Industry 4.0 IT meets Industry

Transcription

1 Industry 4.0 IT meets Industry Dr.-Ing. habil. Wolfgang Horn Senior Vice President Technical Bosch Rexroth 1

2 Industry 4.0 IT meets Industry Agenda Industry Bosch IT Products for Industry 4.0 Value stream example for Industry 4.0 Conclusion and future outlook 2 04/11/2016 Wolfgsng Horn Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as

3 Industry 4.0 IT meets Industry Important changes in recent years Low priced sensors available Data mining: Analyse big data close to real-time Internet is available worldwide Increase in soft-/hardware usability CPU is available cheap and unlimited Storage is available cheap and unlimited Performance advantages by decentralized networking Worldwide GPS localization is possible 3

4 Industry 4.0 IT meets Industry Challenges Derived From the Market Volatile markets Individual customer requirements Shortened delivery times Shortened product life cycles 24/7 worldwide service Social behavior, new cooperation Disruptive business models Market Requirements Manufacturers Requirements Higher productivity High flexibility Minimize set-up time Smart individual work piece in/out Quality improvement Real-time & preventive service Low inventory Lower dependence on labor Industry 4.0 would be an enabler to handle the challenges 4

5 Features of Industry 4.0 Features of Industry 4.0 Fast integration and flexible configuration Open standards Distributed intelligence People as key-players Virtual real-time representation Secure valuecreation network Digital life-cycle management 5 04/11/2016 DC-IA/ENA DC-IA/PJ-I4.0-T Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as

6 Industry 4.0 IT meets Industry Industry 4.0: Bosch Dual Strategy Lead Provider System manufacturer/ Production resource view I 4.0 solution provider with external business enabler technology or internal I 4.0 solution provider Lead Operator Product manufacturer/ Product view Drive and Control Technology Industrial Sensor Solutions Bosch Software Innovations Bosch Sensortec... Packaging Technology Assembly Systems and Special Machinery Bosch Connected Devices & Solutions Innovationsmanagement Logistik Machine Platforms Data Mining, Big Data RFID@BOSCH 250 Bosch plants world wide Manufacturer of products Machine operator Plant operator Interface to customers/suppliers Many practical pilot applications are bundled within the Innovation Cluster CI 6

7 Industry 4.0 IT meets Industry Agenda Industry Bosch IT Products for Industry 4.0 Value stream example for Industry 4.0 Conclusion and future outlook 7

8 8 Industry 4.0 IT meets Industry Products Product Overview 7. Eco system Solutions with partners 6. Open Core Engineering IT Programming languages 5. Active Cockpit Interactive Shop Floor Communication with real time data, paperless 1. I4.0 upgrade Kit Connect existing Machines to the I4.0 network 4. Active Assit Gudiance for workers 2. IMS-A Sensors & intelligence integrated 3. Smart tightening Wireless connection

9 Industry 4.0 IT meets Industry Products 1. i4.0 upgrade Solution Migration of existing machines in a i4.0 network Standard Data Interfaces Gateway for different communication protocols Device/Sensor Integration with low engineering effort Web based configuration Dashboard Devices Providers Logics 9

10 Industry 4.0 IT meets Industry Products 2. IMS-A: Integrated Measuring System absolute Highly precise position resolution and top repeatability High level of reliability and reduced down times Inductive measuring principle without physical contact Absolute System Complete integration of the measurement function in the linear guide Features Power up without referencing movement minimizes machine run-up time and prevents damages to the tool and work piece Wear- and maintenance-free Not sensitive to dirt and vibrations Not sensitive to EMC interference No magnetic components No adjustment of the measuring system required Very good protection against damage No buffer battery Compatible to common drive manufacturers 10

11 Industry 4.0 IT meets Industry Products 3. Smart tightening Integrated web-server for connection of tablets and other mobile devices Fully autonomous due to integrated process controller Features Wireless handheld tightening system for industrial applications Fully integrated process controller no additional hardware required Configurable display as real-time worker interface Highly precise integrated torque and angle sensors for optimized process results Full connectivity wireless communication of process data / process control information Real time information of experts about process anomalies based on statistics and expert rules Failure reaction time drastically reduced Down time reduced by 10% Failure costs reduced by 10% 11

