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Industry 4.0 – reality, trends, ideas see www.Festo.com/iot

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Dipl.Ing. Eberhard Klotz, MBA Head of Industry 4.0 campaign

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German Government I4.0 Initiative: „Plattform Industrie 4.0“

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Forming of the Term „integrated Industries“ or Industrie 4.0 ~2010 Starting of the new set-up at Hannover Messe 14th April 2015 Dr. Veit (Festo) is one out of four industry speakers in the steering board

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Opportunities presented by Industry 4.0 discussions

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Industry 4.0 approaches are being implemented in practice in all cases where networking will lead to better control, organisation, efficiency etc. and a clear customer benefit can be identified.

The implementation of the vision of Industry 4.0 is an evolutionary process which will progress at different speeds in factories and certain segments of industry.

Action area Customer benefit (to be prooved)

Production

Economic, flexible, convertible production „plug & produce“, batch/lot size 1

Engineering Process Faster commissioning of machines/installations „virtual commissioning“

Energy management Increasing resource efficiency (component, machine, demands)

Logistical processes More efficient control of procedures (incl. demand planning)

Predictive Maintenance Increasing machine availability, Condition Monitoring

… …

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A networked, adaptive and learning production system

The factory of the future

CP Factory partner facility

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Integration of local “intelligence” and communication capacities

Mechatronic systems are turning into cyber-physical systems

Sensors

IP address, controller platform

Valves + IP capacity

+ Internet communication + machine-to-machine communication

• Wireless communication • Semantic description

+ sensors, actuators + integrated intelligence

The Internet of things

Cyber-physical systems

Integrated systems

Physical objects, devices

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Integration of “intelligence” and communication capacities into a sub-system.

Mechatronic SUB-systems are turning into cyber-physical systems

Or into a machine cell.

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Disruption: Full Process Control by SAP ME -

seamlessly integrated from ERP to C.P.S.

Representative Workflow:

1) Maintain all automation relevant data within ERP and SAP ME:

Routing,

Programmable Logic Controller (PLC) parameters,

QM set points

2) Start production - (raw) material arrives at workstation - feed PLC (material/operation specific)

3) Material is produced based on the given data - operation results/measurements returned to and logged in SAP ME

4) Material specific tolerance check within SAP ME - return decision and next operation to machine

5) Mechanisms inside machine based on this decision (e.g. open scrap gate, move to next operation …)

6) Material moves to next operation, requests PLC parameters …

OPC UA

round-trip < 200ms!

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New level of human-machine cooperation

Work organisation in the digital industrial era

Direct collaboration of people with machines and robots ensure safety

Intuitive and simple operation of machines and systems develop new operating concepts, AutoID

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Standardisation, modularity, OPC-UA

Research Application transfer to reality

Festo Didactic: CP Factory

Festo TechnologieFabrik

TechnologyFactory Scharnhausen

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Clearly identifiable physical objects contain intelligent communication abilities

Vision and innovation for the production of the future

+ + +

=

Value added services

• Analysis • Condition monitoring • Cloud services

Business models

• Pay per user • Predictive maintenance • Customer support

Product Networking Intelligence Communication

Industry 4.0

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Standards for software architecture and machine language along the value creation chain

Horizontal and vertical integration of the tool world

IO Link / AS-Interface

Supporting communication at the shop floor level

OPC UA**

Interface standard for making data available amongst various systems

Automation ML*

Combines the tools of the engineering process

Service Maintenance Commissioning Production Engineering Configuration and offerings

Industrial Ethernet

Communication incl. OPC UA

* pending ** IEC 62541, start 2010

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Production plant of the future for valves, valve terminals and electronics

