Industry 4.0 – Open your mind to ”Robot Revolution” and related new Business Models Smart System driven transformation for growth within EU, Japan and US and related Business Intelligence development for new cognitive factory and business models«

MINDTREK 2016Tue 18thKai Salminen. Hermiagroup, New Factorykai.salminen@hermiagroup.fi

 IoT Event WorkshopIndustry 4.0 - Open Your Mind to “Robot Revolution” and Related New Business 

15.15  Opening session : I4.0- is it revolution or evolution; Core ?Teamwork : Is I4.0 change clear to your business 15.45  Break 16.00 How far is I4.0 now and who are doing and what; Reality ?Teamwork :  What are you and your competitors doing 16.30  What to do? How can we join I4.0 ; RoadMap ?Teamwork: Do we need national, domain and company RoadMaps

Industry 4.0 1. Core; What is Industrie 4.0; Transformation, Growth

2. Reality; What are countries and industry doing1. EU

Germany, Austria, Netherlands, Sweden, France, Finland…2. Japan, South-Korea, China3. US, Canada

3. RoadMap; Recommendations for creating domain specific Cognitive and Smart Systems,

Kai Salminen , Hermia Group, New Factory ltd

INDUSTRY (>20 years)• Lännen Engineering Ltd• Finn Avitech Ltd• Tampella Ltd• Metso Ltd• The Federation of Finnish • Technology Industries • Hermia Group New Factory

EU (>20 Years)• Expert Evaluator• Monitor• Foresight• EU projects

BSc Product DesignMSc Production EngineeringMSc Industrial EconomicsDr studies CPPS

RESEARCH (>10 years)• TU Tampere

Hermia Group

• Innovatio Oy New Factory, Non profit support for companies• Tamlink, partnering anf joint ventures

Industry 4.0 Director of the Association of German Engineers (VDI), Ralph Appel

Industry 4.0 & education 4.0 is an umbrella term; nobody yet really knows what I4.0 as Cyber Physical System of systems will look like. One could also say that Industry 4.0 is the first revolution that has been announced and prepared for before it actually happened.

The dual engineering education model “Industry 4.0 & Education 4.0” helps pushing (incremental) innovation in systems through and integrate to market driven domain specific systems of systems solutions platforms.

I4.0 is not only about technology, but about who “owns” interface to the consumer and solutions. If you have access to what the consumer/customer needs and solutions, and you can predict customer/ system behavior, you can develop a competitive advantage. Technology in terms of products, manufacturing and services is also very important, but not necessarily driving this. In I4.0 one need to invest more in business models, based on the relevant Cyber Physical solutions.

I4.0 Robot revolution or evolution

I4.0 DbE Design by Experiment

IEC 62890; Efficiency Increse E=Q/qI

Added Possibiliti

es,

Ideas

IEC 62264, 6

1512,

TQM

ISO

DIN

900

1:20

15

Robot revolutionSmart networked Cyber physical Systems like collaborative robots are the logical next step of a technological revolution.

"A human is an animal plus technology. Humans have two ways to evolve - one is genetic - the other is through technology.

We are changing the definition of humans as we develop this new technology. In Samrt CPS we cannot separate human and robots. We will exist in this world together. • Work becomes so difficult that it can be done only by collaborate systems• Old and handicapped people will no longer need wheelchairs, or stair-lifts, and people with

spinal injuries, blind, deft or otherwise handicapped can access the needed capabilities. • Human-/CPSystems can access lethal worlds in space, ocean, mines, cathastrophes.• Individual local systems can network to global ones and have access to huge resources• Communication and collaboration Human- Technical System- Nature becomes possible

History of Smart Factory; Toyota

FORD /Taylor, Gilbreth, Gantt (Scientific management)Kiichiro Toyoda visited Ford Motor Company in 1930’s

Toyota introduced SQCand quality circles with Ishikawa, Deming, and Juran TWI after 45 Koromo (later called Honsha) Plant in 1937;

introduction of flow production and JIT

Eiji Toyoda visited Ford 1950’

