Industrie4.0 -Intelligent production of tomorrow · decisions. Augmented reality, computer-assisted augmentation of reality, also helps to produce the tools. Result To carry out fully

Anja MoldehnSenior Project Manager Industrie 4.0Phoenix Contact Inc.

Industrie 4.0 - Intelligent production of tomorrow

Evolution of manufacturingThe world is becoming more digital, intelligent and flexible. Initiatives such as Industrie4.0 in Germany, the Industrial Internet Consortium in the USA or China Manufacturing 2025 are providing the first responses to the question of how digitalization will affect our surroundings.

Mechanicalproduction

Work-piece production

PLC-basedautomation

Leve

l of c

ompl

exity

End 18th Century Begin 20th Century Begin 1970s

Intelligent networkedautomation

Today

Challenges today: Digitalization in industry

… stands for the digitalization of production and product life cycle

…stands for the technical integration of cyber-physical systems and the Internet of Things and Services in production and logistics

…stands for new value added business models, services and work organization

Industrie 4.0Challenges today: Digitalization in industry

source: Umsetzungsempfehlungen für das Zukunftsprojekt Industrie 4.0, Forschungsunion, acatech

From the hierarchy to the Industrial InternetChallenges today: Digitalization in industry

Industry 4.0 effects 3 dimensions

Source: ZVEI

Smart Services

Smart FactorySmart Plant

Smart ProductsSmart Systems

New businessmodels

Digitization of theproduct & serviceporfolio

Digitization & integrationof value-added chains

Internet of Things andServices

Challenges today: Digitalization in industry

The goal – integration in three dimensionsChallenges today: Digitalization in industry

Source: ZVEI working group for system aspects; Prof. Wollschläger, TU Dresden

Integration across thebusiness processes

Integration across the value- addedchain

Visions for 2030

Source: Platform Industrie 4.0

Industrie 4.0

Industrie 4.0 has been a common buzzword for eight years. Since then, a lot has happened. Especially with regard to standards and tangible implementations in companies. Digital transformation is in full swing. So it's time to look a little further into the future and draw the big picture. The year 2030 appears in the National Industrial Strategy as well as in the vision of the platform Industrie 4.0. What's it all about?

National Industrial Strategy 2030 is strongly discussed


Industrie 4.0 - Visions for 2030

Digitization is changing our global and already complex world. The Federal Ministry for Economic Affairs and Energy (BMWi) of Germany is therefore asking itself how we can maintain and expand our private and public prosperity in Germany and Europe. In February of this year, the BMWi published the National Industrial Strategy 2030 for this purpose. It contains strategic guidelines for a German and European industrial policy.

Targets for 2030 from the Platform Industrie 4.0


Industrie 4.0 - Visions for 2030

In March 2019, the platform Industrie 4.0presented the first draft of the 2030 vision for Industrie 4.0. Like the National Industrial Strategy 2030, the vision is to be seen as a basis for discussion. It is intended to set targets for Industrie 4.0. Three major topics will be discussed: Autonomy Interoperability Sustainability

The German platform „Industrie 4.0“

Working Groups

WG 4: Regulatory framework

Phoenix Contact is member in 4 working groups

Working Groups

WG 4: Regulatory framework

Phoenix Contact is member in 4 working groups

WG 1: Reference Architecture & StandardsWG 2: Research & InnovationWG 3: Security of linked systems

WG 5: Labour, training, education

Objective Steering committee• Strategy development

Member: Roland Bent, CTO Phoenix Contact

Objective Steering committee• Strategy development

Member: Roland Bent, CTO Phoenix Contact

How to start Industrie 4.0?

Industrie 4.0 at work (http://www.plattform-i40.de/I40/Navigation/EN/InPractice/Map/map.html)

Seamless Digital - from Engineering to ProductionThe „Digital Article“ enables an efficient Engineering for Automated Production

Seamless Digital - from Engineering to ProductionThe „Digital Article“ enables an efficient Engineering for Automated Production

Versatile Production by Phoenix ContactFlexible modular Facility and Control ConceptVersatile Production by Phoenix ContactFlexible modular Facility and Control Concept

Smart Engineering and ProductionSeamless Using of Engineering data in ProductionSmart Engineering and ProductionSeamless Using of Engineering data in Production

Process mixed Line automation in Tool shopIncreasing efficiency in Phoenix Contact Tools shop: Reducing idle times by Process mixed automated Chains

Process mixed Line automation in Tool shopIncreasing efficiency in Phoenix Contact Tools shop: Reducing idle times by Process mixed automated Chains


Testbed Management & Standardization

• Strategy & Strategic recommendations• SME mobilization• International Cooperation

• Network of test beds• On-road testing• Validated regression into standardization

• Initiation of cross-sectoral standards• Coordination of standards• Strengthening international cooperation

52 Testbeds in Germany

Concretize technical capabilitiesMatching test centers Perform individual workshops Accompany test scenarios Initiate Standardization


Test bedsCommittee work and test-beds

SmartFactoryOWL is an open research and demonstration platform for digital transformation. As an "Industrial IoT Experience Center (IIOT)", new technologies can be tested.

