how to apply digitization in smart machine & factory …29b-2].pdf6.20 5.30 4.00 3.50 4.60 5.60...

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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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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

2018_03_29 I Albert Kim I © Phoenix Contact2

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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!

12 2018_03_29 I Albert Kim I © Phoenix Contact

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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.


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.


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


2018_03_29 I Albert Kim I © Phoenix Contact

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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


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!


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


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…


… 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 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


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.


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.


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

Usage of configuration data in production2018_03_29 I Albert Kim I © Phoenix Contact41

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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 !

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