Evolution based manufacturingJIDOKA, Teams, Kaizen, Kanban, Suggestion System

Toyota Central Research & Development Laboratories, Inc, 1960

Toyota Motor Corporation introduced TQC in 1961, and in 1965 were awarded the Deming Application Prize

Taiichi Ohno and Shigeo Shingofor manufacturing development

30

50

70

90

Spin off Denso and emergence of KEIREZU

Toyota's first US plant, NUMMI 1984

Deming Application Prize for quality control 1986

Womac coined LEAN manufacturing60 % US trade deposits to Japan, Commercial crisisIMS project main goal: Japan to relieve international trade problems by giving its advanced manufacturing technology to the US and Europe

Toyota Industrial robots development to production

“Made in America” research, Harvard

Manufacturing 21 Japan ; “we won’t use half-baked ideas to tackle half-cooked problems.”

Toyotas first Environmental Action Plan launched 1993Toyotas Environmental Committee set up 1992Toyotas Introduction of Center system for 21th century needs

1990

2000

IMS Intelligent Manufacturing SystemsJapan, US, EU, Canada, Australia, South Korea

Toyota project G21, 21th century car and factory 1993, CPPS strategy

Toyota CPS Partner Robots in production 2004 Takaoka plant

1997 Prius introduced

1998 FGMS - Future Generation of Manufacturing Systems/IMS

1999 Prius and Tahara, Takaoka and Tsusumi CPPS plants“Global 500 Award,” and several other awards

2000 , 21 th century COE Programme JMS/TPS for Smart Factories formally documented 2001

"The New Toyota Production System 1998 - Leaner Manufacturing for a Greener Planet".

Introduction of complete CS3 with Denso ,2008

27 Toyota factories 1995

G21 Dream car/ factory – that can make the air cleaner than it is, that cannot injure people, that prevents accidents from happening , that can make people healthier the longer they drive it /work in it, a vehicle and factory that can excite, entertain, and evoke the emotions of its occupants, a vehicle that can drive around the world on just one tank of gas and factory that is resilient and sustainable. (Toyota Motors)

2016 • METI “Robots for Everyone Project,” • METI ”New Robot strategy”• Toyota announces $1bn artificial intelligence and robotics plan

2016 Toyota Research Institute (TRI),2011 Industry 4.0

Kiribo in Car Moon Project

2016

Industry 4.0 (I4.0)Everything communicates with everything

Industry 1.0

Mechanisation1.0

1776

Industry 2.0Electricity and electronics

1.01880

Industry 3.0

Computing 1.0Analog/Digital

Vrtual 1960

Industry 4.0Cognition

Smart/CPS 1990

INDUSTRALISATION

Industry 1.0

Mehch. 2,0 Micromech.

1880

Industry1.0

Mech.. 3.0Nanomechanics

Mechatronics1970

Industry 1.0

Mech. 4.0 Bio Organic

1990

Industry 2.0

E+e 2.0 Semiconductors

Photonics1955

Industry 2.0

E+e 3.0Organic

/Hydrogen2000

Industry 3.0

Computing 2.0A/D/V, AI

Propabilistic1990

2. Wave

•Electr

ical

•Chemica

l

•Engines

4. Wave

Informatio

n

Servi

ces

V

irtual

5. Wave:Cognition/KMCPS/Robotics/IoTOrganicHydrogenLimited Resources

• Collaboration• Symbiotic• Localisation• Circular economy• Bio- /organic• Spacetech• Oceantech• Arctictech• Undergoundtech

3. Wave

•Mecatro

nics

•Energy

•Materia

ls

1. Wave

•Steam

•Railw

ay

•Steel

•Machines

How I4.0 Changes world, RWTH Aachen

Industry 4.0 (I4.0)Everything communicates with everything

Smart SystemsCyber Physical Systems (CPS)

Smart CitiesSmart Growth

Smart Robots, Cars, IoT..

Smart FactoriesHospitalsMinesOceanSpace..

