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A Realization Guideline forIndustrie 4.0Prof. Dr.-Ing. Reiner AnderlDepartment ofComputer Integrated Design (DiK)Faculty of Mechanical EngineeringTechnische Universität DarmstadtOtto-Berndt-Straße 264287 .2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl
A Realization Guideline forIndustrie 4.01. Introduction2. Approaches for Implementation of Industrie 4.0 Implementation Recommendation Plattform Industrie 4.0 Sample Solutions Efficient Factory 4.0 Competence Center Mittelstand 4.03. The VDMA Guideline Internal Competence Analysis – External Perception AnalysisToolbox ProductsToolbox ProductionStrategic Orientation towards Industrie 4.0Business models4. Summary05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 2
A Realization Guideline forIndustrie 4.01. Introduction2. Approaches for Implementation of Industrie 4.0 Implementation Recommendation Plattform Industrie 4.0 Sample Solutions Efficient Factory 4.0 Competence Center Mittelstand 4.03. The VDMA Guideline Internal Competence Analysis – External Perception AnalysisToolbox ProductsToolbox ProductionStrategic Orientation towards Industrie 4.0Business models4. Summary05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 3
Development of information andcommunication technology (1)Hypermediahyperlinked documentsMultimediahyperlinked mediaSocialmedia (1)networking 5)(1999)(2006)(1994)World Wide WebWeb1995Java, UML, XMLWeb 1.02000Web ServicesWeb 2.02005Source: Dr. Dais, Bosch05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 4
Development of information andcommunication technology (2)Socialmedia (2)networkingcompaniesCyber-Physical Mediainterconnected andcommunicating systemsFuture Media?App technologyIndustrie 4.0componentWeb 3.0Web A.BWeb X.Y20102015202005.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 5
Approaches for smart systemsImprovement of the added valueBased on functional integrationFurther improvement of the added valuebased on cyber-physical systemsSensorAktorMechanicsMControllerAdaptive controllerMechatronicsAdaptronicNetworked and communicating systemsSmart PlantSmart FactorySmart CityCyber-physical systems supportnetworking and communication Condition MonitoringSource: TU Darmstadt, Effiziente Fabrik 4.0Smart GridSource: TU DarmstadtSmart Products Smart LogisticsSmart Home Systems and StructuralHealth Monitoring Remote Diagnosis and Control Tracking and TracingSource: TU Darmstadt, ESE05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 6
A Realization Guideline forIndustrie 4.01. Introduction2. Approaches for Implementation of Industrie 4.0 Implementation Recommendation Plattform Industrie 4.0 Sample Solutions Efficient Factory 4.0 Competence Center Mittelstand 4.03. The VDMA Guideline Internal Competence Analysis – External Perception AnalysisToolbox ProductsToolbox ProductionStrategic Orientation towards Industrie 4.0Business models4. Summary05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 7
Plattform Industrie 4.005.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 8
Board of Academic Advisors05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 9
Implementation recommendations forIndustrie 4.0Effective: April 14, 2015Industrie 4.0componentRAMI 4.0Research roadmap05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 10
Implementation recommendations forIndustrie 4.0Effective: April 14, 2015Business modelsAdded ValueUse CasesExamples of executionProductsProduction05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 11
Model factory for Industrie 4.0Unique selling point TU Darmstadt: Effiziente Fabrik 4.0 Build on existing, real production systemBrown instead of Green Field Statistical system for the organizational andeconomic evaluationQuantification of benefits viabefore/after comparison People are the focus Industrial use cases (application scenarios)05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 12
Uses Cases – Efficient Factory 4.0Use Case 4 Flexible intelligent workerassistance systemsUse Case 1 Paperless and integratedquality assurance Components asinformation carriers Unified datamanagementUse Case 3 Condition and energymonitoringUse Case 2 Digital value stream image Real-time capableproduction controlling05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 13
Uses Cases – Efficient Factory 4.0Use Case 4 Flexible intelligent workerassistance systemsUse Case 1 Paperless and integratedquality assurance Components asinformation carriers Unified datamanagementUse Case 3 Condition und energymonitoringUse Case 2 Digital value stream image Real-time capableproduction controlling05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 14
