Industry 4.0 reality, trends, ideas. see Dipl.Ing. Eberhard Klotz, MBA Head of Industry 4.0 campaign

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1 Industry 4.0 reality, trends, ideas see Dipl.Ing. Eberhard Klotz, MBA Head of Industry 4.0 campaign Created: 22nd/9/2015 1

2 German Government I4.0 Initiative: Plattform Industrie 4.0 Forming of the Term integrated Industries or Industrie 4.0 ~2010 Starting of the new set-up at Hannover Messe 14th April 2015 Dr. Veit (Festo) is one out of four industry speakers in the steering board Created: 22nd/9/2015 2

3 Opportunities presented by Industry 4.0 discussions Industry 4.0 approaches are being implemented in practice in all cases where networking will lead to better control, organisation, efficiency etc. and a clear customer benefit can be identified. Action area Production Engineering Process Energy management Logistical processes Predictive Maintenance Customer benefit (to be prooved) Economic, flexible, convertible production plug & produce, batch/lot size 1 Faster commissioning of machines/installations virtual commissioning Increasing resource efficiency (component, machine, demands) More efficient control of procedures (incl. demand planning) Increasing machine availability, Condition Monitoring The implementation of the vision of Industry 4.0 is an evolutionary process which will progress at different speeds in factories and certain segments of industry. Created: 22nd/9/2015 3

4 The factory of the future A networked, adaptive and learning production system CP Factory partner facility Created: 22nd/9/2015 4

5 Mechatronic systems are turning into cyber-physical systems Integration of local intelligence and communication capacities Valves Sensors IP address, controller platform The Internet of things + IP capacity Cyber-physical systems + Internet communication + machine-to-machine communication Wireless communication Semantic description Integrated systems + sensors, actuators + integrated intelligence Physical objects, devices Created: 22nd/9/2015 5

6 Mechatronic SUB-systems are turning into cyber-physical systems Integration of intelligence and communication capacities into a sub-system. Or into a machine cell. Created: 22nd/9/2015 6

7 Disruption: Full Process Control by SAP ME - seamlessly integrated from ERP to C.P.S. OPC UA round-trip < 200ms! Representative Workflow: 1) Maintain all automation relevant data within ERP and SAP ME: Routing, Programmable Logic Controller (PLC) parameters, QM set points 2) Start production - (raw) material arrives at workstation - feed PLC (material/operation specific) 3) Material is produced based on the given data - operation results/measurements returned to and logged in SAP ME 4) Material specific tolerance check within SAP ME - return decision and next operation to machine 5) Mechanisms inside machine based on this decision (e.g. open scrap gate, move to next operation ) 6) Material moves to next operation, requests PLC parameters Created: 22nd/9/2015

8 Work organisation in the digital industrial era New level of human-machine cooperation Direct collaboration of people with machines and robots ensure safety Intuitive and simple operation of machines and systems develop new operating concepts, AutoID Created: 22nd/9/2015 8

9 Research Application transfer to reality Standardisation, modularity, OPC-UA Festo Didactic: CP Factory Festo TechnologieFabrik TechnologyFactory Scharnhausen Created: 22nd/9/2015 9

10 Vision and innovation for the production of the future Clearly identifiable physical objects contain intelligent communication abilities Product Intelligence Communication Networking = Industry 4.0 Value added services Analysis Condition monitoring Cloud services Business models Pay per user Predictive maintenance Customer support Created: 22nd/9/

11 Horizontal and vertical integration of the tool world Standards for software architecture and machine language along the value creation chain Configuration and offerings Engineering Production Commissioning Maintenance Service Automation ML* Combines the tools of the engineering process IO Link / AS-Interface Supporting communication at the shop floor level OPC UA** Interface standard for making data available amongst various systems Industrial Ethernet Communication incl. OPC UA * pending ** IEC 62541, start 2010 Created: 22nd/9/

12 Making the future adaptable in the Technology Plant Production plant of the future for valves, valve terminals and electronics Automated and flexible Flexible, flowing production Optimised energy consumption Learning taken for granted Highly flexible, energyefficient assembly lines An optimised flow of information and materials Energy network for buildings and production processes Training factory as practical, integral constituent Created: 22nd/9/

