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How to Apply Digitization in Smart Machine & Factory
Digitization
Albert Kim / PhoenixContact Korea
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De
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fc
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ple
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y
Evolution of Manufacturing
Industry 4.0
Industry 1.0
End of 18th century
Mechanical production
Industry 2.0
Begin of 20th century
Line production
Industry 3.0
Begin of 1970s
PLC-based automation
Industry 4.0
Today
Intelligent networked automation
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Digitization will cover Industry and areas
Digitization
Folie 3
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Relevant trends in Smart Factory
Predictive Maintanance
Remote Services
Internet of Things
Big Data AnalyticsIndustrie 4.0
Networked production
Smart devices
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Use of smart devices
Quellen:
Marktstudie Maschinenbediehnung 2016, Rothhöft
Maschinenbau-Initiative ICE
10%use
Tablets
67%Plan to use
94%use
Ethernet
Trend: Communication with smart devices
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Trend: Communication with mobile systems
Shuttles
Smart devices AGVs
Conveyer systems Cranes
Moving machine systems
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Challenges for Manufacturing Industry
Industry 4.0
Increasing product variety
Flexible lot sizes
Short lead times
Transparent and controlled processes
Time-consuming processes in engineering,
set-up, configuration and parametrization
Waiting times and inventories
Insufficient transparency in processes2018_03_29 I Albert Kim I © Phoenix Contact9
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The disruptive factor
DIGITIZATION
The Disruptive Factor
Digitization
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The phase of “digital omnipresence”
Digital dawn
Computers develop and penetrate professional and private applications
Digital
breakthrough
The Internet becomes universal
For the first time, digital information storage is more powerful than analog information storage
Digital
omnipresence
Convergence of telecommunications/computers (smartphones, Internet of Things)
Revolution of the user interface (touchscreen)
Boom of disruptive business models
Technological
singularity
Artificial intelligence surpasses human intelligence and accelerates the technological progress
1940 – 1980 1980 – 2010 2010 – 2025 2025 – ??
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The world is changing …
due to digitization!
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Internet of Things
Digitization is changing the world
Source: Cisco IBSG, April 2011
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Rome, 2005: Death of Pope John Paul II.
Digitization is changing the world
Believers watching large displays…
Source: http://www.spiegel.de/panorama/papst-momente-bilder-zeigen-vergleich-zwischen-2005-und-2013-a-889031.html
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Rome, 2013: Resignation of Pope Benedict XVI.
Digitization is changing the world
Digital Involvement!
Source: http://www.spiegel.de/panorama/papst-momente-bilder-zeigen-vergleich-zwischen-2005-und-2013-a-889031.html
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Paradigm Shift in Automation
16
▪ New ways of thinking automation
▪ Intelligent and globally networked machines
and plants
▪ Business moving faster
▪ Our customers need …
▪ … a high degree of flexibility
▪ … short reaction times
▪ … capacity to quickly adapt to new
market requirements
Digitization is changing the world
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▪ Hierarchical systems become open and flexible networks
▪ “Cyber-physical systems” – new roles for automation devices
Dissolution of Classical Automation Structures
17
Digitization is changing the world
Yesterday Today Tomorrow
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All this is true…
- however, not really sufficient…
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There are more challenges to be met!
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Further trends & topics…?
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▪ Comprehensive digitization facilitates virtually
unlimited availability of data of all connected “things”
▪ Basis for (new) business models
▪ Classical industry branches are shifted towards a
new distribution of value-added shares
▪ Differentiation increasingly takes place via web-
based services
▪ Increased risk for disruptive changes which might
endanger our long-term business
Digitization is changing the world
Again: Digitization changes the World
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The drivers of the current “digital revolution”
Digitization
Sensors Information processing Networks (connectivity) Interaction
Measuring of changes in
a system
Structured handling of
massive amounts of data
Linking of different
elements
Reciprocal influences
between players
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2
2Software
Hardware
&
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Digitization of the
value added chain Only those providing a virtual
representation of their production
results will be able to be a part of
this chain in the future.
Digitization leads to disruptive changes
Digitization
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... for the intelligent networking of business processes, things,
plants, components and people and is the key to future
success.
.
