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September 30th, 2015 | Mechanical Engineering | Department of Computer Integrated Design | Prof. Dr.-Ing. R. Anderl ‹1.›

Industrie 4.0 Fundamentals, Scenarios for Application

and Strategies for Implementation

Prof. Dr.-Ing. Reiner Anderl

Computer Integrated Design

(Datenverarbeitung in der Konstruktion, DiK)

Fachbereich Maschinenbau

Technische Universität Darmstadt

Otto-Berndt-Straße 2

D-64287 Darmstadt

Email: [email protected]

Tel: +49 6151 16-6001




Overview

1. Introduction

2. Fundamental Approaches of Industrie 4.0• Cyber-Physical Systems, Internet Technology, Manufacturing Objects

as Information Carriers, Holistic Approach for Safety, Security,

Privacy and Knowledge Protection

• RAMI 4.0 – The Reference Architecture Model Industrie 4.0, Industrie

4.0 Components

3. Scenarios for Application

4. Implementation Strategies

5. Conclusion




Overview

1. Introduction





4.0 Components



5. Conclusion

The Impact of Information and

Communication Technology(1)


Web Web 1.0 Web 2.0

1995 2000 2005

World Wide Web

Hypermedia

Interlinked Documents

Multimedia

Interlinked Media

Java, UML, XML Web Services

Socialmedia (1)

Interlinked People

Source: based on Dr. Dais, Bosch


Web 3.0

2010

Socialmedia (2)

Interlinked

Enterprises

App Technologie

Web A.B

2015

Cyber-Physical Media

Interlinked

Systems

IoT, IoS, IoD, …

Industrie 4.0 Components

Web X.Y

2020

Future Media

?

The Impact of Information and

Communication Technology(2)

Industrie 4.0 – The 4th Industrial Revolution


End of

18th Century

Beginning of

20th Century

Beginning of the

1970s

Leve

l o

f C

om

ple

xit

y

Today

1. Industrial Revolution

by introduction of

manufacturing plants

with help of hydro power

and steam power


by introduction of shared

mass-prodution with help

of electric energy


by electronics and IT for

enhanced automization in

production


based on Cyber-Physical

Systems

First

mechanical loom

1784

First assembly line

Union Stock Yards 1870

time

First Programmable

Logic Controller (PLC)

Modicon 084

1969

3rd Industrial

Revolution

4th Industrial

Revolution

2nd Industrial

Revolution

1st Industrial

Revolution

Source: Kagermann, H.; Wahlster, W.; Held, J.; (Hrsg.) : Bericht der Promotorengruppe Kommunikation. Im Fokus: Das Zukunftsprojekt Industrie 4.0. Forschungsunion, 2012

Industrie 4.0 – what does it mean?


Industrie 4.0 means the 4th industrial revolution and aims at new value chains

covering the whole product lifecycle.

The technological approach is the use of so-called Cyber-Physical Systems,

which comprise modern control sysetms containing

embedded systems equiped with an internet address..

Applying this approach future, products and production

equipment are enabled to be logically

interlinked and are able

to commuinicate.

The New Platform Industrie 4.0


Research and Implementation Roadmap

of the Platform Industrie 4.0


IMPLEMENTATION STRATEGY

Methods for newbusiness modelsHorizontal integration

via value creationnetworks

Integration of real and virtual worldsSeamless

engineering throughout life cycle

Systems Engineering

Automation of value creation networks

Sensor data analysis and derivation of data-based process control systemVertical integration and networked

production systems Intelligence - Flexibility - Adaptability

Multimodal assistant systemsNew social infrastructures

for work Acceptance of technology and nature of work

Wireless communication for Industry 4.0 scenariosContinuous

development of hybridtechnologies

Security & safety

Industry 4.0 platform with reference architectures and decentralized service-oriented architecture

2015 2018 2025 2035

Methods for framework Value creation networks

INDUSTRY 4.0 by DESIGN

Approaches for Smart Systems

August 24, 2015 | Mechanical Engineering | Department of Computer Integrated Design | Prof. Dr.-Ing. R. Anderl | 10