Test bed for the validation of the asset administration shell developed in the open source project openAAS based on a practical example.

Test bedsCommittee work and test-beds

The Smart Engineering and Production 4.0 technology network provides specific answers to the question of how to achieve end-to-end digitization of industrial engineering and production processes. A live demonstration using the example of a switchgear installation shows what highly automated manufacturing based on a batch size of 1 looks like.

Professional Education CenterHow to start Industrie 4.0?

RAMI 4.0 – The Reference Architectural Model for Industrie 4.0How IoT and Industrie 4.0 are connected

RAMI 4.0 is a three-dimensional map showing how to approach the issue of Industrie 4.0 in a structured manner.RAMI 4.0 ensures that all

parties involved in Industrie4.0 communication understand each other.

Graphics © Plattform Industrie 4.0 and ZVEI

RAMI 4.0 – benefitsHow IoT and Industrie 4.0 are connected

RAMI 4.0 is a SERVICE-ORIENTED ARCHITECTURE. RAMI 4.0 combines all elements and IT components in a layer and life cycle model. RAMI 4.0 breaks down complex processes into easy-to-grasp packages, including data privacy and IT security.

Graphics © Plattform Industrie 4.0 and ZVEI

Axis 1 – hierarchy: the factoryHow IoT and Industrie 4.0 are connected

The old world: Industrie 3.0:

Hardware-based structureFunctions are bound to hardwareHierarchy-based communicationProduct is isolated

Graphics © Anna Salari, designed by freepik

Axis 1 – hierarchy: the factoryHow IoT and Industrie 4.0 are connected

The new world: Industrie 4.0 Flexible systems and machines Functions are distributed

throughout the network Participants interact across

hierarchy levels Communication among all

participants Product is part of the network

Graphics © Anna Salari, designed by freepik

Axis 2 – IT-architectureHow IoT and Industrie 4.0 are connected

Graphics © Plattform Industrie 4.0 and ZVEI, pictograms © Anna Salari, designed by freepik

Axis 3 – product life cycleHow IoT and Industrie 4.0 are connected

Procuct lifecycle graphics from RAMI 4.0 © Plattform Industrie 4.0 and ZVEI, additions: Dr. Peter Adolphs

German National Platform Industrie 4.0How IoT and Industrie 4.0 are connected

We shape the intelligent production of tomorrow:

Phoenix Contact is a member of the steering committee is involved in 4 working groups

Co-ordination of reference architecturesHow IoT and Industrie 4.0 are connected

The Industrial Internet Consortium and Platform Industrie 4.0 co-ordinate RAMI (reference architecture model for Industrie 4.0) and IIRA (Industrial Internet reference architecture) to ensure the interoperability of future systems

RAMI 4.0 <> IIRA

The intelligent production of tomorrowThe intelligent production of tomorrow and todays benefit

Phoenix Contact is converting the sometimes abstract advantages of Industrie 4.0 into practical areas of action.

• Consistently digitally described • Communicative and secure

• Autonomous and adaptive • Easy to install

• Easy to operate • Resource-efficient

ChallengeProducts and processes are first of all created virtually and are fully transparent.

ImplementationThroughout the entire lifecycle of a product, all process phases are supported by a consistent digital description within the value-added network, such as the engineering, installation or production phases.

ResultAll operating states are known at all times; their visualization simplifies planning, analysis, and operation.

Consistently digital descriptions - in future

Digitalization improves processes in tool engineering

The intelligent production of tomorrow and todays benefit

Consistently digital descriptions - todayChallengeComplex injection molding tools are used to manufacture sophisticated plastic parts, which need to be ready in ever shorter time frames.

ImplementationData is consistently used to optimize processes. Digital boards provide the information needed for upcoming decisions. Augmented reality, computer-assisted augmentation of reality, also helps to produce the tools.

ResultTo carry out fully automatic production in the future, and thereby save time and costs, tools and processes are described fully digitally.

Augmented reality supports the manufacture of injection molding tools


Surface analysis is currently generated automatically by design software Creo ED and can therefore be extracted and displayed using augmented reality.

The example shows a tool cavity, in which the digital twin can be displayed for checking contact surfaces.

This shows the skilled worker at a glance where to pay attention and where exactly the components have their contact surfaces.

AR for surface analysisThe intelligent production of tomorrow and todays benefit

AR in tools shop and building automationThe intelligent production of tomorrow and todays benefit

The modular production line integrates the essential processes required for the production of tool components: electrode production, milling, sink erosion, cleaning processes and the determination of quality.

In a CAD / CAM environment, the digital twins of the workpieces and electrodes to be produced are created. A central software automatically transfers all further process data and manufacturing information to the process control system.

The virtual components are networked by means of real-time monitoring with the required NC programs, work steps, milling tools and electrode assignments. The physical components are automatically identified by RFID chip and control the system.