12 Industry 4.0 IT meets Industry Products 4. Active Assist Industry 4.0 Workplace Ergonomic & interactive worker guidance Web-based, configurable software MES/ERP integration, Connection to Active cockpit Worker identification via bluetooth tag. Adaption of language, qualification level and ergonomics. Reduced failure costs 12

13 Industry 4.0 IT meets Industry Products 5. Active Cockpit Information & communication platform for shop floor management Creating Visualization & consistency of relevant production data Ergonomic & interactive worker guidance 30% efficiency increase in preparation of information and decision making Technical data Browser-based software (App/Widget) Communication to various back end systems Mobile and stationary end devices Intuitive user interface Functional data management 13

14 Industry 4.0 IT meets Industry Products 6. Smart Control IndraControl XM Multi-Ethernet Connected Real-Time Fieldbus, OPC UA, Web & IoT, Cloud Connection* Real-time enabled for C/C++ based PLC Smart Control combines PLC Automation with IoT solutions Smart Devices & Web HMI Automation apps Multi-language enabled IEC (PLC, Motion) G-Code (CNC) Java (IoT) Lua (Open Source) C/C++/C# (Real-time) Operating via Smart Devices ios, Android, Windows Enabled for simulation and model-based engineering LabView, Matlab, Simulink, Modelica (CATIA, SolidWorks) IT/IoT/Cloud communication (OPC UA, WebSockets, MQTT, JSON / REST, MES protocols) Safety on board Energy Management Data Analytics 14 * Bosch IoT Cloud, Oracle, SalesForce, Microsoft Azure etc.

15 Industry 4.0 IT meets Industry Products 7. Eco-System & Partner In building the Connected World of the future, we believe no single company will be able to do this alone. We believe in Open Platforms, in Open Standards, in Open Source and in Strategic Alliances. 15

16 Industry 4.0 IT meets Industry Agenda Industry Bosch IT Products for Industry 4.0 Value stream example for Industry 4.0 Conclusion and future outlook 16

17 Implementation roadmap Industry 4.0 Innovation level 1) Pilot projects 2) Value streams 3) International Production Network /11/2016 DC-IA/ENA DC-IA/PJ-I4.0-T Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as

18 Industry 4.0 IT meets Industry Value stream example Case I : Homburg Plant Industry 4.0 Award Zero change over High variance +10% Productivity Tailored Homburg Plant multi-product line Small batch 6 product families ~4 million yuan savings each year for the product line -30% stock Over 2000 different products 18

19 Industry 4.0 IT meets Industry Value stream example Case II: Suzhou Plant Suzhou Suzhou 苏州工生产线 Plant Plant line line 20% direct productivity improvement 10% indirect productivity improvement 40% on-line inventory SMT project 19

20 Industry 4.0 IT meets Industry Value stream example Case III: QCMT Robot gearboxes production Autonomous workstations Horizontal networking User Identification & Adaption Heating system Data controlled Self guiding product Deviation and malfunction management Process control Pick to light Quality control Laser sensors & camera system Smart connection Tablets & ActiveCockpit High Product Variance 7 types, 35 variants Connected - Workers - Machines - Automation - Products Complete Bosch Rexroth Automation System CNC and Motion Controls and PLC (line control) Smart Tightening Tools Nexo Multi-Touch HMI & Smart Devices Rexroth Active Cockpit MES Bosch OpCon Flexibility 100% Productivity x 10 ROI 2.5 years 20

21 Industry 4.0 IT meets Industry Industry 4.0 in Education Case IV: The Rexroth Drive & Control Academy Universities: Combining automation and IT capabilities Start active with i4.0 know how Research and development and partner for industry Providing additional skill development Vocational Institutes: Integrate first i4.0 features / presentation in your mechatronic courses Start with first i4.0 courses or projects Possibly provide additional skill development courses 21

22 Industry 4.0 IT meets Industry Conclusion Production lines Multi product line Homburg Plant Suzhou Plant Customer QCMT Industry 4.0 always starts with production! Products I4.0 upgrade Kit Smart Control XM Tightening Nexo Open Core Interface ActiveCockpit Active Assit IMS-A Thanks for your Attention 22