» GERMAN -CHINESE AND HONG KONG COOPERATION PATHS …

© Fraunhofer IFF, M agdeburg 2016 , Univ.-Prof . Dr.-Ing. M ichael Schenk

K ay M atzner, A PA C Innovation Summit 2016 Series-Internet of Things, 07.04.2016;

» GERM A N-CHINESE A ND HONG K ONG COOPERA TION PA THS ON INDUSTRY 4.0«

Image: China News Image: TRIAD


GERM A N-CHINESE A ND HONG K ONG COOPERA TION PA THS ON INDUSTRY 4.0

Fraunhofer IFF – Technology contribution 3

Industry 4.0: Hong Kong, China and Germany 2

1 Industry 4.0: Evolution status in Germany


3

Prepare to Evolve Industry 4.0: Development by interaction of many individual technologies

New products, usages, methods, tasks, and business models

Computer performance Miniaturisat ion Connectedness Data storage

Ident if icat ion Posit ion systems Robots Simulat ion


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Prepare to Evolve Industry 4.0 – Domains and Challenges

The working world of tomorrow: Progressive computerizat ion of the workplace: M obile computing devices in production (SmartPads,

Smartphones) A pp technology for the production Information technology marketplaces (e.g., for tools, semi-

f inished products, materials) Internet-based services (e.g. services for remote diagnosis )

Digitalisat ion of the workplace: Availability and analysis of large amount of data (process

individualised analysis software) Early fault detection Preventive maintenance and servicing

More Flexibility through: Decentralisation and Networking M achine condition monitoring Remote diagnostics and remote control


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Prepare to Evolve Industry 4.0 – Opportunities

Energy and resource efficiency as decisive competitive factors

Shorter innovation cycles

More complex products

Larger volumes of data

Mass Customization Volatile markets High productivity


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Industry 4.0 High quantitative expectation on Industry 4.0 solutions by German industry

Increased Ef f iciency Cost Reduct ion

See: PWC (2014) Industrie 4.0-Chancen und Herausforderungen der vierten Industtiellen Revolution,

PWC quest ioned 235 German companies f rom 5 dif ferent indust ries /many of them global market leaders

Expected addit ional effects due to Industry 4.0 solut ions for next 5 years

Increased eff iciency and cost reduct ion are reached via:

• Focusing on core competences • Reduct ion of redundancies • Improving product quality • Higher f lexibility and standardizat ion of processes


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Industry 4.0 High qualitative expectation on Industry 4.0 solutions by German industry



Expected qualitat ive advantages of Industry 4.0 solut ions

Improved Planning (Product ion, Logist ics)

Higher customer sat isfact ion

Greater product ion f lexibility

Faster Time-to-Market

Improving quality

Customizat ion of products

Signif icance of Ef fect

high medium limited

Improved horizontal and vert ical integrat ion of value chains is improving ef f iciency and product ion f lexibility


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• Fundamental change of existing business models;

• Shift f rom mass production to individual products (lot-size 1);

• Salaries of a region will not matter so much anymore;

• Production will be strengthened in developed countries (Germany, USA );

• Optimization of production processes regarding energy and resource consumption;

• Until 2020 globally 7 million traditional jobs will be lost and 2 million jobs with new prof iles created (data: W EF);

• Requirements of demographic change will be met, as most new job-prof iles will not be physically demanding;

Prepare to Evolve Industry 4.0: Some trends relevant for Economy and Society

Image: webportglobal.com


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Prepare to Evolve Industry 4.0: some economic numbers f rom Germany

See: https://www.bcgperspectives.com/content/articles/engineered_products_project_business_industry_40_future_productivity_growth_manufacturing_industries/?chapter=3 See: PWC (2014) Industrie 4.0-Chancen und Herausforderungen der vierten Industtiellen Revolution, See: IAB (2015) Industry 4.0 and the consequences for labour market and economy Image: rickbouter.wordpress.com

Technology • Due to advanced know how in sensor technologies Germany is globally

leading in I4.0; Product ivity and revenues: • Product ivity in manufacturing sectors will increase between 6 and 8% up

to 2020; • Annual growth ef fects by I4.0 technology on nominal German GDP will be

30 billion € up to 2020 (more than 1% annually); • Driving industries in Germany are: the process industry, automot ive

industry and mechanical industry; • German industry needs to invest annually 18 billion € into Industry 4.0; Employment • 6 percent increase of employment in manufacturing sectors during the

next ten years. Prof iles of about 500K jobs will change;

https://www.bcgperspectives.com/content/articles/engineered_products_project_business_industry_40_future_productivity_growth_manufacturing_industries/?chapter=3




