industry 4.0 pai
DESCRIPTION
Fourth Industrial revolution - Cyber Physical Production Systems - Internet of Things and Factory of the FutureTRANSCRIPT
Keynote Address:
Industry 4.0:the Internet of Things
Smart Factories
From to
JAYESH C S PAIMSME TOOL ROOM, KOLKATA
© DFKI GmbH
The German Future Project: Industry 4.0 Industrial production is the backbone of Germany‘s economic performance:
Germany is preparing the 4th industrial revolution based on theInternet of Things, Cyber-physical Production Systems, and theInternet of Services in Real industry.
Exponential growth of data
This is how we see our world
This is how we should see our world
From Industry 1.0 to Industry 4.0: Towardsthe 4th Industrial Revolution
FirstMechanicalLoom1784
mechanical production
water and steam
End of18th
Century
t
Deg
ree
of
Co
mp
lexi
ty
1. Industrial Revolution
facilities powered by
Industry 1.0
From Industry 1.0 to Industry 4.0: Towardsthe 4th Industrial Revolution
FirstMechanicalLoom1784
Industry 1.0water and steam
End of18th
Century
Start of20th
Century
t
Deg
ree
of
Co
mp
lexi
ty
2. Industrial Revolutionmass production based on
the divisionof labour powered by
electrical energy
Industry 2.0
1. Industrial Revolution through introduction of
mechanical production facilities powered by
From Industry 1.0 to Industry 4.0: Towardsthe 4th Industrial Revolution
Industry 3.0of production
FirstMechanicalLoom1784
Industry 1.0water and steam
Start of70s
End of18th
Century
Start of20th
Century
t
Deg
ree
of
Co
mp
lexi
ty
3. Industrial Revolution electronics and IT and heavy-
duty industrial robots for a further automization
2. Industrial Revolutionthrough introduction of mass
production based on the division of labour powered by
electrical energy
Industry 2.0
1. Industrial Revolution through introduction of
mechanical production facilities powered by
From Industry 1.0 to Industry 4.0: Towardsthe 4th Industrial Revolution
001010100100101010
Industry 3.0of production
FirstMechanicalLoom1784
Industry 1.0water and steam
Start of70ies
End of18th
Century
Start of20th
Century
today t
Deg
ree
of
Co
mp
lexi
ty
010001101
010010101
4. Industrial Revolution based on Cyber-Physical
Production Systems
Industry 4.03. Industrial Revolution
through Introduction of electronics and IT for a further
automization
2. Industrial Revolutionthrough introduction of mass
production based on the division of labour powered by
electrical energy
Industry 2.0
1. Industrial Revolution through introduction of
mechanical production facilities powered by
The Industrial Revolution
Industrial Revolution Hearths• The iron industry was first to
increase production through extensive use of (James) Watt’s steam engine, plus other inventions.
• The textile industry followed.
• From these two pioneering industries, new industrial techniques diffused during the nineteenth century.
Fig. 11-1: The Industrial Revolution originated in areas of northern England. Factories often clustered near coalfields.
SELLING PRICE-
COST PRICE=
PROFIT
Towards Intelligent Environments based onthe Internet of Things and Services
4) Embedded Computers Smart Factory
1) Central Computer 90% of all3) Smart Phonecomputers areembedded
2) PC, Notebook Smart Card
1 Computer1 User
Many UsersMany Computers, 1 User
20201960 20001941 1980
5) IntelligentEnvironments
4) Embedded Computers Smart
1) Central Computer 3) Smart Phone
2) PC, Notebook Smart Card
1 Computer
1 User Many Computers,
Vision: Internet der Dinge
Intelligente Umgebungenz.B. Smart City
Future Project Industry 4.0
500 M€ for 3 YearsNational Program:250 M€ Funding of Ministry for Research and Ministry for Economics
Evolution fromEmbedded Systems to Cyber-Physical Systems
Cyber-Physical SystemsEmbedded Systems
Intelligent Environments/Smart SpacesDigital City
Cyber-Physical SystemsSmart Factory, Smart Grid
Networked EmbeddedSystemsIntelligent Street Crossing
Embedded Systems
Airbag
National Roadmap
Agenda
Internet of Things
Iron Man Suit
Talos in Greek mythology
Liquid ArmorIt is liquid under low or normal pressure and solid under high pressure. This liquid is made with polyethylene glycol and the solid part is made of nano-particles of silica. This liquid is soaked into all the layers of a Kevlar vest.
Industry 4.0: Smart, Green, and Urban Production
Smart ProductionHigh-precision, superior
quality production of high-mix, low volume smart
products
Urban ProductionGreen Productionclean, resource-efficient,
and sustainable
Smart Factories in the cityclose to the employees‘
homes
What is Smart Manufacturing?