Adaptive Intelligent ApplicationsMachine learning applications and analytics

Smart =Sense – Think - Act

CommunicateCollaborateLearn-Teach

Identify

• Each functionality independently of location,

• context-aware,• in accordance with the requirements

and situation• semi-autonomously,• in a semi-automated manner,• multifunctionally.• in a distributed and networked manner,• learning and teaching

The rise of Intelligent systems

”What Industrial revolution did to human,

Industry 4.0 will do to machines”; Ian Morris

Watt Steam Engine 1775Global population explosion

Social development

CIRCULAR ECONOMY / COLLABORATIVE SYSTEMS

SOCIAL- / ECOSYSTEM

TECHNICAL SYSTEM

Industrie 4.0 change the role of people within industrial sosio-technical ecosystem and requires to develop new skills and acquire new tools; Industry 4.0 & Education 4.0.

Industrie 4.0 gives the chance to keep industrial value creation in Europe through ”Coopetition” (Cooperative competition) over domains;Infrastructure, structure and superstructure jobs; Domain specific OWLs

Industry 4.0 creates possibilities also there where there has been none before; very demanding and difficult places, tasks, products and systems, assistance for handicapped, collaboration with human, technical systems and nature, concrete and virtual; Design by Experiments

Industry 4.0 and human jobs; Aachen RWTH”Ideas, Possibilities and Efficiency” : Von Förster on Cybernetics

I4.0 is a Standard for Smart Systems Standardization Council Industrie 4.0• Bundesverband Informationswirtschaft,

Telekommunikation und neue Medien (Bitkom)

• Deutsche Institut für Normung (DIN), • Deutsche Kommission Elektrotechnik

Elektronik Informationstechnik (DKE), • Verband Deutscher Maschinen- und

Anlagenbau (VDMA),• Zentralverband Elektrotechnik und

Elektronikindustrie (ZVEI)

I4.0 platforms;German; http://www.plattform-i40.de Dutch; http://www.smartindustry.nl French; http://www.usine-digitale.fr/industrie-du-futur Austrian; http://plattformindustrie40.at Swede: http://www.produktion2030.se/Belgian: http://www.madedifferent.be Danisch; http://www.made.dk USA: https://smartmanufacturingcoalition.org/ Norwegen: http://ikuben.no/ Japan: https://www.jmfrri.gr.jp/english/ China; ”Made by China 2025”

How far is I4.0 now and who are doing and what; Reality ?

Industry 4.0 is German driwen and EU wide

DenmarkMADE

?

ARAW ( przemysl40.pl/ )

Education 4.0

Plattformindustrie40

?

?“Industria Conectada 4.0”

NorwegenSPARC2014

?

Plattform Industrie 4.0Concrete recommendations for action for companies and politics

Reference architecture model RAMI 4.0.

Education 4.0 Labour and employment questions

New initiatives emerging out of the network Plattform Industrie 4.0. Labs Network Industrie 4.0

International cooperation in standardization within DIN, ISO, EU China, Japan, US. France…

Concrete instruments and event possibilities for companies. 1. The online map Industry 4.0 (www.plattform-i40.de/I40/Landkarte) with

• about 250 application examples.

2. The new online library Industry 4.0 (www.plattform-i40.de/I40/Online-Bibliothek) 3. Cooperates with associations, chambers and other initiatives and institutions,

• Germany-wide series of IHK (Chamber of Industry and Commerce)events

GERMANY

RE- INDUSTRALISATION STRATEGY PROGRAMMEhttp://www.regeringen.se/regeringens-politik/smartindustri/http://www.produktion2030.se/en/

Four focus areas: (over 300 projects, over 80 Industry 4.0 Companies; Volvo, Sandvik, SKF, ABB….)

1. Industry 4.0 – Sweden Industry to leading position2. Sustainable production- Regenerative development –

Resource efficiency, Circular economy Environment regeneration; resulting value creation brings jobs and healthy economy.

