smart manufacturing and the challenge of international ... · The 4th level of industrialization...

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smart manufacturing and the challenge of international value networks

Digital Transformation and Globalization in Germany and Japan

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Facts and Figures 2016

Founded 1923 in Essen, Nordrhein-Westfalen, Germany

Group Executive Board Frank Stührenberg, CEO

Roland Bent, CTO

Prof. Dr. Gunther Olesch, CHRO

Turnover 2016 1,97 billion €

Employees 15.000 worldwide, 7.500 of them in Germany

Production sites Argentina, Brazil, China, Germany, Greece, India,

Poland, Sweden, Turkey, USA

Distribution in more than 100 countries

Phoenix Contact GmbH & Co KG

Sven Holsten / Phoenix Contact GmbH & Co KG / May 30, 2017

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PxC Employee and sales development


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2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

1,97 Mrd. € turnover15.000 employees

worldwide

million

€

Turnover distribution

Germany

25%

International

75%


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Phoenix Contact Markets

power supply process industry Automotive Renewable Energies telecommunications

railway industry water Management mechanical engineering industrial electronics building automation



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Corporate Structure

Core Business Areas

Device

Connectors

New business fields

E-Mobility, Innovation Ventures,

Additive Manufacturing...

Industrial Components

and Electronics

Industry Management

and Automation

Group Functions


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4 locations (Germany,

Poland, China, India)

285 employees

400 molds per year

Global spare parts service

18 million EUR sales

TSP – Facts and Figures



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Mold Making in global competition


Pictures: Chinese mold making companies earlier and today / Source: WBA Aachen


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Portfolio



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Quality

Reliability

Innovative Capability

Flexibility

Agility

market requirements – mold industry


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Fully automated single piece

production

Digital commissioning

Virtual Engineering

Networked manufacturing

Delivery

Central objective of industry 4.0



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Industrialization levels

describe the degree of

decoupling of machine and

human interaction

The 4th stage is the

decision-making /

configuring at the product

change

Theory of Industrialization



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Automation is

ALWAYS in a fixed

chronology

Otherwise, there is a

risk of "automation of

waste"

Anatomy der Automation



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The 4th level of

industrialization includes:

Decentralized network

Almost intelligent

Actuators (Cyper-Physical

Systems)

Enabler - Cyber-Physical Systems



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New molds (2x)

Spare parts / service

Rapid plastic parts

Plastics Technology Center

Technology Development

PROTIQ (prototypes)

Units at the Blomberg site



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segmentation

Pull principle (FiFo)

process simplification

Information Platform (GTIS)

Visualization / Assistance

Systems

… first lean then automated

Industrial Internet in the Global Mold Making Network


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segmentation

Visual Shop Floor

Management

On-site decision / control

Continuous improvement

process

...

Uniform global production system



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Establishing industrial

production logistics

flow production

Short-cycle on-site

decision

Visual Shop Floor

Management

Production Logistics / Process Control



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Provide the "right" information

for on-site decision making

Consistent data model

Efficient data processing

Digital twin / shadow as process-enabler



Increased efficiency in the global networking of people, processes

and machines through digital systems

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Consistent, consistent data model


PxC controls its global mold

building network

Globally networked

Mobile available

Global Tool Shop

Information System

(GTIS)


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Classification standard eCl@ss


Integration of the eCl@ss

CAx expert group

requirements

Target: upgrade of the

eCl@ss standard with

CAx relevant information

from version 7.0

Result is one import

format for all CAx tools


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Classification standard eCl@ss



Product description and

classification information for

Multi supplier catalog

systems

Engineering data for CAE

Tools

Continuous data for the

production process

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Digital control / interaction platform


Daily control schedules

Interactive information /

communication panel

(touch pad)

On-site visualization

Target-oriented data

processing


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Decentralized

communication platform

Direct access to data

management systems

(ERP, EPLM, CAD, ...)

Daily on-site decision

Digitally assisted production / assembly control



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Digitally assisted project control


Interactive project

visualization

Short-cycle project control

Direct access to data

management systems

(ERP, EPLM, CAD, ...)

Daily on-site decision


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Real-time tracking with RFID tags


Process data are processed

in the Try Out Center

RFID tags on the tool

Unattended recording

To the host computer

system

RFID-Tag

Terminal

Sensor


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Tomography replaces conventional measurement


Replacement of the 2D

dimension

Fast 3D data acquisition

Consistent data chain

Direct evaluation of the real

component functions


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Consistent data models

Process-mixed automated

production

measurement

cleaning

Without interacting staff

Automated multiple process manufacturing



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Automatic product changes

require an automated work

preparation (CAM)

Solutions for electrodes /

molds are available

Solutions for cavities are in

development

Automated CAM programming


CPS (Cyber Physical Systems)

require automated engineering


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Additive manufacturing

processes replace

established production

Virtual engineering is

required

The methods enable novel

solutions

Additive Manufacturing - PROTIQ



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Innovative tool concepts

Virtual tool design

Topology-optimal design

Additive manufacturing

… to make things different



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… to make things different



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Outlook - Augmented Reality in Shop Floor


Virtual assisted assembly

Elimination of 2D

documentation

Accelerated orientation

error prevention


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Tool Shop Plastics


Thank you for

your attention!


smart manufacturing and the challenge of international ... · The 4th level of industrialization...

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