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1 Roland Berger 14 th Strategic Planner Circle Dr.-Ing. Peter Heekenjann 1

2 Topic feels like a hype but it will stay Digital Factory predictive maintenance RFID Anything invented before your fifteenth birthday is the order of nature. That's how it should be. augmented Anything invented between your 15th and 35th birthday is new and exciting, and you might get a reality Real Time career there. Anything invented after that day, however, is against nature and should be prohibited Cloud Ubiquitous computing Remote Douglas Adams, IoTS Monitoring Cyber-Physical Systems Embedded systems Smart Factory Context awareness Networked objects Autonomous Self-organized 2

3 Connected Industry (Industrie 4.0) Connected Industry: The next industrial revolution 1. industrial revolution First mechanical loom 1784 Mechanisation Mech. control (cam disc, cam) Energy: water / steam power First assembly line Slaughterhouse in Cincinatti industrial revolution Electrification Punch cards as program memory Conveyer belts Master shafts Energy: electrical First Programmable Logic Controller, Modicon industrial revolution Digitalisation Freely programmable control units PLC and PC based control units Field busses (ethernet based) Flexible production systems Electronical data storage 4. industrial revolution Connection / Internet Usage of internet standards Integrated IPconnection Identifiable and communicating objects Mobile operation Scalable systems (cloud as storage,..) Self-optimising systems Cyber physical systems Industry 1.0 Industry 2.0 Industry 3.0 Industry 4.0 Exponential growth in complexity - and as well in speed (since the 3. revolution) 3

4 Megatrend: Connected people Of 5.7 billion people 0.7 % are connected. Of 6.5 billion people 15 % are connected. Of 7.3 billion people 75 % are connected World population People with internet access The last 20 years 75% of the world population has been connected 4

5 Megatrend: Networking Humans (example: papal election) 5 Quelle: https://www.facebook.com/photo.php?fbid= &set=a &type=1&ref=nf (Software Innovations)

6 Megatrend: Connected things 6.6 billion connected things in billion connected vehicles billion connected telemedical devices billion connected security systems billion connected electric meters billion smart TVs billion tablets billion smartphones billion laptops billion desktop PCs billion servers Driver Higher processing capacity bandwidth and speed CAGR of about 20% leading to 50bn connected things in

7 Connected Industry: Definition Fusion of the physical world of production with the virtual world of information technology and the internet. Humans, machines, objects and systems are connected and communicate in a dynamic, real time optimised and self-organised way. In these intelligent production systems, all instances of the added value chain from the supplier over logistics to the customer are connected across the company. The industrial production can implement individualised customer requests on the wellknown high-quality level, while reaching higher flexibility and robustness as well as optimal resource allocation. 7

8 Connected Industry (Industrie 4.0) Connected Industry: Motivation Flexibility and speed Customer-orientation with individualised products Efficient, scalable production resources based on open standards, high degree of modularity and connection Connection of production for managing high variance Efficiency Small batch production down to lot size 1 with advantages of mass production Optimised processes and stock due to high transparency within the complete value creation High availability in production based on intelligent data analysis Industry 4.0: chances for the whole economy Competitiveness Low production cost High innovation potential due to combination of IT and production Preserving the future of locations 8

9 Categorization of Industrie 4.0 elements Virtual World: All virtual images of objects may interact: Centralized rules and procedures Man are Machine considered as services Decentralized rules, attached to objects, are considered as intelligence Reality becomes transparent in IT in real time by individually adapted, automated and holistic data selection preprocessing and visualization Information (augmented reality). This assists humans in fast decision. Connectivity of real world: All objects need to have an identity and upload as much data about their actual condition (physical) as possible into their virtual image (cyber) cyber-physical-systems (CPS) Influence of virtual world: Since the virtual world becomes the leading system, changes in the virtual image need to trigger appropriate action in the real objects. Objects have to be constructed accordingly cyber controls physical 9

10 Categorization of Industrie 4.0 elements Interneting: All virtual images of objects may interact: Centralized rules and procedures are considered as services Decentralized rules, attached to objects, are considered as intelligence Reality becomes transparent in IT in real time by individually adapted, automated and holistic data selection preprocessing and visualization (augmented reality). This assists humans in fast decision. Connectivity of real world: All objects need to have an identity and upload as much data about their actual condition (physical) as possible into their virtual image (cyber) cyber-physical-systems (CPS) Influence of virtual world: Since the virtual world becomes the leading system, changes in the virtual image need to trigger appropriate action in the real objects. Objects have to be constructed accordingly cyber controls physical 10

11 Connected Industry (Industrie 4.0) From the added value chain to the added value network value network value stream machine / MMI component sensor Industrie 4.0 should start with a clear use case 11

12 Two perspectives of Bosch LEAD PROVIDER System manufacturer view / production resource view LEAD OPERATOR Product manufacturer view / product view With its innovative hardware and software solutions as well as services as a machine equipment provider, machine builder and software supplier, Bosch advances integration in the industry. In doing so, Bosch generates benefits for its customers and secures the sustainability of the product portfolio. In its own plants, Bosch uses networking to increase productivity, reduce stock and economically produce down to batch size 1. The transport logistics and quality control of products is optimised through networking with customers and suppliers. Technology and solution supplier for OEMs und end users First mover in the realisation of integrated concepts with equipment providers 12

13 Connected Sensors Solutions available today Examples for Application Areas Features Preventive maintenance by utilization counting of tools and replacement parts Predictive maintenance by in-time detection of wear-signatures Detection and avoidance of transport damages 3 axes of acceleration and yaw rate 3 axes of magnetic field Temperature, humidity Air pressure Light, acoustic Connected via Bluetooth Low Energy or via gateway, via WiFi, GSM or cable to cloud or local computer 62 mm Connected Industrial Sensor Solution (CISS) Gen1 CISS Gen1 with magnetic fixation 13

14 Process Improvement at Supplier Application: Molding tool Information Speed Time Sensor Decision Acceleration Gyroscope Temperature Tool life-cycle monitoring Max. specified shots Cycle interruption detection Cycle time Automatic tool re-order Excessive usage alarm Part-specific inspection Production planning 14

15 Logistic Monitoring Application: Transport Result Sensor Acceleration Temperature Humidity Light Mechanical shock Excessive humidity Opened box (light) Decision Parts rejection Parts to drying stock Detection of theft 15

16 Vibration Schwinggeschwindigkeit [mm/s] Torque Torque [a.u.] Drehmoment [Nm] Connected industry (Industrie 4.0) Improved Process Monitoring Application: Screwing Result , bad 2 1, good 0 0,5 1 1,5 2 2,5 Zeit [s] 0,5 0 Sensor i.o. Schockkurve n.i.o. Schockkurve i.o. Schraubkurve n.i.o. Schraubkurve Decision Acceleration Borderline z-axis acceleration Excessive z-axis acceleration Correlation with screwing curve Feedback to operator Parts rejection Process window optimization 16

17 Improved Machine Monitoring Application: Electrical Cabinet Result Sensor Temperature Smoke Critical temperatures Smoldering fire / smoke Decision Feedback to operator Machine stop Fire alarm 17

18 Huge Potential, but still some challenges ahead 1 Master of data 2 Data refining 3 Standards for communication 4 Changing working conditions 5 Ethics 18

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