3. Industrial skills boost- Knowledge transfer to Industry – long sight , long term programmes with best.

4. Testbed Sweden – Sveden as leading in relevant research for Swedish Industry renewal for local manufacturing.

SWEDEN

NETHERLAND , Smart Industry27 themas , 1 mrd euro additional government funding 2016

Japan, https://www.jmfrri.gr.jp/english/

METI Signed a Joint Statement Regarding Japan-Germany Cooperation on IoT/Industrie 4.0 Plattform Industrie 4.0 and its Japanese counterpart – the Robot Revolution Initiative –

• Industrial Cyber Security • International Standardization • International Regulatory Reform • Facilitation for Small- and Medium-sized Enterprises (SME) • Human Resource Development • Research and Development (R&D)

Make Japan the world's center of robot innovation, 1. Reinforcing Japan's ability to create robots2. Japan the world leader in utilizing robots in society3. Demonstration platforms of the new era of collaborative robots that includes the IoT.

FRANCEIndustrie du Futur launched in 2013 by Arnaud Montebourg, then the French minister of reindustrialization. 34 industry-focused projects. In April 2014, Emmanuel Macron, the current minister of Economy, Industry and Digital Affairs has launched the second phase, With total funding of €730m for 2nd phase a new technology platform launched in January 2016. Aim is to strengthen France's collaboration with European and international initiatives, with a particular focus on the European Commission's Horizon 2020 project and the initiation of a partnership with the German platform Industrie 4.0.

Industrie du Futur nine industrial solutions for priority markets are:1. New resources2. Sustainable cities3. Ecological mobility4. Transportation of the future5. Health of the future6. Digital economy7. Intelligent objects8. Digital trust9. Intelligent food

330 sub-projects have been started up as part of the program, involving over 400 companies, with a cumulative projected investment €3.7 billion, including €1.5 billion support from the French state.

USA, In March 2014 AT&T, Cisco, General Electric, IBM and Intel founded the “Industrial Internet Consortium (IIC)” in order to coordinate the priorities for the industrial Internet, and to enable the technical applications required for this. • 250 companies have joined the movement. • The aim is to bring together “operational systems”, which mean machines and industrial

plants in the widest sense of the term, and information technology. • 16 Center of Excellence around US• Miltary adaptations and NASA lead the way

"Made in China 2025" is an initiative to comprehensively upgrade Chinese industry. The initiative draws direct inspiration from Germany's "Industry 4.0" plan, which was first discussed in 2011 and later adopted in 2013. The Chinese effort is far broader, as the efficiency and quality of Chinese producers are highly unevenThe plan was drafted by the Ministry of Industry and Information Technology (MIIT) over two and a half years, with input from 150 experts from the China Academy of Engineering. The plan highlights 10 priority sectors: 1) New advanced information technology; 2) Automated machine tools & robotics; 3) Aerospace and aeronautical equipment; 4) Maritime equipment and high-tech shipping; 5) Modern rail transport equipment; 6) New-energy vehicles and equipment; 7) Power equipment; 8) Agricultural equipment; 9) New materials; and 10) Biopharma and advanced medical products.

CHINA”Made in China”, 13th five year plan 2016

The EU • Horizon 2020 programme• I4MS• EFFRA European Factories of

the Future Research Association

• FET Future and Emerging Technologies Programme

• Sparks

EU Industry 4.0Digitalisation for productivity and growth

Finland, No Industry 4.0 strategy yet but lots of Activities witin Compnanies.

ABB YUMICPPS assembly factories

AGCO POWERCPPS factory

Robot shuttleBus Helsinki

Planmeca3D scanRobot+print

Smart GridFortum

Finland strong in IoT, but I4.0 ?

I4.0 is not digitalisation

I4.0 is about CPS and newBusiness models and Possibilities with them.

I4.0 is about new mentalmodel; paradigm of resilient collaborative Systems of Systems

Strong

Production Engineering 2011

Experiment based Learning:

Self-OrganisationSelf-ConfigurationSelf- Correction

SenseThinkAct

What to do? How can we join I4.0 ; RoadMap ?

• Standards• Education 4.0• Business Model; Ideas, Possibilities, Efficiency• Design by Experiment; Product + Identification + Intelligence +

System + System of systems• Business Intelligence and domain based sTQM & KM• Coopetitive evolutionary growth with customers and

competition.

