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Tokyo | 2016 April 22nd | Reinhold Achatz
Implementation of Industrie 4.0 in an industrial Company
Example thyssenkrupp
2 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Components Technology
Elevator Technology
Industrial Solutions
Materials Services
Steel Europe
Steel Americas
thyssenkrupp - Diversified Industrial Company Leveraging synergies between the business areas creates huge benefits
In the past the focus was on productivity only – In future connecting value chains is a key success factor
3 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
thyssenkrupp‘s innovation strategy
Sustainability includes economical, social and environmental aspects
Sustainability
• Products and Solutions
• ThyssenKrupp‘s Production
Resource Efficiency
• Raw Materials
• Energy
• CO2
Leading edge technology
• Products
• Processes
System Optimum
vs.
Local Optima
Cycle economy
4 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
In the past, industry was focused on productivity – In future, the connection of value chains will be the key of success
thyssenkrupp will use the digital technologies available to create a competitive advantage
The digital transformation of
thyssenkrupp
Industrie 4.0
5 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
SCENARIO 1: “Flexperience“
PEOPLE & LIVING People are highly experience driven in every moment of their life and like to move and be active. In this world
no daily routines exist.
The work environment is flexible and offers self-fulfillment for the people.
MOBILITY INFRASTRUCTURE Buildings have diverse purposes and are seamlessly connected within one
system.
In this world a flexible and seamless infrastructure between buildings enables an individual last mile.
MOBILITY BEHAVIOR Mobility if more than getting from A to B –it´s a platform to do sports,
shop, interact etc. Mobility is shared and diverse to offer people the
flexibility for their diverse demands.
6 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
9
SolarCity
8 Juno Thera
peutics
7
Tencent
6
Sun Edison
5
Counsyl
4
Alibaba
10
Netflix
3
Illumina
2
Xiaomi
1
Tesla Motors
19
Amgen
18 IDE
Technolo gies
17
Voxel8
16
Apple
15
Gilead Sciences
14
AliveCor
20 Aquion
Energy
13
Amazon
12
11
Ova Science
49
Imprint Energy
48
Microsoft
47
Snapchat
46
IBM
45
DN Anexus
44
Intrexon
50
Uber
43
Generali
42
3D Systems
41
HaCon
39
Enlitic
38
Improbable
37
Line
36
Slack 35
thyssenkrupp
34
Bluebird Bio
40
Coinbase
33
Cellectis
32
Philips
31 Rethink Robotics
29
28
Nvidia
27
Teladoc
26 Bristol-Myers
Squibb
25
Universal
Robots
24 Freescale
Semi conductor
30
Alnylam
23
Sakti3
22
SpaceX
21
Baidu
External perception: thyssenkrupp is one of the 50 “smartest companies” 2015
Quelle: MIT Technology Review 2015
7 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Digital Transformation Success of the digital transformation depends on three elements
Internet Business
Industrie 4.0 / Industrial Internet of Things
Big data / Predictive Analytics
Nobody needs the Digital Transformation,
if it has no added value!
8 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Internet business - thyssenkrupp in e-Business Example
thyssenkrupp trades materials in the U.S. since many years online!
9 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Internet Business „materials4me“ is an additional sales channel for thyssenkrupp Material Services
Conventional and new customers 24/7/365 can buy materials online. Delivery by the existing logistic chain.
United Kingdom
Spain Switzerland Germany (start 04/2016)
10 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Steam engine
1. Industrial Revolution
Source: Historisches Archiv Krupp
Dampfhammer „Fritz“ (1861)
11 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Taylorism
2. Industrial Revolution
Lawn mower production (1930s)
Source: Historisches Archiv Krupp
12 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Automation
3. Industrial Revolution
Automated production line with robots (1989)
Source: Historisches Archiv Krupp
13 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz Source: inpro / thyssenkrupp
Collaboration
Industrie 4.0
Industrie 4.0: Project „Installation-Monitoring“
14 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Transformation of Industry was driven by value creation What value is created by the fourth industrial revolution?
