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First Insights of

Industrie 4.0 Projects in

the German Machinery

and Plant Engineering

Industry

First Insights of German Industrie 4.0 Projects

© UNITY Public

Management Consultancy for Future-oriented Corporate Management

Customer Benefits

sustainable increase of clients‘ success through innovative

processes and business models

Clients

19 of the DAX-30-companies and SMEs,

more than 1.000 client projects since 1995

Execution

from the initial concept to the successful execution

Locations

8 branch offices in Germany, 6 international branch offices,

project sites throughout the world

Heinz Nixdorf Institute

strong ties to science and research

Facts

Founded: 1995

Employees worldwide: 210

UNITY-Beratungsansatz

Unser Spirit für Ihren Erfolg!

2

UNITY [´ju:niti]; UNITY with clients to

create customized improvement:

Consulting and innovation;

Overall management expertise;

Team spirit in project work;

Think ahead, enable, execute.

The UNITY Consulting Approach

Our Spirit, Your Success.

© UNITY Public

Four-level Model of Future-oriented Corporate Management

3

Is the business strategy based

on a vision (future draft)?

Do the processes follow

a business strategy?

Are the targeted business

processes defined?

Industrie 4.0

© UNITY Public

4. INDUSTRIAL REVOLUTION

Autonomous products and decision-making process

control value-adding networks in almost real-time


Mass production of goods based on division of labour and with

help of electric energy


Introduction of mechanical production facilities


Automation of production processes by electronics and IT

Each industrial revolution caused an improvement in productivity and was accompanied by fundamental changes in society.

Industrie 4.0 Industrial Revolutions Overview

4

STEAM

ENGINE

ELECTRIC

ENERGY

COMPUTER

INTERNET

ON THE

SHOP

FLOOR

© UNITY Public

Industrie 4.0 helps us to control variances, to reduce complexity and to make manufacturing processes more transparent.

Designing an Industrie 4.0 Production The Value Added of Tomorrow – IP-Enabled Work Pieces ...

... CONTROL THE PRODUCTION.

5

... ASSIST IN ASSEMBLY. ... ASSIST IN PRECISION

MACHINING PROCESSES.

... INDEPENDENTLY CARRY

THROUGH QUALITY INSPECTIONS.

... SHOW PRODUCTIVITY IN REAL

TIME. ... ARE ALWAYS TRACEABLE.

© UNITY Public

A high wage economy competitiveness is secured. Made in Germany.

The Vision of Industrie 4.0

Individualization (batch size 1) of the economic

conditions of a mass manufacturer becomes reality.

Production is highly flexible, highly productive (up to +50%)

and urban friendly, resource-friendly (up to -50%).

Value creation processes are optimized in real time demand:

education ad-hoc virtual organizations.

Reconciliation of work and family with regard to the

individual availability of employees.

Older workers benefit from intelligent assistance systems.

The existing infrastructure can be upgraded step by step.

Source: Kagermann, 2013 6

© UNITY Public

Gross value added 2013 of selected industries in Germany (billion €)

Gross value added 2025* of selected industries in Germany (billion €)

*Prediction

Key

Chemicals Automobiles

& Parts Engineering

Electrical

equipment

Agriculture

and forestry ICT-Industry

Industrie 4.0 is a vision of the future, which begins today. Almost all major economies have launched several initiatives in order to use the digitization of traditional industry for a competitive advantage in the world market.

1.7% Additional Growth each Year through Industrie 4.0

7

i

40.1 74.0 76.8 40.3 93.7

TOTAL

343.3

1.7%

ANNUAL

INCREASE

52.1 88.8 99.8 52.4 21.3 107.7

TOTAL

422.1

Source: Fraunhofer IAO/BITKOM

18.6

© UNITY Public

“Industrie 4.0” Understanding Evolution and Categorization

8

INDUSTRIE 4.0

INTERNET OF

THINGS &

SERVICES

INTERNET OF DATA

AND SERVICES

+

MAINFRAME

DATA WAREHOUSES,

INTERNET, PC BIG DATA,

CLOUD COMPUTING,

SMART DEVICES

Many users, 1 computer

1 user, 1 computer

1 user, many computers

Source: German Research Union And acatech, 2013

EMBEDDED

SYSTEMS

CYBER-PHYSICAL

SYSTEMS (CPS)

PHYSICAL OBJECTS,

TOOLS, EQUIPMENT

+ Sensors, actuators

+ Integration of high performance

electronics and mini computers

+ IP-Capability

+ Semantic description

+ Connected, Internet, M2M

+ Wireless communication

+ only mechanical components

© UNITY Public

It not only concerns production, but also the digitalization and networking of all environments. New risks as well opportunities as are created for all participants!