Competence Centers Industrie 4.0 in iT tKarlsruheStuttgartSource: Wissenschaftlicher Beirat Industrie 4.005.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 15
SME Technology Centerfor Industrie 4.0 (MiT 4.0) The service portfolio includes a target group-oriented competence development. For thispurpose, different plotlines and instruments for SME-friendly exchange in MiT 4.0 aredefined. Launch at Q1 2016PlotlinesIT-SecurityEfficient valueadded processesIndustrial Work 4.0Validation and adaptationSensitization Use CasesLearningfactories(Efficient.Factory 4.0) Use CasesindustryNew Business modelsEnergy management Demonstrators ExpertlecturesAnalysisQualificationTraining in thelearningUse case –specific training factories forin order to RegionaldevelopSMEIndustrie 4.0 Multiplicatorspotentials Implementationpartners05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. AnderlImplementationLocal supportfor Conceptcreation Technologydesign Start up andoperationTarget FiguresCosts, time, quality,flexibilityPerformance andmotivationNew services /marketsEnergy costs Folie 16
A Realization Guideline forIndustrie 4.01. Introduction2. Approaches for Implementation of Industrie 4.0 Implementation Recommendation Plattform Industrie 4.0 Sample Solutions Efficient Factory 4.0 Competence Center Mittelstand 4.03. The VDMA Guideline Internal Competence Analysis – External Perception AnalysisToolbox ProductsToolbox ProductionStrategic Orientation towards Industrie 4.0Business models4. Summary05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 17
VDMA guideline Industrie 4.0Initial situation: 86% of German SMEs have recognized the potential of Industrie 4.0(Source: Commerzbank AG) Visions of Industrie 4.0 are intangible and too general for the industry Way to realize Industrie 4.0 is unknown for the industryObjectives: Break down the visions of Industrie 4.0 on realizable development stagesfor product ideas and production improvements Understanding Industrie 4.0 as a pioneer of new business models Sketch and support path to successful implementation05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 18
The key element of the guideline Industrie 4.0 is the Toolbox Industrie 4.0 The Toolbox Industrie 4.0 is used to analyze the company‘s competencesand to generate strategies for approaching Industrie 4.0.05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. AnderlSource: Leitfaden Industrie 4.0 – Orientierungshilfezur Einführung in den Mittelstand, VDMAVDMA guideline Industrie 4.0:Toolbox Industrie 4.0 Folie 19
Structure of the toolbox: Application level: Six application levels to identifythemes for ideas in the field ofIndustrie 4.0. The combination provides thefunctionality.Applicationlevel Performance level: Five technological, buildingon one another performancelevels for positioning andstrategy development. The highest level representsthe vision Industrie 4.0.Performancelevel05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. AnderlSource: Leitfaden Industrie 4.0 – Orientierungshilfezur Einführung in den Mittelstand, VDMAVDM guideline Industrie 4.0:Toolbox Industrie 4.0 Folie 20
Application levels: Integration of sensors / actuators Communication / Connectivity Functionalities for data storageand exchange of information Monitoring Product-related IT services Business models around theproduct05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. AnderlSource: Leitfaden Industrie 4.0 – Orientierungshilfezur Einführung in den Mittelstand, VDMAVDMA guideline Industrie 4.0:Toolbox Products Folie 21
Application levels: Data processing in production Machine-to-Machine- Communication(M2M) Company-wide networking with theproduction ICT infrastructure in production Human Machine Interfaces Efficiency for small batches05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. AnderlSource: Leitfaden Industrie 4.0 – Orientierungshilfezur Einführung in den Mittelstand, VDMAVDMA guideline Industrie 4.0:Toolbox Production Folie 22
Generic Process ModelPreparationProcedureKnowledge of Industrie 4.0Internet technologyAnalysisDetecting the currentstate of the enterpriseIdeagenerationValue added chainValuationImplementationFields of actionProductsAdded ValueProductionCyber-physical systemsIntralogisticsFeasibility studyRoadmapDevelopment trendsResultsMethodsLiterature reviewInternalcompetence analysisMutual understanding ofIndustrie 4.0 in the teamPrioritization / clustermethodsInvestment planningSimulationCapacity planningInternal/ external consultingExternal consultingInternalknowledge exchange /seminarsToolboxExternal perceptionanalysisIllustration of thecurrent state of thecompany‘s Industrie 4.0competenceOptimization potentialsMethods forgenerating ideasRealizationOptimization ideasbusiness modelsRecommendation for .2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 23