Industry 4.0 Collaboration

ISO I4.0Industry 4.0: New ISO strategic advisory groupCooperations with the International Electrotechnical Commission (IEC) and the International Telecommunication Union (ITU) are planned The Technical Management Board (TMB) of the International Standard Organization (ISO) in Geneva has now agreed to set up a Strategic Advisory Group (SAG) on Industry 4.0/Smart Manufacturing. The SAG will be chaired by

Prof. Dr. Kai Rannenberg, who holds the Deutsche Telekom Chair of Mobile Business & Multilateral Security at Goethe University in Frankfurt. AFNOR (France), ANSI (USA), NEN (Netherlands), SNV (Switzerland), JISC (Japan), SAC (China), SA (Australia) und BSI (UK) SAG is due to report to the TMB by September 2016 at the latest.

Industry 4.0 Collaboration

Technical System design to CPS, SiemensBuild systems “autonomous”, “information terminal device” and “networked” CPS ones, • Use standardized data-driven devices such as actuators that make it feasible for integrate with distributed

intelligence/control system to offer a range of robot functions in various scenes of customer processes within society.

• Use novel functions, services and features to provide new possibilities to exceed the current capabilities of embedded systems with controlled behavior.

New CPS systems thus provide their services to users and stakeholders:• largely independently of their location,• but nevertheless in a context-aware manner,• in accordance with the requirements of the current application situation• semi-autonomously,• in a semi-automated manner,• multifunctionally and• in a distributed and networked manner.A particularly significant feature of Cyber-Physical Systems is the fact that they are directly integrated into the physical world (“real world awareness”). Cyber-Physical Systems are capable of standardised self- description that allow self-organisation, self-configuration and self- correction using standard mechanisms.

CPS for specific domainsCyber-Physical Systems (CPS) refers to embedded systems, i.e. devices, buildings, vehicles and medical equipment, as well as logistics, coordination and management processes and Internet services that consists of Internet of Things, Data and Services e.g. for Smart Cities, Smart Factories and Smart Logistics etc. configured from embedded systems e.g. airbag, networked embedded systems e.g. autonomous aviation, Intelligent Systems e.g. intelligent networked Fighter that: Sense; use sensors to directly capture physical data and actuators to affect physical processes,Think; interpret and store data which they then use as the basis for active or reactive interactions with the physical and digital worlds, Act and Collaborate;

• are connected to each other via digital networks that may be wireless or wired and local or global, • use data and services that are available globally, • are accessible by a range of multimodal human-machine interfaces, offering a variety of

differentiated and dedicated options for both communication and control, for example using voice and gesture commands.

Experiment (DbE) and BI (Business Intelligence) based design for I4.0; Case ReconCell- I4MS project

Entities => IoT => Intelligence => Systems => Systems of Systems

IMS; CPS Reference Architechture

Evolution of your embedded systems IdentifySense- Think- Act

Communicate Collaborate

Key non-functional features:– Functional safety– Dependability– Usability, controllability (human-machine interaction, shared control)– Valid mental model; users have an accurate idea of what the system is capable of– Compliance – system behaves in accordance with expectations, observes rules, norms and standards, including engineering– IT security issues associated with functionalities in networked systems

Industry 4.0 ; Sense- Think- Act

Business; Total cost of ownership, Productivity, Resiliency, Responsiveness

TCO

System size

CPS ja CPPS www.toyota.comwww.kuka.com

Smart ConstructionKOMATSU

www.komatsu.com

Case Toyota Homes: Smart Homes

Intelligent grid; Energy from fuel cells. Solar panels and even from hybrid car

1. Earth quake resistant, inflammable, affordable environmental bening.

2. Adaptable to changes in life and different life styles3. Factor 4 thinking (2 times better living & 2 times

more sustainable).4. 4R (Recycle, Reuse, Re-furbish, Redesign)5. Smart Systems

100 years LCHouse can be redesigned, refurbished, moved,60 years garantie ..

Supporting columns and beams can be placed freely and space modules are freely variable enabling easy robotised assembly

Earth quake laboratoryDigital modelling, Smart Systems labCustomer involving 3D planning40 days to completion4 days factory time6 hours erection time

ResilientSmart, Recyclable, Adaptable

Adaptable resilient,sustainable houses since 1975.

