04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Dr.-Ing. habil. Wolfgang HornSenior Vice President TechnicalBosch Rexroth
Industry 4.0 – IT meets Industry
1
04/11/2016 | Wolfgsng Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry
Agenda
Conclusion and future outlook
Industry 4.0 @ Bosch
Value stream example for Industry 4.0
IT Products for Industry 4.0
2
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry
Important changes in recent years
CPU is available cheapand unlimited
Low priced
sensorsavailable
Data mining:Analyse big
data close toreal-time
Increase insoft-/hardware
usability
WorldwideGPS localization
is possible
Performance advantages bydecentralizednetworking
Internetis availableworldwide
Storageis availablecheap andunlimited
3
Individual customerrequirements
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
MarketRequirements
Manufacturers’Requirements
Volatile markets
Shortened delivery times
Shortened product lifecycles
24/7 worldwide service
Social behavior, newcooperation
Disruptive business models
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry
Challenges Derived From the Market
Industry 4.0 would be an enabler to handle the challenges
4
04/11/2016 | DC-IA/ENA DC-IA/PJ-I4.0-T | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Features of Industry 4.0
Distributedintelligence
Secure value-creation network
Digital life-cyclemanagement
People as key-players
Fast integrationand flexible
configuration
Openstandards
Virtual real-timerepresentation
Features of Industry 4.0
5
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry
Industry 4.0: Bosch Dual StrategyLead ProviderSystem manufacturer/ Production resource viewI 4.0 solution provider with external business
enabler technology or internal I 4.0 solution provider
Assembly Systems and Special Machinery
Industrial Sensor Solutions
Bosch ConnectedDevices & Solutions
Bosch Sensortec
Machine Platforms
RFID@BOSCH
Data Mining, Big Data
Bosch Software Innovations
Packaging Technology
Drive and Control Technology
Innovations-management Logistik
...
Lead OperatorProduct manufacturer/ Product view
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
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry
Agenda
Conclusion and future outlook
Industry 4.0 @ Bosch
Value stream example for Industry 4.0
IT Products for Industry 4.0
7
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Products
Product Overview
7.Eco
systemSolutions with
partners
1.I4.0
upgrade KitConnect existing Machines to the
I4.0 network
6.Open Core
EngineeringIT Programming
languages
2.IMS-A
Sensors & intelligenceintegrated
3.Smart
tighteningWireless
connection
4.Active Assit
Gudiance for workers
5.Active
CockpitInteractiveShop Floor
Communicationwith real time data,
paperless
8
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Products
1. “i4.0 upgrade” Solution
Migration of existing
machines in a i4.0 network
Web based configuration Dashboard Devices Providers Logics
Standard Data Interfaces Gateway for different
communication protocols Device/Sensor Integration
with low engineering effort
9
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
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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
10
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Products
3. Smart tighteningFeatures 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
Integrated web-server
for connection of tablets and other mobile devices
Full connectivity
wireless communication of
process data / process control
information
Fully autonomous due to integrated process controller
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
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Products
4. Active Assist Industry 4.0 WorkplaceErgonomic &
interactive worker
guidance
Web-based, configurable
software
Worker identificationvia bluetooth tag.
Adaption of language, qualification level and
ergonomics.
MES/ERP integration,
Connection to Active cockpit
Reducedfailure costs
12
5. Active Cockpit
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Products
Technical data Browser-based
software (App/Widget)
Communication to various back end systems
Mobile and stationary end devices
Intuitive user interface
Functional data management
Ergonomic & interactive
worker guidance
Information & communication
platform for shop floor
management
30% efficiency increase in
preparation of information and decision making
Creating Visualization & consistency of relevant pro-duction data
13
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Products
6. Smart Control „IndraControl XM“ ► Automation apps► Multi-language enabled
− IEC 61131-3 (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 andmodel-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
Smart Controlcombines
PLC Automation with
IoT solutions
* Bosch IoT Cloud, Oracle, SalesForce, Microsoft Azure etc.
Multi-Ethernet
ConnectedReal-Time Fieldbus, OPC UA, Web & IoT, Cloud Connection*
Real-time enabled for
C/C++
SmartDevices & Web HMI
based
PLC
14
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Products
“In building the Connected World of the future, we believe no singlecompany will be able to do this alone.
We believe in Open Platforms, in Open Standards, in Open Source and in Strategic Alliances.”
7. Eco-System & Partner
15
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry
Agenda
Conclusion and future outlook
Industry 4.0 @ Bosch
Value stream example for Industry 4.0
IT Products for Industry 4.0
16
04/11/2016 | DC-IA/ENA DC-IA/PJ-I4.0-T | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Indu
stry
4.0
Inno
vatio
n le
vel
2013 2014 2015 2016 2017 2018 2019 2020
1) Pilot projects
2) Value streams
3) International ProductionNetwork
Implementation roadmap
17
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Value stream example
Industry 4.0 Award
Homburg Plant multi-product line
Small batch
change over
stock6
~4 million yuan savings each year for the product line
productfamiliesTailored
Over 2000different products
Zero
-30%Productivity
High variance
+10%
Case I : Homburg Plant
18
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Value stream example
Suzhou Plant line苏州工生产线
20% direct productivity improvement
10% indirect productivity improvement
40% on-line inventory reduction @ SMT project
Suzhou Plant line
Case II: Suzhou Plant
19
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Value stream example
Case III: QCMT – Robot gearboxes production
Connected- Workers- Machines- Automation- Products
Autonomous workstationsHorizontal networking
Self guiding product
Deviation and malfunction management
Quality controlLaser sensors & camera system
User Identification & Adaption
Smart connection
Tablets & ActiveCockpit
Heating systemData controlled
Process control“Pick to light”
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
Productivity
x 10
ROI
2.5 yearsFlexibility
100%
High Product Variance
7 types, 35 variants
20
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry – Industry 4.0 in Education
Case IV: The Rexroth Drive & Control Academy
21
Universities:Combining automation and IT capabilitiesStart active with i4.0 know howResearch and development and partner for industryProviding additional skill development
Vocational Institutes:Integrate first i4.0 features / presentation in your mechatronic courses Start with first i4.0 courses or projectsPossibly provide additional skill development courses
04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Industry 4.0 – IT meets Industry
Conclusion
Production lines Multi product line
Homburg Plant Suzhou Plant Customer QCMT
ProductsI4.0 upgrade KitSmart Control XMTightening NexoOpen Core InterfaceActiveCockpitActive AssitIMS-A
Industry 4.0always
starts with production!
Thanks for your
Attention
22