A future vision
…the integration of data…
Smart Manufacturing is:
…with process expertise…
…to enable “evidence based” management…
…of manufacturing.
Internet der Dienste
© DFKI GmbH
The Internet of Things and Services as aBasis for the Smart Factories in the Industry 4.0
Products
Plattform
Internet of Things
Smart
App
SmartMaterial
AppPlattform
Semantic PLM-, SCM-, CRM-, QMS- and
ERP-Services SmartFactory
App Plattform
Cyber-PhysicalProduction System
Internet of Services
Pipelines of Smart Factories for Industry 4.0based on Secure Networks of Clouds
…
Machine 1
Secure CloudNetworks
SmartProducts
SmartMaterials
Smart Factory 2…N
Smart Factory 1
M2M- Comunication
Smart … SmartMachine N
Application Plattform for Machines
Cyber-Physical Production Systems
CPPS
Raising the Level of AbstractionIf Smart Manufacturing is such a smart idea why aren’t companies
already doing it?
What is Smart Manufacturing?
Business (Collaboration, Broader MetricsReal-time Decisions)
Technology(Horizontal & VerticalPervasive)
Workforce(Innovation & Broad-Based)
OrganizationalMindset
21st Century Smart Manufacturing
Data
Analyze
Model
Apply
• Demand-dynamic economics keyed on the intelligence of the ‘customer’
• Coordinated enterprise responses throughout the entire manufacturing supply chain
• Predictive, preventive
• Integrated computational materials engineering
• Performance-oriented enterprise,
minimizing energy and material usage and maximizing environmental sustainability, health and safety and economic competitiveness
Dramatically intensified application of manufacturing intelligence using advanced data analytics, modeling and simulation to produce a fundamental transformation to transition/new product-based economics,
flexible factories and demand-driven supply chain service enterprises
SMLC Priority: Situational Awareness performance tools across the enterprise to manage dynamic production, use,
and storage of essential resources (energy, water, air)
Supply ChainDistribution Center
Customer
Business Systems, ERP
an interconnected world… voice, data, mobile, etc.
Smart Grid
Smart Factory
Modern, smart factories will be interconnected with supply chain, distribution and business systems
SMLC Priority: Production and Demand-Dynamic Supply Chain Efficiency - At Scale Virtual Supply Chain Planning, Computational Materials Engineering and Product Tracking & Traceability Tools
Manufacturing Plant
Supply Chain
Customer
Distributor
Farming
Mining
SMLC Priority: New Productivity/Efficiency Metrics – Change from output/input productivity measures to customization, flexibility, responsiveness, energy performance and reuse
• Customers “pushing” demands• Flexible production of smaller volumes of custom products • Less vertically integrated• More information driven and automated
Smart Manufacturing is the Application of a Manufacturing Industry Internet
Supply ChainDistribution Center
Customer
Business Systems, ERP
Smart Grid
Smart Factory
New Degrees of freedom forPerformance, efficiency and productivity
Anticipate, plan,manage riskacrosssuppliers
Merging actionablebusiness &Operationsinformation
New formsequipmentbenchmarking
Tracking &traceability
New real-time globalperformancemetrics
Old Traditional Factory• More jobs: labor-intensive• Lower output and productivity• Lower quality products• Lower paying unskilled jobs• Higher risk working conditions• Higher environmental impact• Higher production costs• Rigid, high-volume production• Longer time-to-market• Socially optimized (Six Sigma)
New Smart Manufacturing Plant• Less jobs: automation-intensive• Higher output and productivity• Higher quality products• Higher paying skilled jobs• Safer working environment• Less waste, resource use• Lower production costs• More flexible customization• Faster time-to-market• IT-optimized (models, simulation)
Attributes of a Smarter Manufacturing Sector
21st Century Manufacturing EcosystemMuch Greater 3x to 15x+ Economic Multiplier - Smart Manufacturing: The Essential Nucleus For SME’s & The Service Economy
100% automated Intel Chip FAB – Some engineers and technicians
Smart Factory
Innovation and specialties 25% automated 75% labor
Small Businesses
Components and other suppliers 50% automated, 50% labor
Medium-size Manufacturers
Financial, IT Services, Consulting, etc. 100% labor
Services & Support Community colleges and Universities, healthy knowledge workers, public-private partnerships
Education, Health Care and Government
As Factories Get Smarter, More Jobs Surround Them
Products with Integrated Dynamic Digital Storage,Sensing, and Wireless Communication
The product as an information container
CapabilitiesI wasproduced on30 April 2010 and shipped on 3 May 2010– The product carries information
across the complete supply chain and its lifecycle. Grasp at
the middleThe product as an agent
– The product affects istenvironment