Internet of Things and Services (IoTS) Inter-connectivity and Digitalization of Different Living Environments

9

Smart

Products

Smart Mobility

Smart

Grids

Smart Health

Smart

Factory

Smart Logistics

INTELLIGENT

NETWORKED

WORLD

Smart Buildings

Internet of

Things

Internet of

Services

Source: Forschungsunion, 2012; Nokia 2016

100 Mbit/s wherever needed

>10 Gbit/s peak data rates

M2M ultra low cost

FLAT ENERGY

10 years M2M battery life

<1 millisecond latency

10-100 x more devices

10,000 x more traffic

2020+

Performance requirements

ULTRA RELIABILITY

Capacity

Latency

Energy consumption

Cost

User data rates

Coverage

© UNITY Public

Research Projects – INBENZHAP & GEMINI

10

INBENZHAP International Benchmark Industrie 4.0

Future Options in Production worldwide

GEMINI Business Models dedicated

to Industrie 4.0

Key Questions:

What level of development have leading

industrial nations attained?

What framework conditions must exist in order

for Germany to become a leading market?

Where are the markets for the German leading

provider industry and what do they require?

What competitors will the German supplier

industry encounter?

How does the supplier industry need to develop

in order to be successful in future markets?

How does this affect work organization and

structure? Is Industrie 4.0 accepted by relevant

stakeholders?

What kind of dedicated Business Models

based on Industrie 4.0 principles evlove?

© UNITY Public

Digitalization in Production is a Global Trend Feasible Scenarios per Country

11 Source: INBENZHAP, International Benchmarks, Future Options and Recommendations for Action in Production Research

1. Reindustrialization

makes the USA a

leading market and a

leading Industrie 4.0

provider

2. Expansion of its

dominating position in

the area of Smart

Services

3. The USA falls behind

in terms of high quality

industrial connectivity

SCENARIOS

IN USA

1. The basis for success is

the balance of society,

technology and the

government

2. Ubiquitous digitalization,

technology-centric work

place

3. Digitalization is hindered

by many barriers

4. Digitalization controlled

by others and global

factors

SCENARIOS

IN GERMANY

© UNITY Public

Culture in Silicon Valley Christoph Keese, 2014

12

Technicians, not sales people dictate decisions in Silicon Valley

Difficult tasks will be taken on.

The greater the challenge, the better

What appears to be hopeless is often the most profitable

Wealth is more likely to be created by chance TE

CH

NO

LO

GY

-

CU

LT

„Disruptive Innovation“ is the magic formula. Silicon Valley is a master at recognizing

weaknesses in the business models of well established companies. It attacks

aggressively and is often victorious.

„If someone wants to eat your food, be sure that it is you.“ Gilles BianRosa, CEO von Fanhattan U

NL

IMIT

ED

INN

OV

AT

ION

SC

AL

E O

R

LO

SE

Everything that can be, will be digitalized. In the future, automobiles, airplanes and

refrigerators will be mere sheets of metal that will barely generate revenue. Winners

will be the intermediaries, thanks to network effects.

„Information is currency in an information society.“ Geoffrey Moore

„Problems, give

us problems“

„No one is safe from

constant attacks from

below“

„From the age of

platforms“

Source: Silicon Valley, Christoph Keese, 2014, page 91

© UNITY Public

Critical focus areas | Strategic direction | Recommendations for action

Industrie 4.0 Strategies in Countries and Regions!

