industry 4.0 – evolutionary leap in...

Industry 4.0

Dr. Virginijus Valevičius / Business Unit Manager Industrial Components, Remigijus Dambrauskas / Business Unit Manager Industrial Electronics May 19, 2016

Industry 4.0

Concept history

2006 - the first concept

Industry 4.0

Concept history

2006 - the first concept

2011 – a part of “High-Tech Strategy 2020 for Germany”

Industry 4.0 Evolutionary Leap in Manufacturing

Mechanical Production

Work-piece production

PLC-based Automation

Leve

l of c

ompl

exity

End 18th Century Begin 20th Century Begin 1970s Today

Intelligent networked automation

Industry 4.0 environment

... are an integral part of an "intelligent production "

Cyber Physical Systems (CPS) … Industry 4.0

... are an integral part of an "intelligent production " ... are systems with embedded

software



software ... are connected with each other via

digital communication interfaces



software ... are connected with each other via

digital communication interfaces ... have communication interfaces for

digital networks e.g. to the Internet of things , of services , of data and of human


Cyber Physical Systems (CPS) Industry 4.0

… worldwide use of data and services

… acting via actuators … sensing data via sensors

… control

… communicate via interfaces … interact via multi modal Human-

Machine-Interfaces (HMI)

Cyber-Physical Systems (CPS)

PLC, IPC & embedded systems

Physical Objects, Devices, …

Internet of Things, Data, Services and Human

+ IP capability

+ Link to the Internet + Link to machine and human + Machine to machine communication

+ Embedded micro-computer

Industry 4.0

- Why Industry 4.0 is creating such interest?

Industry 4.0

- Why Industry 4.0 is creating such interest? - Why industry players are investing such significant resources in Industry 4.0?

Industry 4.0

- Why Industry 4.0 is creating such interest? - Why industry players are investing such significant resources in Industry 4.0? - Companies are dedicating specialized teams and creating cross-industry networks

to drive its development.

Industry 4.0


to drive its development. - Traditional productivity levers have been widely exhausted.

Industry 4.0


to drive its development. - Traditional productivity levers have been widely exhausted. - 1970s and 1980s the Toyota Production System (TPS) / Lean system.

Industry 4.0


to drive its development. - Traditional productivity levers have been widely exhausted. - 1970s and 1980s the Toyota Production System (TPS) / Lean system. - 1990s Outsourcing and offshoring, (low skilled manufacturing moving to low-cost

countries LCC).

Industry 4.0


to drive its development. - Traditional productivity levers have been widely exhausted. - 1970s and 1980s the Toyota Production System (TPS) / Lean system. - 1990s Outsourcing and offshoring, (low skilled manufacturing moving to low-cost

countries LCC). - 2000s the advantages of offshoring began to shrink as LCC wages rose and freight

costs increased.

Industry 4.0 - Time to market and customer responsiveness are today’s key factors of

competitiveness.


competitiveness. - Companies are investing in automation and robotics technologies that have the

potential to meet LCC labor cost levels in any location.



potential to meet LCC labor cost levels in any location. - Companies redesigning their manufacturing networks and moving closer to their

customers and R&D centers.




customers and R&D centers. - The pressure on companies continues to increase and many are looking for a

new opportunities to boost productivity.




customers and R&D centers. - The pressure on companies continues to increase and many are looking for a

new opportunities to boost productivity. - IT-enabled manufacturing and increased computing capacity hold the promise of

smart factories that are highly efficient and increasingly data integrated.

McKinsey global Industry 4.0 survey

- January 2015.


- January 2015. - 300 experts (manufacturing companies, technology suppliers and start-up

companies).



companies). - 100 companies per country.



companies). - 100 companies per country. - 50 or more employees.



companies). - 100 companies per country. - 50 or more employees. - Automotive OEMs, automotive suppliers, chemicals, consumer goods, health

care, paper and packaging, software, transport and logistics, industrial equipment, industrial automation and semiconductors.


Companies expect Industry 4.0 increase revenues by 23 % and productivity by 26 %.


Companies expect Industry 4.0 increase revenues by 23 % and productivity by 26 %. “Internet of Everything”


Companies expect Industry 4.0 increase revenues by 23 % and productivity by 26 %. “Internet of Everything” “Industry 4.0 offers high impact at a relatively low cost”


Companies expect Industry 4.0 increase revenues by 23 % and productivity by 26 %. “Internet of Everything” “Industry 4.0 offers high impact at a relatively low cost” “Every company and every industry will become a digital company“

Industry 4.0

Are we prepared for Industry 4.0?

37 I © PHOENIX CONTACT

The Fourth Industrial Revolution has already started…

Intelligent networking of business processes, machines, work pieces, components and people

Construction Research Developement

Usage & Service

Recycling Scrapping

Rapid Prototyping

Factory

Factory

Services Services Se

rvic

es

Industry 4.0 – Use Case From Digital Twin to the finished mounting rail

Data Source E-Shop

Article Engineering

ERP/ Control

Individual Product

E-CAD Engineering

Digital Twin

Smart Engineering and Produktion From the shop floor to the top floor

Industry 4.0 will digitalize the value chain


Industry 4.0 will digitalize the value chain A Digital Modell – the Digital Twin - will

exist in all phases of the value chain


Industry 4.0 will digitalize the value chain A Digital Modell – the Digital Twin - will

exist in all phases of the value chain The required and necessary Integration of

engineering tools and data models can be realized starting today


The digital agenda

Digitization affects all company areas and employees

Changes in technical systems, organizational structures, collaboration, processes and data models

Industry 4.0 is the model showing us how digitization is changing industry and companies


Industry 4.0 Component Communication capabilities of physical components

Unit without communication capabilities



Unit without communication capabilities Unit with passive communication capabilities



Unit without communication capabilities Unit with passive communication capabilities Unit with active communication capabilities



Unit without communication capabilities Unit with passive communication capabilities Unit with active communication capabilities Unit with I4.0-compliant communication capabilities

(I4.0-component)



Not machine-readable Machine-readable Machine-readable with changeable content


Industry 4.0 Use Case Life cycle

The article has a unique identifier and product memory • Location and description of the

installation


Industry 4.0 Use Case Life cycle

The article has a unique identifier and product memory • Location and description of the

installation • Service and system connection

during operation


The product will have a digital memory through it´s Life cycle – The digital product

Industry 4.0 Lifecycle - The next Dimension of Integration

Development Simulation Production Maintenance Recycling

Big Data and Industry 4.0

Big data is no longer a pipe dream!


Big data is no longer a pipe dream! 90 % of the world’s data has been produced in the last two years. Big data has increased access to sensitive information.



Big data becomes more user-friendly



Big data becomes more user-friendly How to secure an access to sensitive data sets and other areas of the network?

Big Data security and Industry 4.0

There is a significant challenge for those seeking to use big data !!!

industry 4.0 – evolutionary leap in...

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