2 mins openPlease close!The product as an observer
– The product monitors itselfits environment
and
Service-oriented planning of plant systemsHardware-independent planning of plant systems
ERP Enterprise Resource Planning
MESManufacturing
Execution System
Field Layer
Service Library
Sensor-Service Valve-Service Pump-Service Control-Service Communication-Service
Industry 4.0: All-IP Factories, no chaos of field buses, Internet-based Factory Networking based on IoS and IoT
Abstract Servicehardware-independent
Device Controlhardware-dependent
The SmartFactory Shop Floor: Wireless,RFID-, Sensor- and Service-based Architecture
continuous flow process discrete handling processbottling, handling, labeling, QC, packaging…
Live Webcam: http://www.smartfactory.de/webcam.de.html
discrete handling procebottling, handling, labeling, QC, p
continuous flow procecolored soap production
Data Mining and KnowledgeSmart Factories
Manufacturing stores more data than any other industrial sector.Close to two exabytes of new production data were stored in 2010 from multiple sources:
Discovery in
•
•
instrumented production machinery
supply chain management systems
• product life-cycle systems
New ICT Coordination Action of EU:
BIG: Big DataPublic PrivateForum
Industrielle Assistenz- systeme
Human-Centered CPS-based AssistanceSystems for the Smart Factory
Physical Assistance by Exoskeletons
Mobile, Personalized,
Situation-Adaptive,
Tutoring Systems
Context-adaptive Assistance for Fault Diagnosis
AR/VR/DR- Assistance in Complex Work
Processes
Multimodal Human-Machine
Interaction
Location-based Maintenance and
Planning Assistance
App Stores for the Smart Factory: DownloadingTailored User Interfaces for User Groups:
Supervisors…Elderly, Trainees, Disabled,
Location-based Industrial Assistance Systems in SmartFactories for Resource Efficiency Improvements
Industrial Environment
Advanced Industrial Assistant Systems Basedon Augmented Reality Technologies
Industrial Workerwith Google Glasses
Mobile, Interactive and Situation-Aware
Tutoring
Tools
Augmented Reality Systems Supporting Maintenance Staff
Industry 4.0: Robots are no Longer Locked inSafety Work Cells but Cooperate with Human Workers
Today
Tomorrow
A new generation of light-weight, flexible robots collaborate withhumans in the smart factory
DFKI’s Fembot AILA: Using the Semantic ProductGrasping and Smart ProductMemory for
AssemblyAdaptive
Stereo Cameras in the Head and a 3DCamera on the Torso for Approachingan Object
Readingfrom the
Size, Weight and Lifting PointsProduct Memory with an
antenna in the left hand – the Robotgets instructions from the product beingproduced in the CPPS
W3C Standards as a Basis for the Project ofthe Future Industry 4.0
Product Memory
Standardization
EMMA: Multimodal Industrial
Assistance Systems
Industry 4.0
Smart Factory
OMM:Semantic
USDL: Semantic Services in Cyber-Physical
Production Systems
111010010101101101101100010000010010000111101001001101010010010010010101010101011000100010010010100101000100010
10011101000000000000000000000000000001100100101001010000010011111110101011
0001001001001001001010100100111011001010101101001001001010010010010010010
00100100101111111110101011101111111001101011111110100000000000010010010000101000000000100000000010010101010100100
The Software-defined Car: Customizinga Car Environment
Android Market
through AppsApp Store
IntelligentUser
Interface Apps
MotorManagem
entApps
DriverAssistan
ceApps
GreenDrivingApps
1001010110111010001010010010010010001000111101001011111111011111111111110001011100111111101000101001111011110001111111101001101111101001001010
10010010010011101010100001001101001001001000110010000000000010001000
00010010001001001010100110101011101001001001001010110011010111010010010010010111111001111001 1
00000000100100101001111111111111101000010101001101101010100111110111010100100100100100100100
1111100000000001001011011 01010000100101001111010
1001000110110
© DFKI GmbH
BMW Apps: Integrating the Most RecentWeb Services Into the Car Environment
Source: BMW
Conclusions
1. High-precision, superior quality production of high-mix, low volumesmart products are the future of Europe’s successful export-oriented economies like Germany.
2. 80% of the innovations in manufacturing are based on ICT. They willlead to Smart Factories, Green and Urban Production.
3. The fourth Industrial Revolution will be based on cyber-physical systems,the Internet of Things and the Internet of Services. It will generate enormous BIG data streams that can be harvested and analyzed for resource-efficient and ultra-high quality production.
4. CPS-based industrial assistant systems are needed to support, helptrain the next generation of workers in smart factories.
and
5. Augmented and dual reality systems allow individualized workflows andfast learning of new production processes.
Thank you very much for your attention.
THANK YOU METALLIX & JADAVPUR UNI