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Industry 4.0Discover what's behind it

2 Industry 4.0

3The fourth industrial revolution

Industry 4.0 – The fourth industrial revolutionThe significance of Industry 4.0 for the process industry

Some say "Industry 4.0 represents a quantum leap in industrial production and will have key effects on all areas of production, as well as on our working world." However, others claim that "Industry 4.0 is not a revolution, but at best an inevitable evolution that results from the further development of technologies." The fourth industrial revolution – it is hard to think about another topic that polarizes experts from the economy, as well as the fields of production and automation quite as much as this part of the German government's high-tech strategy. But what lies beneath the veil of this strategy, which is intended to take Germany to the top of the international table in key technologies?

A wide array of topics Media reporting and lectures held on Industry 4.0 predominantly focus on technologies and concepts to automate manufacturing operations. Here, a workpiece might itself dictate which manufacturing steps it is to pass though and on which machines. This is because the production machines needed for this know their current schedule and what they are capable of, which enables them to offer corresponding services to the workpiece. "Swarm intelligence" and "batch size 1" are other terms often used in this context. The objective is to establish self-organizing, self-optimizing, extremely flexible manufacturing operations, which can adapt to individual customer wishes both quickly and economically.

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But which concepts and technologies are used in the process industry? In some cases, huge plants are constructed here to produce just a few or even just one single product. Customer-specific modifications, flexible production paths or even single-item series are either difficult or impossible to implement here. So does Industry 4.0 also offers concepts for the process-engineering industries?

"Computerizing" production At first glance, the models of production engineering and the process industry appear markedly different. However, these areas have one thing in common: Digitization of production and associated integration via the Internet. Digitization is what makes data available to information technology systems, while integration allows this digital data to be networked in a meaningful manner. Collecting and networking as much distributed production data as possible allows new, beneficial and targeted information to be gained. This targeted information can then be used to design significantly more efficient production processes – which is precisely the objective of Industry 4.0 in the process industry.

4 Industry 4.0

Big data in production operationsMore efficient production through collection, networking and evaluation of as much production relevant data as possible

Data is the fuel that powers Industry 4.0. Information from all potential worldwide sources that could have either direct or indirect effects on production and form the basis for this. This collective knowledge (referred to as big data) contains production relevant information such as resources, customers, suppliers or operating data.

However, additional data such as weather forecasts, stock market information or vacation dates would also be useful here. Although this kind of data does not have a direct influence on production, it can help predict future requirements more accurately. The right data then needs to be filtered from this large data pool and analyzed for the individual tasks at the company, so that targeted and useful information can be generated for production control.

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The three axes of Industry 4.0

Horizontal integrationalong the added value networks beyond production processes

Vertical integrationof all relevant business, production and automation processes

End-to-end engineeringthroughout project planning and the entire lifecycle of devices and systems

Three data axes of a company: The data and information generated along these axes must be networked and integrated into the respective procedures for efficient production.

5Big data in production operations

Complete data integration Efficient production therefore requires a great deal of data and information – huge volumes of which are already available at all production facilities. However, the problem is that this data/ information is generally spread across various systems, often in formats that are not compatible with one another. The key now is therefore to network these standalone systems with one another and prepare the data on the systems in such a way that it can be exchanged between them.

Data integration affects all levels of a company, whether engaged in production and/ or processing-engineering. Vertically, this integration extends from the field device in production up to the ERP system (Enterprise Resource Planning, e.g. SAP). Horizontally, it passes through the entire added value chain from the suppliers of raw materials to the end customer. For end-to-end engineering, data is linked from the first planning phase for systems and their networking, all the way through to decommissioning.

The following section explains for each of these three data axes within a company (horizontal integration, vertical integration and end-to-end engineering) how the corresponding data is typically managed at present, what is already possible with current concepts and solutions, and what the information management practices of Industry 4.0 might look like. Of course, nobody can say for sure exactly how the future will look like, but at least we already know one thing for certain:

With products, solutions and services from Endress+Hauser, you are already well-equipped to handle whatever the future brings.

6 Industry 4.0

Horizontal integrationRecognizing and managing flows of materials and goods throughout the entire added value chain

High stock levels guarantee high delivery performance, although also result in higher warehousing costs. Conversely, low stock levels reduce costs, but increase the risk of not being able to comply with the requirements of the delivery service. It is often difficult to strike the right balance here, particularly in markets with fluctuating requirements. Planning and replenishment processes require up-to-date and transparent inventory data throughout the entire added value chain in order to adapt to market requirements.