Sources: 1. Pfister, Uni Münster, 2008, 2. H. Ford: Mein Leben und Werk, Leipzig 1923 3. Int‘. Federation of Robotics, History of Industrial Robots, 2012
Chassis production time Ford Model T [min] Before and after the implementation of
conveyer belts2
Pig iron production in England [t]1
Robots sold per year3
? 1780 1870 1961 2012
5,800,000t 100,000t 1 unit 160,000 units
7.800
1.800
Average cost in equivalent working hours
12:30 h
1914
Industrie 4.0 3. Industrial Revolution 2. Industrial Revolution 1. Industrial Revolution
1:33 h
1913
15 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Industrie 4.0 - ThyssenKrupp‘s Objectives
React more flexible on customer requests Reduce cost Increase quality Increase throughput Reduce environmental foot print
Seamless communication and integration of processes allows to …
16 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Product Lifecycle Management
PLM @ thyssenkrupp
The three core elements of the implementation strategy of Industrie 4.0 at thyssenkrupp – and are preconditions
ERP = Enterprise Resource Planning MES = Manufacturing Execution System PLM = Product Lifecycle Management
Pro
du
ctio
n C
on
tro
l
ERP
MES
Smart Factory
Plant 1
Plant 2
Plant 3
Customer
External Designer Marketing
& Sales
Marketing & Sales
Marketing & Sales
Management & Planning
Engineering Production
Engineering Production
Production
Engineering
Suppliers
Smart Grid
17 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Implementation at thyssenkrupp Digitalization starts with Description of Business Model and Process Design
2 Process redesign /
Detailed process description
Business Model /
Process design 1
3 IT-Transformation
@ BAs @ BAs
18 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz Source: inpro / thyssenkrupp
Example: System Engineering
19 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Seamless Engineering on Site
On Site Monitoring System
Service Order handling:
o Spare part handling
o Retooling
o Relocation
20 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Virtual Commissioning Integrated Engineering
3D-Visualization Simulation of Material Flow / Logistics Original Robot Programs
Realtime Simulation incl. Bus Simulation
HMI
SPS WinMOD
Controls / PLC Visualization
21 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Save Human Robot Collaboration to Increase Flexibility and Productivity
Human-Robot-Collaboration
Collaboration between human and robot / The robot recognizes the human person
Robot Cell
Clear separation of human and robot / robot does not recognize the human worker.
22 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Beispiel Fertigung von Nockenwellen
Example: Cam shaft production
23 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Smart Factory Example: Real time controlled assembly and machining of camshafts to avoid errors and reduce cycle time
Assembly Trueing Grinding
Status of previous machine and update of process parameters
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Example: Steel Europe
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Horizontal Integration - Cross Factory Exchange Medium-wide-strip steel production at Hoesch Hohenlimburg
Automotive industry Cold rolling industry
Main customers
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… books orders directly into system … defines product details
Customer
… defines start of production
IT-System and business processes
Horizontal integration - Cross factory / cross company exchange Costumers control their orders - thyssenkrupp reduces assets and increases throughput
thyssenkrupp Hoesch Hohenlimburg
Slap casting
Slab production at HKM (vendor)
Production of medium wide strip steel
27 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Big Data: Transparency Example: Data are available in real time
All employees have access to data from a single source
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Big Data and Predictive Analytics
Today we are only using a fraction of the available information.
Today
Tomorrow
The analysis of structured and unstructured data allows to get more information.
Today we are analyzing what happened in the past, with predictive analytics we can use historical data to predict the future.