Functional integration Integrated

cyber-physical systems

Communicating

(self-)controled systems

Structural Health Monitoring

Condition Monitoring

Remote Diagnosis

Remote Control

Cyber-physical systems enable

communication, monitoring, control

Smart PlantSmart Home




Overview

1. Introduction





4.0 Components



5. Conclusion

Folie 12

Technology Approaches of Industrie 4.0


• Cyber-physische Systeme

• Internet Technologies

• Internet of Things

• Internet of Services

• Internet of Data

• Components as Information Carriers

• Holistic Approach

• Safety

• Security

• Privacy

• Knowledge Protection

Recommendation for Implementing Industrie 4.0


Research Roadmap

RAMI 4.0

Industrie 4.0

Component




Overview

1. Introduction





4.0 Components



5. Conclusion

Folie 15

Demonstration Centers for Industrie 4.0 Scenario 1: TU Darmstadt: Efficient Production 4.0


Development based on an existing production line

Brown field instead of green field

Performance indicators for organizational and

economic evaluation

Quantification of efficieny by comparing

previous and new process efficiencies

Kernel role of qualified workers

Folie 16

Scenario 1: Efficient Production 4.0


component as

information carrier

uniform data

management

Use Case 4

flexible intelligent Worker

Assistance Systems

Use Case 1

paperless integrated quality

assurance

Use Case 3

Condition and Energy

Monitoring

Use Case 2

Value stream improvment

real-time capable

production controlling

Folie 17

Approaches for Efficient Production 4.0

Use Case 0: Components as Information Carriers

UC 0: Harmozied data management / Components as information carriers

UC 1:

Paperless and integrated

quality assurance

UC 2:

Digital value stream

UC 3:

Condition Monitoring

UC 4:

Flexible and intelligent

worker assistanceInspection

report

----------

-----

-------------

------

---------

-------

----

Measurement

sheet----------

-----

-------------

------

---------

-------

----

Bill of delivery

----------

-----

-------------

------

---------

-------

----

Data sheet

----------

-----

-------------

------

---------

-------

----


Folie 18

Approaches for Efficient Production 4.0

Use Case 0: Components as Information Carriers

Bill of delivery

----------

-----

-------------

------

---------

-------

----

Data sheet

----------

-----

-------------

------

---------

-------

----

Messprotokoll

----------

-----

-------------

------

---------

-------

----

Prüfprotokoll

----------

-----

-------------

------

---------

-------

----Arbeits-

anweisung

----------

-----

-------------

------

---------

-------

----

Arbeits-

anweisung

----------

-----

-------------

------

---------

-------

----

Arbeits-

anweisung

----------

-----

-------------

------

---------

-------

----

Arbeits-

anweisung

----------

-----

-------------

------

---------

-------

----

Arbeits-

anweisung

----------

-----

-------------

------

---------

-------

----

Arbeits-

anweisung

----------

-----

-------------

------

---------

-------

----

Digital availability of all documents and

unambigous assignment to components

Process data

ID-stations ( )

Datenmanagement on

the shop floor


Work

instruction

----------

-----

-------------

------

---------

-------

----

Work

instruction

----------

-----

-------------

------

---------

-------

----

Work

instruction

----------

-----

-------------

------

---------

-------

----

Folie 19

Scenario 1: Efficient Production 4.0


component as

information carrier

uniform data

management

Use Case 4

flexible intelligent Worker

Assistance Systems

Use Case 1

paperless integrated quality

assurance

Use Case 3

Condition and Energy

Monitoring

Use Case 2

Value stream improvment

real-time capable

production controlling

Folie 20September 30th, 2015 | Mechanical Engineering | Department of Computer Integrated Design | Prof. Dr.-Ing. R. Anderl ‹20.›

Scenario 2: Additive Manufacturing (1)

Folie 21

Scenario 2: Additive Manufacturing (2)





Overview

1. Introduction





4.0 Components



5. Conclusion

Folie 23

VDMA-Recommended Practices Industrie 4.0

Initial Situation:

86% of German SMEs are aware about the potential of Industrie 4.0

(Source: Commerzbank AG)