13

Visionary concepts that integrate

technology, society and the economy

“ENGINEERING EXCELLENCE”

Internet of Things (IoT)

start-ups and a renaissance

in production

“RADICAL INNOVATION”

Use of mature technologies

to develop strategic key

technologies

“SPEED”

© UNITY Public

Overcoming the Bridging Challenges with Office Work 4.0 The Dual Management System for Aligning Employees with Organization

14

SE

LF

- O

RG

AN

IZE

D

OR

GA

NIZ

AT

ION

D

ES

IGN

C

ON

TR

OL

LE

D

DOING CREATING

Coporate Management Level

Operational Management Level

Process Management Level

Control Level

Field Level

INDUSTRIE 4.0

CHAOS ORGANIZATION

RESTRAINTS

OFFICE WORK 4.0

Source: Technology Management Gruppe

ROLE OF THE EMPLOYEE IN

VALUE CREATION

© UNITY Public

Overcoming the Bridging Challenges with Office Work 4.0 The Dual Management System for Aligning Employees with Organization

15

ROLE OF THE EMPLOYEE IN

VALUE CREATION

OR

GA

NIZ

AT

ION

D

ES

IGN

S

EL

F-

OR

GA

NIZ

ED

C

ON

TR

OL

LE

D

DOING CREATING

Stabilizers | 20-30%

Monitor

Operative business processes

Highly automated

Integrators

55-70%

Broker

Innovators | 10-15%

Suppliers

Corporate Strategy

R&D

Marketing & Sales

Producers

Consumers

OFFICE WORK 4.0

Source: Technology Management Gruppe

INDUSTRIE 4.0

CHAOS ORGANIZATION

RESTRAINTS

© UNITY Public

Intelligent Factory

Pre-Assembly Preprocessing

Assembly Inspection Packaging

Smart Planning Smart Sourcing Smart Distribution

Horizontal Integration

Supplier Customer

Supplier Warehouse

Customer

Real time KPI‘s on

enterprise level

Customer specific

configuration of products

Supplier

Development of Business Models Technology Area: Shop Floor/Core Business

16

SHOP FLOOR/

CORE BUSINESS 1

Location bound

Manufacturing/Production 1

© UNITY Public

Intelligent Factory





Supplier Customer

Supplier Warehouse

Customer


enterprise level

Customer specific


Supplier

17

2

Development of Business Models Technology Area: Company

COMPANY 2

View of the entire

company

Spans all locations

Across all functional areas

© UNITY Public

Intelligent Factory





Supplier Customer

Supplier Warehouse

Customer


enterprise level

Customer specific


Supplier

18

Development of Business Models Technology Area: Open Company

3

OPEN COMPANY 3

Company-wide and

cross-sector

Overall added value

Involvement of all

stakeholders

© UNITY Public

Intelligent Factory





Supplier Customer

Supplier Warehouse

Customer


enterprise level

Customer specific


Supplier

19

Development of Business Models Technology Areas

3

OPEN COMPANY 3

SHOP FLOOR/

CORE BUSINESS 1

COMPANY 2

2

1

© UNITY Public

Digitalization and Development of Business Models Action Areas for Companies

Shopfloor Operating Technologies (OT)

Machines Things …

Control Level

Operator Level

Field Level

Inte

rfa

ces &

In

terp

rete

r

Business IT (Office Systems)

ERP

PDM

MES

ERP

…

End User

Apps

Services

Analytics

Platform

APP

Smart Factory, Plant, Production:

Increase productivity by driving the level

of automation and IT expansion

(digitalization).

29.03.2016 Vortrag_Fachkongress_Industrie_4.0_Saarbrücken_16zu9_V_1_0.pptx 20

Smart Services, Smart Products:

Develop new business models to generate

revenue and services that do not yet exist.

© UNITY Public

Reinvent the

Product Experience

Level 1 Level 2

Level 3

Level 4

Level 5

Level 6+

Unconnected Connected Serviceable

Intelligent

Optimized

Differentiated

INNOVATE

MANAGE

CONNECT ) ) )

Service

Analyze

Integrate

On the way to Industrie 4.0 there are 6 levels of maturity. More advanced companies have a higher capability to create value!

Industrie 4.0 Maturity Model Strategic Analysis to Identify the Competitive Position

21

© UNITY Public

On the way to Industrie 4.0 there are 6 levels of maturity. More advanced companies have a higher capability to create value!

