digitalization@schaeffler: smart factory solutions · schaeffler digital platform will integrate...
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Digitalization@Schaeffler: Smart Factory Solutions Condition Monitoring appraoch for machine tools
Matthias Hafner| Director Digitalization Greater China
Schaeffler China
Schaeffler at a glance
More than
92,000 employees worldwide 2)
More than 170 locations in 50 countries
1.1 m tons of processed steel p.a.
Strong customer base with approx.
11,800 customers
1) Before one-off effects 2) As at June 30, 2018
Strong organic growth
5% p.a. Ø Sales growth 2006-2017
Nearly
2,400 patents filed in 2017
Far more than
10,000 different products
74 plants
18 R&D centers
Schaeffler in facts – Strong starting point
2 Digitalization@Schaeffler | ICSM 2018 | November 2018 | Shanghai, China
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1 How we approach Digitalization Strategy Schaeffler at a glance
Urbanization Population growth
Society trends
Increasing complexity Digitalization
Technology trends
Renewable energies Availability of resources
Environmental trends
Globalization Affordability
Economic trends
Key mega trends Focus areas
E-Mobility Industry 4.0
Customer Excellence Digitalization
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From Mechatronical to Digital World: Driving Industry 4.0 and Digitalization Schaeffler at a glance
• Initiative „Industry4.0“ as operational unit
• Focus on Mechatronic and Digital Services
• Digital Office as key driver
• Digital Transformation along the entire value chain
• New Digital Solutions
Combination of Mechatronics and Digitalization
Digitalization@Schaeffler | ICSM 2018 | November 2018 | Shanghai, China
Digitalization In
dust
ry 4
.0
Strategic Pillar Strategic Pillar
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Digitalization will be an integral part of our People
Products
Machines
Processes
Services
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Requirements for Smart Factories Schaeffler Digitalization: overview
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Factory´s layout Organization
Basic Structure
Production process Material process Information process
Processes/Flow
Building
Building form Construction Characteristics/ design
Areas/Functions
Layout areas Other infrastructure
Energy and Media supply Building Technology
Technical Infrastructure
Software Basic Software Specific software
Information system
Hardware Computer Output Input Memory Connectivity Security
Machine / Work Station
Machine concept / machinery Connectivity Transparency Steering Network Optimization
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Smart Factory approach: requirements from Connectivity to Network Optimization Schaeffler Digitalization: overvie
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1 How we approach Digitalization Schaeffler digital agenda towards customer-centric approach Schaeffler Digitalization: overview
Customer
Advanced Business Models
Digital Platform
Analyses & Simulations
Products & Services
Machines & Processes
User Experience & Customer Value
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Schaeffler digital platform will integrate the entire Schaeffler value chain
Product Development
Supply Chain Management Sales Aftersales
Lifetime prediction
Manufacturing Service
Digital Platform
Integration of Schaeffler value chain based on data and information
Schaeffler Digitalization: overview
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Technology Configurator
Holistic Process Optimization
Connector for sensorization Connectivity Standard HMI Information
Management Sensorization &
Optimization
Schaeffler Digitalization: overview
Digitalization @ Production Technology
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Enabler Visualization Transparency Single Machine Production Lines Know-How Database
Edge Computing Machines and IT Services
Unified Operating System
User Specified Needs Production Processes
Optimization Process Chain via Machine Communication
Optimal Requirement Based Value Stream
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Productivity in production
Grinding
Joining Forming
Plastics
Milling
Turning Heat Treatment
Additive Manufacturing
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Digitalization @ Schaeffler
The Machine Tool 4.0 as a part of a digitalized production cell
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tool set-up / measuring 3D measuring / inspection
laser marking system
electrified clamping system
machine tool 4.0
Digital connection of all physical cell objects and sensors enables big data and analytics
Digitalization@Schaeffler | ICSM 2018 | November 2018 | Shanghai, China
machine tool 4.0
digitalization of machining process as enabler for
analytics
3D measuring / inspection
digitalization of dimensions as enabler for analytics
tool set-up / measuring
digitalization of tool management
laser marking system
individualization of every part as enabler for analytics
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Components and solutions for turnkey solutions
Predictive maintance Condition monitoring
Mechanics Mechatronics Digital Solutions
Mechanic components
Condition Monitoring
Predictive Maintenance
Mechatronic products
Mechatronic systems
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Schaeffler Digitalization: overview
Project i4.TP: Turnkey approach focuses on configuration, implementation and operation for turnkey systems
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configuration Implementing Operation
Product to build Customer
Feature extractor
Turnkey configurator Turnkey Builder
Machine Conmmunication
Devices Module
Machines
Turnkey system for product
/MAP /PRO
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autinity software suite: Portfolio overview
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Schaeffler Digital Solutions at a glance
Field Vibration Sensors
Vibration Recording
Integration of PLC
Pre-Processing Data
Recording Part Type, Work
step, Machine Stop, Vibration
to Noise, Crash Detection
PLC
IPC
Control Service
Station
Server
Field
Control Service
Station
Work Center
Four different Sensors
Recording Sensor Data
Integration of PLC
Pre-Processing Data
Time signals, Event Monitor
Transfer to PLC (Recording Part
Type, Spindle Speed, Work step)
Vibration Vibration Thermo Fluid Energy
PLC
IPC IPC
IPC
IPC
Condition Monitoring
Predictive Maintenance
Damage Pattern recognition VibroControl: focus on manufacturing process
autinityCMS: focus on condition monitoring
ERP-Systems (e.g. SAP) SAP
Interface to ERP
Interface to ERP & cloud cloud Connected World Connected World
ERP-Systems
autinityCCS: focus on control and optimization of manufacturing processes Condition-based Control System
Process Analysis
Control Functions
Data Analytics
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Avoidance consequential defects
Avoidance consequential crash
Repearing/Replacement of spindle in planned time
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Customer Benefits
Lower Repairing Costs
Lower Inventory Costs
Avoid Bottleneck Production
Optimization Maintenance Tasks
Avoid Production standstill
Process Optimization
Logging number of valve circuits for air
Vibration and Temperature
Vibration and Temperature
Vibration Monitoring
OFF
ON
Metal forming Detection and prediction
of cushion wear
Save planned machine downtime
Faster schedule maintenance
saving compressed air
Metal cutting Early detection of spindle
crash/breakdown
Metal cutting Early detection of spindle
bearing defects (Roll bearing)
Heat Treatment Early detection of motor
bearing defect
Repearing/Replacement of spindle in planned time
Avoidance of consequential crash of spindle
Avoidance on spontaneous production loss
Avoidance of maintenance tasks during production time
autinityCMS – Vibro Control
Use cases within Schaeffler production sites (samples) Schaeffler Digital Solutions at a glance
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Thank you for your attention!
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Schaeffler Technologies AG & Co. KG | Schaeffler China
Matthias Hafner Director Digitalization Greater China