: Strong growth of the platform with more partners from industry and academia Validated and verified modules Customer request Configuration Turnkey Production System and productoriented counseling Pictures: Puzzle icon, Marta Ambrosetti; CNC icon, jon trillana; thenounproject.com, Strong Sino-German-Consortium I4TP ready for start in 2018 A new level of generated Turnkey Production Systems is within reach Folie 16

17 Smart components for production systems in China Conclusion Requirements of the Chinese market The Chinese market requires customized products, production facilities and development processes Modular, manufacturer-independent plug and play solutions with the shortest delivery times are required Use of the latest technologies for high productivity and competitiveness Approach Create innovative, tailor-made production systems in cooperation with Chinese and German manufacturers Acceleration of the configuration and commissioning of complex production systems Make Innovations made in China and made in Germany compatible Bilder: Puzzleteile, Marta Ambrosetti; CNC Maschine, jon trillana; thenounproject.com, Folie 17

18 Thank you for your attention. Karlsruher Institut für Technologie (KIT) wbk Institut für Produktionstechnik Prof. Dr.-Ing. Jürgen Fleischer Institutsleiter Maschinen, Anlagen und Prozessautomatisierung Kaiserstraße 12, Karlsruhe Tel Folie 18