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Prepare to Evolve Industry 4.0: impact on global competitiveness and trade patterns

Share of manufacturing value added in 2011 • Between 1991 und 2011 emerging economies increased its share f rom 21% to 40% ;

• The cards maybe reshuff led;

• Determining factors maybe:

• A utomation reduces importance of labour costs;

• M anufacturing maybe located closer to markets (transport cost, time to market, f lexibility);

• Improved ICT may enable manufacturers to take advantage of location specif ic costs;

Inspired by: Roland Berger Strategy Consultants (2014): The new industrial revolution


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Prepare to Evolve Three steps tow ards Industry 4.0…..

1. SET CONDITIONS FOR THE 4.0 ECOSY STEM

A ction

Player

Promote Industry 4.0

Policy makers

2. Boost INDUSTRY 4.0 OFFERINGS

A ction

Player

A ccelerate Information's, Develop future champions, Establish a dynamic digital environment

Policy makers , Industry and Finance partners

3. PROM OTE FA ST A DOPTION

A ction

Player

Progressively transition to I4.0

Industrial users Inspired by: Roland Berger Strategy Consultants (2014): The new industrial revolution


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Prepare to Evolve Challenges of German industry regarding I4.0

unclear benef its, high investments

insuff icient qualif ication of labor

missing standards and certif ication options

unclear legal situation regarding usage of external data's

low maturity of required technologies

data security




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Prepare to Evolve W hat should policy makers do about I4.0

upgrading universities and motivating students to study relevant topics

supporting international standardization

creation of competitive data security laws

supporting investments by tax reductions

increasing research support to universities and research institutes

PW C questioned 235 German companies f rom 5 dif ferent industries /many of them global market leaders



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Some questions to be answered by German policy makers:

How to adapt the needed legal system?

How to motivate and activate competences and creativity of SM Es and entrepreneurs?

How to qualify citizens and employees?

How to arrange eff icient f inancing for investments and R& D?

Some actions of German policy makers:

Informing and sensitizing of Industry by establishment of competence centers;

Subsidizing Industry 4.0 introduction consultancy;

Implementation of large scale support programs and initiatives on M icroelectronics (Sensors), standardization, legal f rameworks and IT security;

Dialogues with international partners countries (esp. China and USA );

Prepare to Evolve Industry 4.0: German government visions and actions

Source: BMWi (2016) Digitale Strategie



Fraunhofer IFF – Technology contribution 3

Industry 4.0: Hong Kong, China and Germany

1

2

Industry 4.0: Evolution and status in Germany


16

Industry 4.0 Some German-Chinese Cooperation Issues

• A ging population, rising labor costs and production cost competition force Chinese manufacturers to implement Industry 4.0 solutions;

• Germany has the advanced technology needed for Chinese Industry 4.0;

• Germany is worried that I4.0 cooperation with China will strengthen Chinese competitors;

• Chinese data control laws making effective cooperation's unthinkable;

• The German Government will not proactive support German-Chinese research collaborations on Industry 4.0;

Image: merics


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Industry 4.0 Fraunhofer Training on Industry 4.0 in HK STP in February

SWOT: A pplied to the tangible organizations as HK companies, HK gov.

and HK Industry associations; Object of analysis: introduction of Industry 4.0 in HK : Goal of analysis: improve the innovation culture needed for the

introduction of Industry 4.0 in HK ; Some general f indings: Develop HK as China knowledge base for Industry 4.0

technologies; By: upgrading Universities, upgrading research centres, HK STP etc.

Sensitising of companies on competitive threads A ssist HK based companies with introduction of Industry 4.0

technologies; By: subsidising fact f inding and analysis, provision of information on new technologies (testbeds, showrooms, and missions etc.)

Training/ general overview on I4.0

technologies

Company workshop

Check up of company by

experts

Check and test of technologies in showrooms

Developing

business plan

Developing implemention

masterplan

KPI revison

Funding/Investment

Government funded

Company funded

The Road to I4.0 for HK Companies -systematic -interdisciplinary -disruptive



Fraunhofer IFF – Technology contribution

2 Industry 4.0: Hong Kong, China and Germany

1

3

Industry 4.0: Evolution and status in Germany


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66 institutes and research units

A bout 24,000 employees

Research budget of € 2 billion

Fraunhofer-Gesellschaft in Prof ile

Seven Fraunhofer Groups

Information and Communication Technology

Life Sciences

M icroelectronics

Light & Surfaces

Production

M aterials and Components

Defense and Security

As of March 2014


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Digital Engineering and Operation Use digital methods, tools and models

reliably and sustainably

throughout the entire life cycle of products, equipment and production systems and even factories.