R. T

uokk

o: C

ompe

titiv

e S

usta

inab

le M

anuf

actu

ring

MC

PC

200

9

Smart Systems, IoT, RobotAccesible and Livable House

CPSPhysical Systems (CPS). CPS are “integrations of computation an d physical processes. Embedded computers and networks monitor and control the physical processes, usually with feedback loops where physical processes affect computations and vice versa.” (Lee, 2008, p. 363).

The development of CPS is characterized by three phases: 1. The first generation of CPS includes

identification technologies like RFID tags, which allow unique identification. Storage and analytics have to be provided as a centralized service.

2. The second generation of CPS are equipped with sensors and actuators with a limited range of functions.

3. CPS of the third generation can store and analyze data, are equipped with multiple sensors and actuators, and are network compatible, collaborate and learn.

(Bauernhansl, 2014, pp. 16–17).

Siemens atHannover Messe

I4.0 DbE Design by Experiment

IEC 62890; Efficiency Increse E=Q/qI

Added Possibiliti

es,

Ideas

IEC 62264, 6

1512,

TQM

ISO

DIN

900

1:20

15

Virtual/Real D/V/RPartner

Informaation

D/V/RPartner

IMPLEMENTATION

CONCEPT

INTENTION

Time to MarketTime to QualityTime to CostTime to VarietyTime to VolumeTime to UpgradeTime to Skill

Self-Configuration Self-correctionCPS, IoT, AI Self-Organisationi

Systems

I4.0 InfrastructureI4.0 Strukture I4.0 Superstrukture; Standards, norms, legislation

Smart Factory

Digital/Virtual

I4.0 within Smart Systems

ReconCell I4.0 Learning and teaching systems

Sense-Think-Actmodel predictive control (MPC)

Case ReconCell, I4.0 platform KNOWLEDGE Pool

Domain Semantics, OntologiesBPM (sBPMN/BPMI/BPEL)Digital/ Virtual/ Real data

KPI Sets

CABABILITY PoolDigital: Softwares, SystemdataVirtual: BP Modellers/Simulators: (I4MS, ReconCell)Real: Systems, Modules, Tools,…

COLLABORATION PoolReconCell Consortia

Integrators, I4MS HubsEnd-users

COMPETENCE PoolReconCell/ I4MS Hubs

Integrators/ technology providers Education platform

INFORMATION FLOW VALUE FLOWORDER DELIVERY

Q

CONFIGURATIONPROCESS KPISelf- Configuration

NETWORK KPISelf- Organisation

q

MANAGEMENT KPI QUALITY KPISelf- Organisation Self- Control

ORDER

DELIVERY

Digital /Virtual Digital/Virtual/Real

Case ReconCell; Capabilities needed

Case ReconCell; Intelligent Field Agents

Case ReconCell, Evolutionary processDbE Design by Experiment

New TechnologyNew ProcessesNew Network of cognitive entitiesNew Information process

New CapabilitiesNew CompetencesNew CollaborationNew Knowledge

New smart entities, infrastructure and superstructure

New way of sensing, thinking and acting

CompetitivenessProfitabilityGrowth

New Business ModelsNew PossibilitiesNew Markets

Example; Symbiotic Business ModelCase Yokohama Mobility "Project Zero" (YMPZ), Yokohama City, Nissan Motor Co., Ltd.,

Case; EcoModelCity programmeSmart City

I4.0 Case ReconCell; Coopetitive development

ReconCellproject

RWTH Aachen Test factory

Robot Dalen BOC, OdenseeTest factory

Industry 4.0 based development1. Road Map2. Coopetitive network3. Investment in

1. I4.0 technology2. I4.0 knowledge3. I4.0 competence

4. Education 4.05. DbE Design by Experiment =Field Lab process Hermia,

TampereBI platform

IJSLjubljanaTest factory

Platform Industry 4.0

MADETekes

EUHorizon 2020I4MS

Gostop

5 Case companiesReal Process

16 IoT module providers

6 I4.0 system providers

Case ReconCellCOOPETITIVE DEVELOPMENT

PLATFORMKnowledge, Capabilities, Competences,

Network sharing

Company 1

Systems

Company 2 Company 3

Systems Systems

Thank You !And now you know