30% faster cycle timesThe intelligent production of tomorrow and todays benefit

Digital Twin Backbone of Industrie 4.0

Digital Article

Marking

Color

Test instructions

Layout references

PackagingInstruction

Product description- Function- Feature- Parameter- …

DimensionsPart list Specific

assembly parameter

Serial no.approbation

Print layout

Assembly instruction

Labeling

Cyber Physical System (CPS)

source: VDI/VDE ZVEI Statusreport Referenzarchitekturmodell Industrie 4.0 4/2015

Industrie 4.0 component

Locating

Administrationshell

Object, e.g.drive

Reference architecture modelIndustrie 4.0 (RAMI4.0)

Backbone of Industrie 4.0

Cyber Physical Systems (CPS)

… worldwide use of data and services

… acting via actuators… sensing data via sensors

… control

… communicate via interfaces… interact via Human-Machine-Interfaces (HMI)

Source: Forschungsunion Wirtschaft – Wissenschaft

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

Backbone of Industrie 4.0

The intelligent production of tomorrowThe intelligent production of tomorrow and todays benefit

Phoenix Contact is converting the sometimes abstract advantages of Industrie 4.0 into practical areas of action.

• Consistently digitally described • Communicative and secure

• Autonomous and adaptive • Easy to install

• Easy to operate • Resource-efficient

ChallengeAdaptive behavior strengthens production to handle any kind of disturbance and provides flexibility for maximum efficiency.

ImplementationThere is no central controller; instead there is intelligent collaboration. Distributed controllers adapt independently to processes, equipment, and devices. Complex processes and unexpected events are easier to manage and optimize.

ResultThus producing batch sizes of 1 at the same low cost of mass production has become a reality.

Autonomous and adaptable - in future

Economic production of a batch size of one



Autonomous and adaptable - todayChallengeIndividual production of a batch size of 1 of the MINI Analog signal conditioners.

ImplementationThe freely parameterizable process cells produce individual signal conditioners according to customer requirements. The system works very efficiently based on the consistent material flow in the process chain and due to very short changeover times.

ResultSmall batch sizes can already be manufactured at the same cost as mass production. The intelligent and autonomous production system is economical over the long term.

Minimum set-up times for high flexibility

Standard VariantsVariants

Productvariance in future

Actual costs

Costs in future

Lot size

source: WZL, RWTH Aachen, Phoenix Contact Maschinenbau

Increasing customer demandsThe intelligent production of tomorrow and todays benefit

Challenges for producing industries

Increasing product variety

Flexible lot sizes / Lot size 1

Short lead times

Transparent and controlled processes

Time-consuming processes in engineering,set-up, configuration and parametrization

Waiting times and inventories

Insufficient transparency in processes


What will change in our production?

Customer‘s wish

Vertical integration of business processesfor the manufacturing of individual products

Delivery

Configurator

Online shop

ERP (Enterprise Ressource Planning)

MES (Manufacturing Execution system)

Machine control system

PLM

Pro

duct

lifec

ycle

man

agem

ent

Automated parametrization

Complete digitalproduct description

Optimalshopfloor scheduling

Automated generationof production orders

Transparency aboutthe order status


Engineering Production Operation Service

What will change in our production?

Availability of allrelevantinformation

Flexibility, efficiency and transparency along thevalue chain and the product life cycle

Virtualdevelopment andoptimization

Fast prototypes Efficient logistics

Easy adaptation to quantities and variants

One piece flow

Transparency over the statusComponents

Productionsystems

Self-optimization

Easy set-up and operation


Automated production of lot size one

https://youtu.be/GQ5Ku7OZbMA


Aim of digital transformation We shape the discussions of digitization in the

public and in our industry Our claim: We use the latest technologies to

network our world -> creating a digital vision based on our corporate principles

Importance for our business model: Digitization is the comprehensive, ubiquitous, intelligent networking of things, data and people

Digital strategy

Process of digital transformation Setting up committees & responsibilities Formulate a Digital Vision & Strategy as well as

Lighthouse Projects Internal communication to managers and

employees Establishment of a multi-project management Implementation support & continuous trend

scouting

Digital strategy

Deg

ree

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rate

gic

rele

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low hig

high

low

Learning experiences in digital transformation

16 lighthouse projects

create the necessary basis for the implementation of the digital transformation

generate a significant learning effect in the context of the digital transformation

in the areas of data-centric business models, digital product portfolio, digital customer interface, digital production and business processes

Lighthouse projects

Level 2 project

Level 3 project

Fast learning with lighthouse projectsDigital strategy

For example: Construction of Industrie 4.0 workshops in production Development of Industrie 4.0-capable products, systems and solutions Consistent digitalization of the entire value chain Development of data-centric business models and services Adaptations of organizational structures, collaboration culture, processes Involving all employees to shape the digitization of the workplace

Digital strategy

Fast learning with lighthouse projects

With almost 100 years of experience, we are ideally placed to take the digitization of our world and turn it into the intelligent production of tomorrow.

Your partner in digitizationDigital strategy

Experience in machine building

Process expertise in production

Products for intelligent automation

Documents

Industrie4.0 -Intelligent production of tomorrow · decisions. Augmented reality, computer-assisted augmentation of reality, also helps to produce the tools. Result To carry out fully