Industrie 4.0 Maturity Model Strategic Analysis to Identify the Competitive Position

22

Unconnected

Fight fires

Limited product feedback

High cost of service

Connected

Remote access as allowed

Fragmented information

Reactive response to issues

Serviceable

Remote access as needed

Some proactive monitoring

Service cost avoidance

Electronic software delivery

Intelligent

Predictive maintenance

Monitor and report on services

View and analyse product

Leverage usage data for new product enhancements

Differentiated

New revenue-generating capabilities

Cloud-delivered customer applications

Replenishment management

Remotely control products

Compliance and audit reporting

Mobile integration

Cloud-to-cloud-to-mobile mashups & network effects

Collaboration productivity

Optimized

Enterprise integration

Configuration and warranty management

Pay-per-use models/billing integration

Track and locate/ inventory management

Product CVs

Analytics based services

Reinvent the

Product Experience

Level 1 Level 2

Level 3

Level 4

Level 5

Level 6+ INNOVATE

MANAGE

CONNECT ) ) )

Service

Analyze

Integrate

© UNITY Public

INDUSTRIE 4.0 – MILESTONES

Trend Setters on the Way to Industrie 4.0 Machinery and Plant Engineering

23

KOLBUS GMBH & CO. KG

Use of augmented reality in

the assembly of complex

clamping systems

Virtual template –immediate

comparison of the real image

with the 3D CAD model

Color coding when fitted

incorrectly

Fast training of new assembly

processes

SIEMENS AG

Independent control of parts

throughout the factory

Communication at every

work station and retrieval

of processing operations

Realization of multi-variant

production capabilities

DMG MORI SEIKI AG

Innovative machine operating

concept: continuous and

digitalized management,

documentation and

visualization of order, process

and machine data

Networked with ERP and

MES systems as well as

CAD-CAM applications

WEIDMÜLLER INTERFACE

GMBH & CO. KG

Self-correcting machines

in production

Integration of measurement

technology

Self-correcting algorithms

for intelligent controls enable

continuous fulfillment of

product requirements

© UNITY Public

Digitalization

Industrie 4.0

Farming 4.0

Connected Car

Computerization of traditional

industries beyond IT – additional technologies

like 3D printing

and augmented reality

Internet of Everything (IoE)

Global concept of encompassing connectivity

of objects, processes and humans

Internet of Things (IoT)

Interaction of all physical objects and devices in open and

closed networks mainly based on sensors and actuators.

Industrial Internet

Specific concept for

of IoT applications

for industrial equipment

in Smart Factories

Big Data (Analytics)

Collect, analyze,

process data

M2M (Communication)

Machine-to-Machine communication with direct exchange of

Information between multiple devices and objects in a closed

system

virtual

Concepts and technologies (based on IoT Analytics)

24

WORLD

USER

OBJECTS

MACHINES

IT OT

physical

Technologies

Trends & Concepts

Scenarios

Drivers Cloud

(Computing) Global reatime provision

of data, applications

and infrastructure

Internet (as we know it)

© UNITY Public

Reference Architectures for Industrie 4.0 Current Architectures and Models

25

CPS WITH DISTRIBUTED SERVICES “SINGLE-SOURCE“ SOFTWARE

DEVELOPMENT MES AS A CENTRAL PLATFORM

CENTRAL CONNECTIONS BETWEEN

OFFICE FLOOR AND SHOP FLOOR

OPEN BASIC CONCEPT OF

THE IOT PLATFORM

REFERENCE ARCHITECTURAL

MODEL INDUSTRIE 4.0


Vert

ical In

teg

rati

on

Software

Engineering

Rules

Management

Systems

IT Security in

Production

Plants

Mobile

Apps

Cloud

Computing

Big Data &

Analytics

“Single Source”

Software Development

Shop Floor

(Machine-to-Machine)

Office Floor

(Machine-to-Business)

Logis-

tics PLM

ERP

Control

MES

Enterprise

Network

Real Time

Network

SOA* as a shared

mechanism for

integration

Standards as the basis

for connection to the

enterprise network

Re-use as a unifying

development approach

!