13 Modular Flexible Machine Concepts with decentralised intelligence today I4.0 examples from Festo Flexible and most modulare valve production Economic production of lot size Optimised logistic concept Decentralised control and standardised interfaces per machine cell / module Several C.P.S. (cyber-physical sub-systems in mechatronics) inside each module in total ~400 IP addresses Change over time 13 sec instead of hours Technology adaption / module change: half a day instead of weeks Move to new location: 3 days instead of 3 weeks Created: 24/5/

14 The IT Landscape for GPC Scharnhausen Enterprise Resource Planning Production Data Energy Data Production Energy Data Buildings Production Orders Manufacturing Execution Energy-Data Energy-Management System (Facility Management) Integration Layer for Shop Floor OPC-UA Pilot 1: Shop Floor KPIs OPC-UA Pilot 2: Energy KPI Workstations, lines.. Building installations Created: 22nd/9/2015

15 GPC Scharnhausen: old machines get retro-fit, e.g. parallel PLC in IP65 Enterprise Resource Planning Manufacturing Execution Production Orders Energy-Data Integration Layer for Shop Floor OPC-UA Pilot 1: Shop Floor KPIs OPC-UA Pilot 2: Energy KPI Workstations, lines.. CC-T\Gabriele Goebel-Heise Die Produktion der Zukunft 28. Januar 2016

16 Benefits of comparing machine KPIs and Energy KPIs 1. Bottle-neck optimized work flow (a chain is only as strong as its weakest part) adjust machine performance according to bottle neck situation Avoid buffer stocks, one-piece-flow Reduce waste of energy 2. Energy Peak management Avoid energy peaks start critical machines at different times reduces energy bill (1/3, ~10GWh) Work in progress 1 GWh less energy 2016/ potential: venting and light intensity potential lower pressure p.a. 3. Utilise available energy sources better pre-heat galvanic baths are by waste energy of other machines/compressors optimize these sequences in general, and daily depending on work-load CC-T\Gabriele Goebel-Heise Die Produktion der Zukunft 28. Januar 2016

17 Mobile Maintenance: ROI <6months, higher OEE and value creation CC-T\Gabriele Goebel-Heise Die Produktion der Zukunft 28. Januar

18 Vision and innovation for the production of the future Clearly identifiable physical objects contain intelligent communication abilities Product Intelligence Communication Networking = Industry 4.0 Value added services Analysis Condition monitoring Cloud services Business models Pay per user Predictive maintenance Customer support \ 18

19 IoT Gateway CPX-IOT and Festo Cloud, IP65 Automation Platform Part of out Festo automation platform CPX Offers IT-Security. Supports IoT protocols AMQP/MQTT Connects up to 31 Festo Devices (e.g. pneumatic and electrical axes/drives, valve terminals), e.g. via OPC-UA Festo AppStore App World online Festo Cloud Solutions (Pilot projects 2017) A single Industry 4.0 solution from the mechanics up to the cloud \ 19

20 Festo Cloud and Dashboard examples \ 20

21 Festo Cloud and Dashboard examples -2- \ 21

22 System solutions best matched, application specific solution packages all I4.0 ready \ 22

23 Digital Simplicity - Festo Motion Terminal World first in digital pneumatics Digitalisation for reduced complexity Wide range of functions via motion apps Just one valve technology: maximum adaptability, reduced system complexity Adaptability for greater productivity Maximum process stability with motion apps Self-regulating, independent adaptation e.g. presetting of travel time Standardised networking, data-based decisions Industry 4.0 as CPS. with web server and controller OPC UA using the automation platform CPX Preventive maintenance using condition monitoring apps such as "Leakage diagnostics" \ 23

24 Natural phenomena inspiration for factory and process automation Learning from nature for the production of the future Adaptive and flexible Human-machine interaction Self-organisation Communication Networking Energy efficiency Miniaturisation Learning Created: 22nd/9/

25 Bionic Ants Created: 22nd/9/