Digitization is the basis …
Industry 4.0 requires Digitization
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Digitization is a basis for…
Industry 4.0 requires Digitization
… ubiquitous availability of information: Digital Twin
… networking of machines, products and people: Internet of Things
… new business models and processes
… new collaboration models
… Smart Factories, Smart Products and Smart Services
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Digitization
Industry 4.0 requires Digitization
▪ Industry 4.0 will consequently digitalize
the value chain
▪A Digital Model – the Digital Twin –
will exist in all phases of the value chain
▪The required an necessary integration of
engineering tools und data models can be
realized starting today
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Smart Engineering and Production (SEAP)
Consistent digitization of the entire value added chain
Data source
E-shop
Product
engineering
ERP/ Control
E-CAD
engineering
Customized
product
Digital item
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The Digital Twin @ the core of Industry 4.0
Industry 4.0 requires Digitization
Customer benefit and user
experience
Global or Multiple Factory Network
Lean business
and work
processes
Digital Product Physical Product
Digital Value
Stream
Physical Value
Stream
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What do we expect from Industry 4.0?
Perspective Phoenix Contact
Customer‘s wish
Vertical integration of business processes
for the manufacturing of individual products
Delivery
Configurator
Online shop
ERP system
MES system
Machine Control System
PL
M s
yste
m
Automated parametrization
Complete digital
product description
Optimal
shopfloor scheduling
Automated generation
of production orders
Transparency about
the order status
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Engineering Production Operation Service
What do we expect from Industry 4.0?
Perspective Phoenix Contact
Availability of all
relevant
information
Flexibility, efficiency and transparency along the
value chain and the product life cycle
Virtual
development and
optimization
Fast prototypes Efficient logistics
Easy adaptation to quantities and variants
One piece flow
Transparency over the status
Components
Production
systems
Self-optimization
Easy set-up and operation
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“Unlimited” data availability
Only those who develop new
business models using the data
of “networked things” will have
their share in the redistribution of
proportions of value added.
Digitization leads to disruptive changes
Driver for new business models
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Product functionality
as a service
Dissolution of the fixed
link between the physical
object and its
functionality in cyber
space. Differentiation will
take place via services
from the web.
Digitization leads to disruptive changes
Driver for new business models
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The unlimited availability of information
Big data
Data is like crude oil,
refinement is the key to the business model
The greatest potential for changes caused by digitization does not lie in an
increase of productivity, but in new, data-centric business models.
(Roland Berger)
The machines of the future will not run on oil anymore, they will use data.
(Jack Ma, Alibaba)
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Predictive maintenance
Data and analytics – application examples
Data analysis
▪ Correlation between operation,
configuration, and settings of the
production system and downtime.
▪ Identification of the factors leading
to downtime.
▪ Derivation of algorithms by means
of which even short breakdowns
can be predicted.
Benefits:
▪ Reduces critical downtime
▪ Avoids unscheduled servicing costs
▪ Boosts productivity
▪ Reduces the costs for the provision of
replacement parts
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ConstructionResearch
Developement
Usage &
ServiceRecycling
Scrapping
Rapid
Prototyping
Services
▪Vertical Integration
▪Horizontal Integration
▪Seamless Engineering
▪Humans conduct
From PROFINET to PROFICLOUD
Factory
Enterprise
Resource
Planning
PLC Programing
Engineering
Services
Factory
Realtime
Serv
ices
First Step into the cloud based automation
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Platform PLCnext
First Step into the cloud based automation
…
T1
T2
TS
10ms
100ms
10s
Cloud /
computing-intensive
applications
Controls /
IoT Devices
Field (I/O) A B C D
A C B D
System-/status-/PLM-data (activated via app from sensor-/actuator supplier)
3rd Party
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enhance your automation thinking
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What is PLCnext?
Platform PLCnext Technology
…
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Virtual
Resources
Third Party
Devices
Internet
Services
Database
Global
Access
Integration of smart devices and services
Platform Proficloud
Big DataPredictive
Maintenance
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mGuard Security: Secure machine communication
Secure networking
Protection of machines and plants against
threads and unauthorized access
Secure remote maintenance and monitoring
via Internet through VPN tunneling
Integration of machines and plants in
production networks
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Configurable products
Practical applications
Configuration of product parameters in web shop
Transfer of configuration data:
Web shop → ERP → production
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Intralogistics Application
Practical applications
Digital request of material, production resources, services
SAP integration (transfer orders, label printing)
High transparency and engagement
Based on MaRVIN software platform
Implemented at several hundred work places (PxF, TT, DC, ICC-RUS)
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With Industry 4.0, value chains and product life cycles will
be completely digitized.
The integration and further development of standards like
eCl@ss and AutomationML enables a fully digital
representation of products in all levels of added value.
Using digital product descriptions, it will be possible to optimally
support and to automate important processes in engineering
and production.
Summary
Intelligent Manufacturing at Phoenix Contact
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ILE Unit (Individual Laser Engraving Unit)
PHOENIX CONTACT
Booth No: B100(3층 Smart Factory Expo 정문 입구)
Please visit our booth !