Examples for projects in progress:
- Price prediction
- Optimize material on stock
- Predict quality of end product by analyzing production data of the parts
- Predictive maintenance
- Analyzing social media
29 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
ERP = Enterprise Resource Planning MES = Manufacturing Execution System PLM = Product Lifecycle Management
Product Lifecycle Management
PLM @ thyssenkrupp
Betrieb
1
Betrieb 2
Betrieb3
Customer
Externer Designer Marketing
& Sales
Marketing & Sales
Marketing & Sales
Management & Führung
Engineering Produktion
Engineering Produktion
Produktion
Engineering
Lieferanten
Smart Grid
Pro
du
ctio
n C
on
tro
l
ERP
MES
Smart Factory
Big Data
Smart Services
Analysis/ Simulation/ Prediction
Big Data and Predictive Analytics – better uses of already available information
Great opportunities by utilization of the already available information/Big Data!
30 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Example: Material Services
31 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Optimization of stock turn
32 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Optimization the use of loading and unloading slots for trucks
Just-in-time-delivery.
Inventory and stock management.
Supply-Chain-Management.
33 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Beispiel Wartung von Aufzügen
Example: Elevator maintenance
34 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Example Elevator Maintenance: Big Data / Analytics thyssenkrupp Elevator and Microsoft cooperate in data analysis
Technicians at thyssenkrupp’s call center in Seoul, South Korea
Goal: Increasing the efficiency of maintenance and services for thyssenkrupp‘s elevators
35 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Microsoft Cloud Services
TCP/IP GSM/POTS
Blue Box
tk E Software
ERP*
Big Data and Predictive Analytics Optimization of services at thyssenkrupp Elevator (MAX)
Blue Box has a standardized interface to the cloud
* *) ERP: Enterprise Resource Planning
standardized interface
36 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Big Data and Predictive Analytics Example: Production of electrical steering systems
Partner:
Objective: Prediction of the quality of an assembled system by analyzing the production data of the parts
37 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Trust and Security are Preconditions
With Industrie 4.0 all data of a company are digitally available.
Therefore cyber security is a precondition.
The extended exchange of data and information between factories or even companies
requires a high level of trust.
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38 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Industrial Data Space Secure data exchange between companies
39 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
The Industrial Data Space aims at a »Network of Trusted Data«
Data and Services Trustworthiness Certified Members
Decentralization Federated Architecture
Openness Neutral and User-Driven
Governance Common Rules of the Game
Scalability Network Effects
Ecosystem Platform and Services
Security Data Exchange
Sovereignty
Source:
40 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Industrial Data Space Architecture principal
Upload / Download / Search
Apps Vocabulary
Industrial Data Space Broker
Clearing
Registry Index
Industrial Data Space App Store
Internal IDS Connector
Company A Internal IDS Connector
Company B
External IDS Connector
External IDS Connector
Upload
Third Party Cloud Provider
Download
Upload / Download
Internet
Source:
41 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
Self-organizing
linked
dynamic
Work-life-balance
Robot as a colleague Gen Y
Volatility
Uncertainty
Complexity
Ambiguity
Opportunities and challenges of tomorrows work place
Ergonomic
Digital Transformation/Industrie 4.0 creates significant challenges for enterprises and employees
Empowering and Exciting People at thyssenkrupp
Industrie 4.0@HR
Qualification of the employees Modern Leadership and company culture
Recruiting of „adequate“ employees and „skills“
New flexibility of companies and employees
Security
Quality
Efficiency
Customer orientation
Resource efficiency
42 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
New business models will be feasible by digital transformation
Today‘s business model Future business model
Cars are sold to the end customer Customer buys a mobility solution from A to B
Quellen: http://www.pkw.de/ratgeber/auto-verkaufen/auto-verkaufen-tipps/main.jpg (links), deinewege.info (rechts)
Arising competition of direct access to customer using new business models
43 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz
German Research Summit 2016 “Digitalization”
Digital technologies and new business models will change all industries. The classical business have a fair chance to be the winner of the digital transformation, if they use the new opportunities proactively.
44 | 2016-04-22 | Tokyo | Implementation of Industrie 4.0 in an industrial Company I Reinhold Achatz 44
Thank you for your attention!
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