digitalization@schaeffler: smart factory solutions · schaeffler digital platform will integrate...

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Digitalization@Schaeffler: Smart Factory Solutions Condition Monitoring appraoch for machine tools

Matthias Hafner| Director Digitalization Greater China

Schaeffler China

Schaeffler at a glance

More than

92,000 employees worldwide 2)

More than 170 locations in 50 countries

1.1 m tons of processed steel p.a.

Strong customer base with approx.

11,800 customers

1) Before one-off effects 2) As at June 30, 2018

Strong organic growth

5% p.a. Ø Sales growth 2006-2017

Nearly

2,400 patents filed in 2017

Far more than

10,000 different products

74 plants

18 R&D centers

Schaeffler in facts – Strong starting point

2 Digitalization@Schaeffler | ICSM 2018 | November 2018 | Shanghai, China

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1 How we approach Digitalization Strategy Schaeffler at a glance

Urbanization Population growth

Society trends

Increasing complexity Digitalization

Technology trends

Renewable energies Availability of resources

Environmental trends

Globalization Affordability

Economic trends

Key mega trends Focus areas

E-Mobility Industry 4.0

Customer Excellence Digitalization

Digitalization@Schaeffler | ICSM 2018 | November 2018 | Shanghai, China 3

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From Mechatronical to Digital World: Driving Industry 4.0 and Digitalization Schaeffler at a glance

• Initiative „Industry4.0“ as operational unit

• Focus on Mechatronic and Digital Services

• Digital Office as key driver

• Digital Transformation along the entire value chain

• New Digital Solutions

Combination of Mechatronics and Digitalization

Digitalization@Schaeffler | ICSM 2018 | November 2018 | Shanghai, China

Digitalization In

dust

ry 4

.0

Strategic Pillar Strategic Pillar

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Digitalization will be an integral part of our People

Products

Machines

Processes

Services


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Requirements for Smart Factories Schaeffler Digitalization: overview


Factory´s layout Organization

Basic Structure

Production process Material process Information process

Processes/Flow

Building

Building form Construction Characteristics/ design

Areas/Functions

Layout areas Other infrastructure

Energy and Media supply Building Technology

Technical Infrastructure

Software Basic Software Specific software

Information system

Hardware Computer Output Input Memory Connectivity Security

Machine / Work Station

Machine concept / machinery Connectivity Transparency Steering Network Optimization

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Smart Factory approach: requirements from Connectivity to Network Optimization Schaeffler Digitalization: overvie

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1 How we approach Digitalization Schaeffler digital agenda towards customer-centric approach Schaeffler Digitalization: overview

Customer

Advanced Business Models

Digital Platform

Analyses & Simulations

Products & Services

Machines & Processes

User Experience & Customer Value


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Schaeffler digital platform will integrate the entire Schaeffler value chain

Product Development

Supply Chain Management Sales Aftersales

Lifetime prediction

Manufacturing Service

Digital Platform

Integration of Schaeffler value chain based on data and information

Schaeffler Digitalization: overview


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Technology Configurator

Holistic Process Optimization

Connector for sensorization Connectivity Standard HMI Information

Management Sensorization &

Optimization


Digitalization @ Production Technology


Enabler Visualization Transparency Single Machine Production Lines Know-How Database

Edge Computing Machines and IT Services

Unified Operating System

User Specified Needs Production Processes

Optimization Process Chain via Machine Communication

Optimal Requirement Based Value Stream

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Productivity in production

Grinding

Joining Forming

Plastics

Milling

Turning Heat Treatment

Additive Manufacturing

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Digitalization @ Schaeffler

The Machine Tool 4.0 as a part of a digitalized production cell

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tool set-up / measuring 3D measuring / inspection

laser marking system

electrified clamping system

machine tool 4.0

Digital connection of all physical cell objects and sensors enables big data and analytics


machine tool 4.0

digitalization of machining process as enabler for

analytics

3D measuring / inspection

digitalization of dimensions as enabler for analytics

tool set-up / measuring

digitalization of tool management

laser marking system

individualization of every part as enabler for analytics

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Components and solutions for turnkey solutions

Predictive maintance Condition monitoring

Mechanics Mechatronics Digital Solutions

Mechanic components

Condition Monitoring

Predictive Maintenance

Mechatronic products

Mechatronic systems

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Project i4.TP: Turnkey approach focuses on configuration, implementation and operation for turnkey systems


configuration Implementing Operation

Product to build Customer

Feature extractor

Turnkey configurator Turnkey Builder

Machine Conmmunication

Devices Module

Machines

Turnkey system for product

/MAP /PRO

All r

ight

s re

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Sch

aeffl

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echn

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AG &

Co.

KG

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part

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autinity software suite: Portfolio overview


Schaeffler Digital Solutions at a glance

Field Vibration Sensors

Vibration Recording

Integration of PLC

Pre-Processing Data

Recording Part Type, Work

step, Machine Stop, Vibration

to Noise, Crash Detection

PLC

IPC

Control Service

Station

Server

Field

Control Service

Station

Work Center

Four different Sensors

Recording Sensor Data

Integration of PLC

Pre-Processing Data

Time signals, Event Monitor

Transfer to PLC (Recording Part

Type, Spindle Speed, Work step)

Vibration Vibration Thermo Fluid Energy

PLC

IPC IPC

IPC

IPC

Condition Monitoring

Predictive Maintenance

Damage Pattern recognition VibroControl: focus on manufacturing process

autinityCMS: focus on condition monitoring

ERP-Systems (e.g. SAP) SAP

Interface to ERP

Interface to ERP & cloud cloud Connected World Connected World

ERP-Systems

autinityCCS: focus on control and optimization of manufacturing processes Condition-based Control System

Process Analysis

Control Functions

Data Analytics

All r

ight

s re

serv

ed to

Sch

aeffl

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echn

olog

ies

AG &

Co.

KG

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part

icul

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Avoidance consequential defects

Avoidance consequential crash

Repearing/Replacement of spindle in planned time


Customer Benefits

Lower Repairing Costs

Lower Inventory Costs

Avoid Bottleneck Production

Optimization Maintenance Tasks

Avoid Production standstill

Process Optimization

Logging number of valve circuits for air

Vibration and Temperature

Vibration and Temperature

Vibration Monitoring

OFF

ON

Metal forming Detection and prediction

of cushion wear

Save planned machine downtime

Faster schedule maintenance

saving compressed air

Metal cutting Early detection of spindle

crash/breakdown

Metal cutting Early detection of spindle

bearing defects (Roll bearing)

Heat Treatment Early detection of motor

bearing defect

Repearing/Replacement of spindle in planned time

Avoidance of consequential crash of spindle

Avoidance on spontaneous production loss

Avoidance of maintenance tasks during production time

autinityCMS – Vibro Control

Use cases within Schaeffler production sites (samples) Schaeffler Digital Solutions at a glance

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Thank you for your attention!


Schaeffler Technologies AG & Co. KG | Schaeffler China

Matthias Hafner Director Digitalization Greater China

digitalization@schaeffler: smart factory solutions · schaeffler digital platform will integrate...

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