DRIVING YOUR INDUSTRY 4WARD

Jason Mair

National Product & Marketing Manager

2018

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SICK AT A GLANCE TODAY

SICK – worldwide one of

the leading

manufacturers of

sensors and sensor

solutions for industrial

applications

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RELEVANT MILESTONESDR ERWIN SICK

1951 First marketable safety light curtain launched in Hanover

1967 Bar-code identification of packing lists, folding boxes, tins, tubes, etc. in the pharmaceutical industry

INDUSTRY 4.0 (INDUSTRIAL INTERNET; CPS CYBER PHYSICAL SYSTEMS)HISTORY

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INDUSTRY 4.0 (INDUSTRIAL INTERNET; CPS CYBER PHYSICAL SYSTEMS)THEORY – WHAT DOES IT MEAN

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INDUSTRY 4.0 (INDUSTRIAL INTERNET; CPS CYBER PHYSICAL SYSTEMS)EXAMPLE

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Industry 4.0 is creating new value by connection of data to improve industrial value-added processes.

Connecting recorded Data enables new possibilities of shaping this process. This requires a highly developed infrastructure which uses networking and in real time available information to provide results for optimizing the industrial processes.

Industry 4.0 would not be possible without SICK Sensor Intelligence.

INDUSTRY 4.0SICK SENSOR INTELLIGENCE

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SICK SENSOR INTELLIGENCETWO SIDES OF THE SAME COIN

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SENSORS IN CYBER-PHYSICAL SYSTEMS

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SENSOR INTELLIGENCE IN INDUSTRY 4.0

ROI – HOW CAN I4.0 HELP – BIG DATA

▪ ROI - Return on Investment

▸ Make an investment receive something in return

▸ The goal is profit

▪ ROI - Rate of Incidents

▸ The number of incidents (unscheduled down time, loss of goods) within a certain period of time

▸ The goal is none.

▪ ROI - Risk of Ignorance

▸ The risk you take in not knowing (or not wanting to know) how the factory is operating

▸ The goal is knowing your risks and threats.

▪ ROI - Rate of Intelligence

▸ The degree is knowing how to identify and fix things on the factory floor,

▸ The goal is to be self sufficient.

WHAT DOES IT ACTUALLY MEAN

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SEGMENTATION BY REGIONPHARMACEUTICAL INDUSTRY

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TRENDSPHARMACEUTICAL INDUSTRY

Trends

▸ Big Data to address decling R&D productivity, globalization of supply chain, country specific regulatory compliance requirements and rising commercial demands

▸ Continuous processing to replace Batch-processing of OSD

▸ Small batch manufacturing Modular lines, flexible customization

▸ Visual inspection (increase IPCs / minimize rejects)

▸ Counterfeit prevention, tamper evidence

▸ Serialisation

General considerations

▸ Understand customer need for quality products and supply chain security

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CONTINUOUS PROCESSINGPHARMACEUTICAL INDUSTRY

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CONTINUOUS PROCESSINGPHARMACEUTICAL INDUSTRY

AVAILABILITY – SAFETY THROUGH COLLABORATIONSAFETY HUMAN ROBOT COLLABORATION

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▪ One of the major issues associated with Industry 4.0 is creating working environments that allow close interaction between humans and machines.

▪ One way to achieve this is the introduction of Human Robot Collaboration.

▪ Globally the market for collaborative robots aka co-bots is set to skyrocket, going from $120 million in sales in 2015 to an estimated $3.1 billion by 2020, according to Barclays Equity Research.

HUMAN ROBOT COLABORATIONROBOTS / COBOTS

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WHY HUMAN ROBOT COLLABORATIONMOTIVATION

▪ Human-robot collaboration is a possibility to combine the respective strengths of humans and robots in a joint task, for example industrial production.

▪ Humans with their cognitive capabilities are able to react to influences, such as defective components or changing parameters of parts and processes.