Horizontal integration

Along the added value networks beyond production processes

Suppliers Freight-forwarding

services

Raw materials warehouses Production Goods

warehouses Logistics Customers

Future management of the added value chain

Prices for raw materials Market trends Stock exchange

data Forecast data Customer requirements Production planning

Information on the entire added value chain

RequirementsLogistics

InventoriesCosts

ContractsQuality

Delivery timesDeadlines

AvailabilityTrends

Information on the entire added value chain

Suppliers Logistics Raw materials warehouses Production Goods

warehouses Logistics Customers

Managing the entire added value chain with SupplyCare

Inventories Contracts Delivery times Availability Logistics Costs

Flow of materials and goods

7Horizontal integration

Flow of materials and information The flows of information between the producer and its customers and suppliers are frequently not end-to-end. Data and information are often not accessible at the time or location where they are ideally required. The flow of materials and goods then automatically suffers, as it is directly

Efficiency-enhancing solution Endress+Hauser offers a cloud-based data management solution for the entire added value chain: SupplyCare. With this solution, all relevant data is collected, evaluated and distributed in

dependent on the flow of information. Optimizing the flow of materials and goods therefore requires a higher-level solution, in which all information throughout the entire added value chain is managed in a single system.

a central system. This facilitates an end-to-end flow of information, which in turn leads to an optimized and fluid flow of materials and goods.

Big data in the added value chain SupplyCare represents a first step toward Industry 4.0. In future, this cloud-based solution concept already employed by SupplyCare will simply be extended. Additional information which might impact production is imported from the Internet and integrated into the cloud. After all, even

non-production-related data such as weather forecasts can potentially have a significant influence on sales in several sectors, such as the construction industry, or with specific products such as road salt.

8 Industry 4.0

Vertical integrationEnd-to-end integration and networking of information throughout the entire operational environment

A barrier-free data flow through all levels of a company opens up completely new opportunities. Precise diagnostics of measuring devices is a good example here, as this can be used as the basis for triggering automatic preventative maintenance measures or calibration requests. Management of a system's field devices with automatic database entries for events such as repairs or calibration is another example. Intelligent networking of various subsystems, from ERP systems all the way up to the field level, is of key importance here.

However, reality often looks quite different. It is characterized by closed standalone systems, missing interfaces and a large number of manual data transfers and thus potential error sources.

Vertical integration

of all relevant business, production and automation processes

CMMS

Cloud• Data transparent and available to all• Securing the quality of interventions

Central process and system controlIncreased system efficiency

High degree of flexibility and ease-of-useFast local access to information thanks to modern technologies

Communication of the future

9Vertical integration

Simple data exchange For data transfer from one system to another, the middleware receives the source data and uses a planned matrix to determine which target systems are to be connected with this data. It then establishes

a connection with the corresponding target systems, translates/ converts the source data to the target system's data format and forwards the prepared information to the respective target systems.

End-to-end flow of information The business process integration concept from Endress+Hauser already enables decoupled standalone units to be elegantly connected to create an overall system with end-to-end data flow.

Diagnostics

ERP data

Maintenance

Production data

System status

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End-to-end flow of information using an integration module as middleware

Middleware is used below the subsystems and thereby creates a shared platform for data exchange between these systems.

Communication of the future In one interpretation of Industry 4.0, a cyber-physical system (i.e. a network in which all system components communicate with one

another via the Internet) is created from the automation pyramid. An integration module will assume the role of central control element for operational data traffic here.

10 Industry 4.0

End-to-end engineeringEfficient networking of engineering data throughout the entire lifecycle of devices and systems

To remain competitive in future, operators need more efficient and economical networking of their production units, as well as all people and machines involved in the process. One of the key topics in this regard is end-to-end engineering of production units – from system planning, to the operation phase and through decommissioning.

End-to-end engineering

Throughout project planning and the entire lifecycle of devices and systems

Information on the entire lifecycle

Engineering Procurement Maintenance

Managing engineering information with W@M

Product and system lifecycle

Cross-trade Integration into systems Corporate world

Engineering data management of the future

Information on the entire lifecycle

Product designMeasurement point info

PricesMaintenance cycle

Delivery timesDevice documentation

AvailabilityCertificates

Device infoSpare part info

Manufacturer data Cross-platform Virtual wiring, test and simulation

Product designMeasurement point info

PricesMaintenance cycle

Delivery timesDevice documentation

AvailabilityCertificates

Device infoSpare part info

11End-to-end engineering

Distributed engineering information In practice, there is generally no end-to-end data flow for engineering data. Instead, information is processed and saved locally or within the respective department. Each department retains this information for itself or only passes it on to downstream departments/ processes via "information notices". Procurement of this information is also performed individually and thereby often leads to unnecessary and

avoidable costs. In addition to this, incomplete forwarding of information increases error rates, which in turn can have a negative impact on decision-making processes. Optimizing the flow of information therefore requires a higher-level solution, in which all information on the entire lifecycle of products is managed in a single system.

Efficiency-enhancing solution Endress+Hauser offers a cloud-based solution for digital engineering: W@M (web-based asset management). All relevant data is summarized in a central system here, to which everyone involved in the

process has access. This facilitates a time independent and person independent flow of information, which in turn leads to optimized, end-to-end lifecycle management.

Engineering of the future The W@M Portal is a first step toward Industry 4.0. This kind of cloud-based solution concept, which the W@M Portal already represents, will be retained in future and also connected to other open

systems. Additional information required by a department can simply be uploaded to the cloud and is then available centrally to everyone involved in the process.

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