Connectivity to any end points

Shared semantic model

* SOA: Service

Oriented Architecture

Business

Prcess Application Services Data Cloud Partner

Production

Processes Control Sensors Data Machinery Results HANA®-Platform

Analysis and Forecasting

Partner SAP Customer 3rd Party

App Store (discussed)

Basic Applications (e.g. digital object memory,

connected logistics, predictive maintenance)

Business

Systems

Business

Systems

Business

Systems

Inte

rface I

nte

gra

tio

n

Benefit

E.g. predictive maintenance,

error pattern recognition

for product & quality

E.g. remote

service

E.g. energy

management

Benefit

Benefit

Business

Layers

Functional

Information

Communication

Integration

Asset

© UNITY Public

INDUSTRIE 4.0-CAPABLE

MES-SYSTEM

Integrated networking of all equipment

and systems involved in production

Autonomous/customized rough plan and

detailed order scheduling considering

delivery times, capacity and resources

Provision of all production information

at required locations

Complete transparency of orders,

capacity and resources

26

€0

€2.000.000

€4.000.000

€6.000.000

1.Jahr 2.Jahr 3.Jahr 4.Jahr 5.Jahr 6.Jahr 7.Jahr

Break-Even-Point

Source: Maschinenfabrik Reinhausen GmbH, 2010

© UNITY Public 27 Source: DMG Mori Seiki AG, Universalbearbeitungszentren

UNIVERSAL MACHINES

Complete machining of up to four

different processes on one machine

Operator guidance during order planning

and set-up

Integrated management, documentation

and visualization of all data including

tools and material management

Innovative machining operations: Kinematics

testing and correction, laser measurements,

dynamic workspace monitoring etc.

(€4.000.000)

(€2.000.000)

€0

€2.000.000

€4.000.000


Break-Even-Point

© UNITY

DIGITAL MAINTENANCE SERVICE

Rapid elimination of machine downtimes

Real-time sharing of image, audio and

video files with Technical Support

Editing of images and supplementing

it with additional information

28 Source: Trumpf GmbH & Co. KG, Digitaler Instandhaltungsservice

€0

€100.000

€200.000

€300.000


Break-Even-Point

© UNITY Public

DATA GLASSES

(AUGMENTED REALITY)

Data glasses assist employees when

dealing with multi-variants and manual

assembly processes

Part specific assembly instructions

appear after automated identzification

Recognition of movement,

assistance in individual steps

Notification of correction when an

error occurs

Documentation of work processes

29 Source: VW

(€200.000)

(€150.000)

(€100.000)

(€50.000)

€0


Break-Even-Point

© UNITY Public

MILKRUN 4.0

Control of “Milkrunners” by software

Intelligent scheduling algorithm for

calculating the optimal travel times

Demand detection in real-time and accurate

virtual image of material supply and parts

Consumption-based supplies on the

machine

30 Source: share.sew-eurodrive.de

€0

€2.000.000

€4.000.000

€6.000.000


Break-Even-Point

© UNITY Public

AUTONOMOUS WAREHOUSE

SYSTEMS

Product storage and retrieval by

autonomous systems

Managing storage processes

using intelligent software

Real-time monitoring

Commissioning support through

assistance systems

31 Source: www.techbriefs.com

(€5.000.000)

€0

€5.000.000

€10.000.000


Break-Even-Point

© UNITY Public

Thank You for your Attention!

32

Beijing Berlin Braunschweig Cairo Cologne Hamburg Munich Nuremberg Paderborn São Paulo Shanghai Stuttgart Vienna Zurich

www.unity.de www.unityconsulting.com

Anyone dismissing this development as temporary

hype is in danger of ending up just like Quelle or

Karstadt: these trading companies did not take the

use of internet within their business seriously

meaning that the new players in this sector are now

eBay, Amazon, and Zalando. This is a mistake

which should not be repeated in the manufacturing

industries.

The two key action areas for companies are

digitization, i.e. an increased degree of automation

to boost productivity, and the development of new

business models to generate services and sales.

Prof. Dr. Heiko Seif

Senior Manager

+49 89 13010065-172

+49 160 8825534

[email protected]

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