▪ Advantages of robots are the accuracy, repeatability, the handling of high loads and endurance.Robots cannot replace every task so we will still need people

within

our manufacturing processes

PERFORMANCE - SMART SENSOR TECHNOLOGYHIGH SPEED COUNTING AND SPEED MONITORING

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SMART SENSOR TECHNOLOGY

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PHARMA: BLISTER PACK INSPECTION

▪ Application

▸ Inspection of blister shape, pill content, and batch code

▪ Product

▸ Ranger E (PC-based MultiScan camera)

Gray scale 2D

Scatter

3D

Tamper evidence

▪ Detection of a transparent seal on a pharmaceutical box.

▪ The seal ensures that the box can not be opened in secrecy.

▪ *AU Guideline covers non prescription and complimentary health care products

EU Regulation

▪ A tamper evident technology is mandatory in pharmaceutical packaging starting February 2019.

Customers examples

DETECTION OF TAMPER EVIDENT SEALAPPLICATIONS FOR GLARE SENSOR

*Source: Guideline for the Tamper-Evident Packaging of Medicines, Complementary Healthcare Products and Medical Devices ; APMA, ASMI, CHC, MIAA, CHF

QUALITY – TRACK & TRACE

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KAGOME SUCCESS

SAFETY ISSUE

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WEIGHBRIDGE

▪ Goal: No driver to leave truck at the weighbridge.

▪ Goal: Paperless automated identification solution at weighbridge.

STAGE 1: INSTALL RFID READERS AT WEIGHBRIDGE

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NO PAPER WORK, NO QUEUES

▪ Driver does not have to leave truck at weighbridge

▪ Human error of the paper based system is eliminated

BINS ARE UNIQUELY IDENTIFIED

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TRUCKS ARE TRANSPORTING BINS TO & FROM THE PADDOCKS

RFID Tag

STAGE 1: CUSTOMER BENEFITS

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TANGIBLE BENEFITS REALISED

▪ Only one product sample needed from 1 of 3 bins coming from Kagome farms.

▪ Truck time at weighbridge reduced to 2 minutes from previous 12 minutes.

▸ Enhanced driver safety due to not leaving truck at weighbridge

▪ No Truck jamming up in front of weighbridge and tomato drop hill

▪ Extra trip per truck per 12hr shift

▸ Due to the distance one trip is 90 minutes.

▪ Efficiency & Productivity

▸ 12 truck fleet x Ave 28 tonnes per truck = Additional 336 tonnes per shift.

▸ Fleet utilisation

▸ Bin utilisation

▪ Reliable, accurate track and trace due to reliable data collection

▸ “Paddock to plate”

STAGE 2: USE BIG DATA TO IMPROVE QUALITY

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INSTALL 12 HARVESTERS WITH RFID READERS & RADIO COMMUNICATION

▪ Each bin filled at the harvestors will “drop a pin” onto the map

▪ Allows fleet controller to optimise trucks to the required position.

▪ Improved the efficiency of the truck fleet, time, fuel and wear & tear

▪ “Big data” made simple - converting data to information!

▸ Know yield from grower x paddock x row

▸ Know the quality (nutrient information) of product x paddock x row

▸ Enables optimisation of irrigation, nutrient & fertiliser application, thereby reducing costs and increasing yield and quality, resulting in significant competitive advantage.

Controller in weighbridge has google map with GPS data position of all trucks

Datum Name | Vertraulich 28

UNDERSTANDING THE END TO END PROCESS – THERE IS A GAP?CHALLENGES I4.0 AUSTRALIA/ NEW ZEALAND

Steps towards I4.0

1. Document and/or understand your entire process

2. Apply lean thinking3. Then go digital

SENSOR INTELLIGENCE IN THE FACTORY OF TOMORROW

Datum Name | Vertraulich 29

FUTURE

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JASON MAIR

Product & Marketing Manager Australia / New Zealand

Mobile +61 418 336615

Email jason.mair@sick.com.au

MANY THANKS FOR YOUR ATTENTION.