Internal Competence andExternal Perception AnalysisObjectives: Identification of already existingIndustrie 4.0 competences External perceptionOften competences for Industrie 4.0approaches are already existing in thecompanyProcedure:1. Classification into the stages ofdevelopment of the Toolbox Industrie 4.02. Questionaire and Interviews of product andproduction expertsExample from the questionnaire:How are electronic sensors andof into youractuators are Integrationintegratedsensors / yand canBusiness modelSensorsarearoundthe productintegratedbe processed directly from theproduct.Classification: 12 In the fieldof product34 In5the application levelProduct-related„Integration of sensors“ Data storage &information exchangeIT services Stage of development 33. External Perception (through analysis ofproducts presented in media)4. Graphical representation as a radar chart05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. AnderlMonitoringInternal Product viewPerception view Folie 24
Source: Leitfaden Industrie 4.0 – Orientierungshilfe zur Einführung in den Mittelstand, VDMAVDMA guideline Industrie 4.0:Results for products und productionProcedure:1. Classification with respect to performance levelsof the Toolbox Industrie 4.02. Identification of the existing performance profile in the toolbox3. Definition of the target profile in the toolbox05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 25
Definition of the target profile forthe product portfolioProduct 1Product nProduct 2 05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 26
Definition of the target profilefor the areas of productionIntralogisticsProduction 05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 27
Production, products, business models:Industrie 4.0 development trendsNew approaches forinternet-basedbusiness modelsBusiness Platforms, B2B MarketplaceIndividualized Products and Production,Apps, Services instead of productsServiceNew level oforganization andmanagement of thevalue added chainInterlinked andcommunicatingsystemsPreventiveComponent trackingmaintenanceConnectivityDevices / SystemsCondition monitoringEnergy monitoringSystem and structuralmonitoringComponents andequipment act asinformation carriersSensors / : Lee05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 28
A Realization Guideline forIndustrie 4.01. Introduction2. Approaches for Implementation of Industrie 4.0 Implementation Recommendation Plattform Industrie 4.0 Sample Solutions Efficient Factory 4.0 Competence Center Mittelstand 4.03. The VDMA Guideline Internal Competence Analysis – External Perception AnalysisToolbox ProductsToolbox ProductionStrategic Orientation towards Industrie 4.0Business models4. Summary05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 29
Summary Industrie 4.0 provides new impulses for the development and application ofcyber-physical systems on the way to the internet of things, of services and data. Industrie 4.0 still requires research and development initiatives, neverthelessapplicable solutions are already visible. Impulses for the Industry: Customization through customer and market interaction New ICT infrastructures Innovative business models through integrated product and service quality Current state of debate: Politics: Politicians have recognized the importance of Industrie 4.0 at the federal level andthe state level and became active (Plattform Industrie 4.0, IT summit, European initiatives) Industry: The industry has organized itself through the platform industry 4.0 Society: Change of the working environment! Increasing digitization and computerizationthrough Industrie 4.0 requires training and continuous qualification of employees Industrie 4.0 offers to companies a serious vision, that hasto be evaluated and implemented company-specific.05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 30
Thank you!Source: Potthast Fachschaftenkonferenz05.04.2015 Fachbereich 16 Fachgebiet Datenverarbeitung in der Konstruktion Prof. Dr.-Ing. R. Anderl Folie 31
Visions of Industrie 4.0 are intangible and too general for the industry Way to realize Industrie 4.0 is unknown for the industry Objectives: Break down the visions of Industrie 4.0 on realizable development stages for product ideas and production improvements Understanding Industrie