Boost production performance throughout the entire life cycle

Fraunhofer IFF as Technology Partner

© Fraunhofer IFF

© Lintje GbR

© Thomas Ernsting, National Geographic

Smart W ork Systems

Ressource Eff icient Production and Logistics

Convergent Supply Chains


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Industry 4.0 CheckUp: Prepare to Evolve A pproach

Smart Factory

Any Industry; done fg. for Daimler, BMW etc. Company classification in relation to the guiding principles of »Industry 4.0«; Process mapping and visualization; Classification of the company regarding to the requirements ( maturity); Estimation of potential efficiencies and cost reductions; Derivation of short-, medium- and long-term measures for implementation; Strategies , migration, recommendations, actions towards the " factory of the future” ;

© Fraunhofer IFF, M agdeburg 2015

Univ.-Prof . Dr.-Ing. M ichael Schenk

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Zero-defect manufac-turing

M achine M anufacturers Diversity of models and high complexity of jobs in assembly operations V isual assistance and inspection systems for the assembly of clamping systems V irtual templates to position and align

components A ugmented reality: Information supplied by

camera images of the assembly scene, overlaid with 3D CA D models

Upgradable with an inspection assistant

Smart W ork Systems-Fraunhofer IFF Research V isual A ssistance and Inspection Systems

Shortened assembly time 20%

Reliability in the process chain


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A viation Suppliers (A irbus) Small lot sizes and complex large parts M odel-based tools for optical inspection planning robot path planning provision of desired states inspection documentation of inspection results

Smart W ork Systems Flexible Inspection of Large A ssembled Parts

High f lexibility for quantities down to 1

Sustainable quality documentation

© Fraunhofer IFF


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A utomotive and Supplier Industry (A udi) V alidating and expediting product approval Facilitating communication between OEM and suppliers with virtual technologies Interactive planning and documentation A utomatic linking of CA D data and assembly

procedure data Pooling of data and knowledge in a database

Smart W ork Systems V irtual Technologies for Product A pproval

© Audi AG, Fraunhofer IFF

V alidation and optimization of critical processes

Early certainty for suppliers and OEM



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W ork areas Shared by Humans and M achines Safe cooperation between humans and machines Projection and camera-based sensor system generates optical safeguarded

zones display of robot status, instructions

for procedures, etc.

Smart W ork Systems-Fraunhofer IFF Research W orkplace M onitoring for M ore Safety

© Fraunhofer IFF

Immediately recognizable safeguarded zones

Ergonomic interaction



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Calculation and optimization of manufacturing parameters

Resource Ef f icient Production and Logistics Simultaneous Plant and M anufacturing Development

Commissioning and service

Chemical Industry

Integrated digital engineering of a plant that produces membrane f iltration elements

Reduction of Development risk Time and cost Defective products,

f rom 10% to 1%

Shortened development time 15–20% project period

New options for qualif ication

Virtual model: Control system development and programming by “ virtual teaching”

V R aided design of manufacturing plant

V R layout planning

Product design and optimization

Pictures © Fraunhofer IFF


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Technology development cooperation's on robotics, measurement, testing, virtual development & training;

Supporting HK s re-industrialization road mapping

Cooperation on designing Industry 4.0 strategies for companies;

Cooperation on establishment of a Industry 4.0 M odel-Factory to:

• Show of select Industry 4.0 technologies, systems and methods under real conditions of use;

• Provision of general trainings to companies on Industry 4.0 potentials;

• developing manufacturing processes, optimizing processes, selecting software and hardware components by development of user based scenarios;

Technology Partner Fraunhofer IFF V isions on Industry 4.0 cooperation's w ith Hong K ong & China


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Technology Partner Fraunhofer IFF Let us research your application together!

Fraunhofer Institute for Factory Operation und A utomation IFF

Sandtorstrasse 22 39106 M agdeburg

Germany

Phone: +49 391 4090-0

ideen@iff .f raunhofer.de www.if f .f raunhofer.de

© Fraunhofer IFF

© Fraunhofer IFF

Dipl.-Vw. Kay Matzner Logistik- und Fabriksysteme Telefon +49 391 4090-159 Fax +49 391 4090-432 [email protected]

mailto:[email protected]

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