Vision of Industrie 4.0, however, is difficult to implement in SMEs

Implementation roadmap for Industrie 4.0 is unknown

Goals:

Visions of Industrie 4.0 have to be defined for innovative products and

improved production processes in clear and implementable steps

To promote Industrie 4.0 as a breakthrough technology to establish new

business models

To explain a roadmap for a successful implementation of Industrie 4.0


Folie 24

Kernel approach of recommended practices Industrie 4.0 is the Toolbox-

Approach Industrie 4.0

This approach aims at analyzing enterprise specific competences to derive

implementation use cases and ideas for new business models

VDMA-Recommended Practices Industrie 4.0:

Toolbox Industrie 4.0

So

urc

e: L

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den In

du

str

ie 4

.0 –

Orie

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run

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e

zu

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infü

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en

Mitte

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nd

, V

DM

A


Folie 25

Structure of the Toolbox:

Application Layers:

• Six application layers for

indicating implementation

areas for Industrie 4.0.

• The combination clarifies the

expected functionality.

Performance Classes:

• Five successive performance

classes are indicated to

idebtify potential

implementation ideas.

• The highest performance

class approaches the

Industrie 4.0 vision.

Application

Layers

Performance

Classes


Toolbox Industrie 4.0

Qu

elle

: L

eitfa

den In

du

str

ie 4

.0 –

Orie

ntie

rungsh

ilfe

zu

r E

infü

hru

ng in d

en

Mitte

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nd

, V

DM

A


Folie 26

Application Layers:

• Integration of Sensors/Aktuators

• Communication / Connectivity

• Functionalities for data

management and information

exchange

• Monitoring

• Product related IT-Services

• Business models for new

products


Toolbox Products

So

urc

e: L

eitfa

den In

du

str

ie 4

.0 –

Orie

ntie

run

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zu

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infü

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en

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September 30th, 2015 | Mechanical Engineering | Department of Computer Integrated Design | Prof. Dr.-Ing. R. Anderl ‹26›

Folie 27

Application Layers:

• Information technology for

production

• Machine-2-Machine-

communication (M2M)

• Enterprise-production

interconnection

• ICT-Infrastructur in production

• Human-Machine-Interfaces

• Efficiency for small lot-sizes


Toolbox Production

Qu

elle

: L

eitfa

den In

du

str

ie 4

.0 –

Orie

ntie

rungsh

ilfe

zu

r E

infü

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en

Mitte

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, V

DM

A

September 30th, 2015 | Mechanical Engineering | Department of Computer Integrated Design | Prof. Dr.-Ing. R. Anderl ‹27›

Folie 28

Goal:

Identification of existing Industrie 4.0-Competencies

Approach:

1. Analysis of publically available information

2. Adjusting the performance classes of the toolbox

Industrie 4.0

3. Definition of the strategic goals based on the

toolbox Industrie 4.0


Analysis of Competences and Strategic Goals

So

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e: L

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den In

du

str

ie 4

.0 –

Orie

ntie

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e z

ur

Ein

führu

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Folie 29

Approach:

1. Analysis of publically available information

2. Adjusting the performance classes of the toolbox

Industrie 4.0

3. Definition of the strategic goals based on the

toolbox Industrie 4.0


Results for Products and Production

So

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e: L

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den In

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str

ie 4

.0 –

Orie

ntie

run

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e z

ur

Ein

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Overview

1. Introduction





4.0 Components



5. Conclusion

Conclusions

Industrie 4.0 is a key initiative of the German hightech strategy supported by the

German government and to be implemented by industry.

Key strategy of Industrie 4.0 is the creation of new innovation for smart systems such

as smart products, smart production systems, smart logistics or smart grids

based on the integration of internet based communication and embedded control

software to ensure sustainablity and environmental soundness.

Future research activities will also need to address

- safety, security, privacy and knowledge protection,

- new business models as well as

- human factors impact

New advanced engineering methods are required to support the developemnt of

smart products able to self-control their functionality and to communicate with other

smart systems as well as with humans.

Industrie 4.0 is a fascinating technology and each enterprise has to decide whether,

and if so, how to implement Industrie 4.0.


Source: Potthast Fachschaftenkonferenz
