Industrie 4.0: IoT as a Game Changer in Future Manufacturing

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1 Industrie 4.0: IoT as a Game Changer in Future Manufacturing Prof. John Soldatos, PhD, Athens Information Technology 2nd IoT Conference by Naftemporiki December 8th, 2016

2 Drivers of Future Manufacturing From capacity to capability New production models Profitable proximity sourcing and production Workforce engagement Manufacturing Flexibility Respond to variable market demand and achieve high levels of customer fulfillment Moving away from mass production From make-to-stock (MTS) to make-toorder (MTO), configure-to-order (CTO) and engineerto-order (ETO) production Becoming more demand driven Mass Customization Modular products based on common platforms and configurable options Adopt hybrid production and sourcing strategies Produce modular platforms centrally, while leveraging suppliers, distributors, or retailers to tailor final products locally to better serve local customer demands People will remain at the center of the factory of the future People will provide the degree of flexibility and decision-making capabilities required to deal with increasing operational complexity Higher levels of collaboration

3 Fourth Industrial Revolution (Industrie 4.0) Role of IoT & Cyber-Physical Systems (CPS) IoT CPS Sensing of the physical world Control of combined organizational and physical processes Internet connectivity Tight Human Machine Interaction Used in China and EU Used in USA and EU (Industry 4.0) Source: Recommendations for implementing the strategic initiative INDUSTRIE 4.0 by The Industry-Science Research Alliance & Sponsored by the German Federal Ministry of Education and Research 11

4 IoT Interconnects factories and the manufacturing chain Source: Cognizant.com

5 Connected Supply Chain (Across Factories) Case Study - Dell Employees are engaged with customers to help them find the best customized choice that fits their need. Orders translated to OptiPlex manufacturing facility, which is able to build more than 20,000 custom-built products Orders arrive and are consolidated at the part level via real-time factory scheduling and inventory management Churns out a revised manufacturing schedule every two hours Enables communications (with time stamps) to suppliers to ensure that required materials are delivered to specific buildings, dock door and manufacturing lines Source: Cognizant.com

6 Flexible Decentrialized Factory Automation EU s H FAR-EDGE Project (Inside the Factory) FAR-EDGE = Joint effort of global leaders in manufacturing and IoT towards adoption of virtualized Factory Automation Cloud and Edge Computing for Manufacturing Decentralization of control RAMI 4.0 & Industrial Internet standards Expected Outcomes Reduced Time to deploy new automation concepts and technologies (e.g., 3D printers) Better Exploitation of Data Increase automation in factories Improve process agility Enable x-factory collaboration RAMI Compliant Implementation FAR-EDGE Aligns to RAMI4.0: Common Language for I4.0 (workin-progress) Advisory Board Member

7 FAR-EDGE: Mass Customization & Reshoring Process Agility (mass-customization) X-Factory Collaboration (reshoring)

8 Source: & Case Study (in Greece): SENSAP s INTEGRA Product INTEGRA Industrial Traceability Kiosk ITK Controller Standalone automation module (i.e. sensor and actuator docking station and control unit) Used for product quality inspection, item-identification and code-verification, carton-box and pallet labeling, Monitors of materialconsumption, machine-speed and machine-utilization. INTEGRA IVS Vision System Robust, all-in-one camera controller, Plug-n-play, built-in automation functions, for demanding machinevision applications Operation of multiple frame-grabbers at high-speed. INTEGRA KL/KR/KM/KI-OPTION The KL/KR/KM/KI- OPTIONs are Spoilage Marking and Rejection modules for the ITK automatically track, mark or remove nonconforming cartons or printed sheets, without the need for machine stoppages. SENSAP s patented spoilage monitoring algorithms guarantee accurate rejection.

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