Making the future adaptable in the Technology Plant

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Automated and

flexible Flexible,

flowing production

Optimised energy

consumption

Learning taken

for granted

Highly flexible, energy- efficient assembly lines

An optimised flow of information and materials

Energy network for buildings and production processes

Training factory as practical, integral constituent

An optimised flow of information and materials

Energy network for buildings and production processes

Training factory as practical, integral constituent

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I4.0 examples from Festo

Modular Flexible Machine Concepts with decentralised intelligence today

Flexible and most modulare valve production • Economic production of lot size 10-10.000 • Optimised logistic concept • Decentralised control and standardised interfaces per machine cell / module • Several C.P.S. (cyber-physical sub-systems in mechatronics) inside each module • in total ~400 IP addresses • Change over time 13 sec instead of hours • Technology adaption / module change: half a day instead of weeks • Move to new location: 3 days instead of 3 weeks

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The IT Landscape for GPC Scharnhausen

Integration Layer for Shop Floor

…

Manufacturing Execution

Enterprise Resource Planning

Energy-Data Production Orders

Energy-Management System (Facility Management)

Production Data Energy Data Buildings

Energy Data Production

Workstations, lines ..

Building installations OPC-UA Pilot 2:

Energy KPI OPC-UA Pilot 1:

Shop Floor KPIs

CC-T\Gabriele Goebel-Heise Die Produktion der Zukunft

28. Januar 2016

GPC Scharnhausen: old machines get retro-fit, e.g. parallel PLC in IP65

Integration Layer for Shop Floor

…

Manufacturing Execution

Enterprise Resource Planning

Energy-Data Production Orders

Workstations, lines ..

OPC-UA Pilot 2:

Energy KPI OPC-UA Pilot 1:

Shop Floor KPIs

CC-T\Gabriele Goebel-Heise Die Produktion der Zukunft

28. Januar 2016

Benefits of comparing machine KPIs and Energy KPIs

1. Bottle-neck optimized work flow

(a chain is only as strong as its weakest part)

• adjust machine performance according

to bottle neck situation

• Avoid buffer stocks, one-piece-flow

• Reduce waste of energy

2. Energy Peak management

• Avoid energy peaks

• start critical machines at different times

• reduces energy bill (1/3, ~10GWh)

3. Utilise available energy sources better

• pre-heat galvanic baths are by “waste”

energy of other machines/compressors

• optimize these sequences in general,

and daily depending on work-load

1 GWh less energy

2016/2017

100.000 € potential:

venting and light intensity

80.000 € potential lower pressure p.a.

Work in progress

CC-T\Gabriele Goebel-Heise Die Produktion der Zukunft

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Mobile Maintenance: ROI <6months, higher OEE and value creation

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Clearly identifiable physical objects contain intelligent communication abilities

Vision and innovation for the production of the future

+ + +

=

Value added services

• Analysis • Condition monitoring • Cloud services

Business models

• Pay per user • Predictive maintenance • Customer support

Product Networking Intelligence Communication

Industry 4.0

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Part of out Festo automation platform CPX

IoT Gateway CPX-IOT and Festo Cloud, IP65 Automation Platform

• Festo AppStore “App World” online • Festo Cloud Solutions (Pilot projects 2017) • A single Industry 4.0 solution from the mechanics up to the cloud

Connects up to 31 Festo Devices (e.g. pneumatic and electrical axes/drives, valve terminals), e.g. via OPC-UA

Offers IT-Security. Supports

IoT protocols AMQP/MQTT

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Festo Cloud and Dashboard examples

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Festo Cloud and Dashboard examples -2-

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System solutions – best matched, application specific solution packages all I4.0 ready

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Digitalisation for reduced complexity Wide range of functions via motion apps Just one valve technology: maximum adaptability, reduced system complexity Adaptability for greater productivity • Maximum process stability with motion apps • Self-regulating, independent adaptation – e.g.

presetting of travel time

Standardised networking, data-based decisions Industry 4.0 as CPS. with web server and controller OPC UA using the automation platform CPX Preventive maintenance using condition monitoring apps such as "Leakage diagnostics"

World first in digital pneumatics

Digital Simplicity - Festo Motion Terminal

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Learning from nature for the production of the future

Natural phenomena – inspiration for factory and process automation

Energy efficiency Learning

Self-organisation Communication

Networking

Adaptive and flexible

Miniaturisation

Human-machine

interaction

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Bionic Ants