© Fraunhofer IAO, IAT Universität Stuttgart

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 2

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

„

„

Slide 3

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 4

ü

ä

Fraunhofer building

in the Romanstrasse in München

Entrepreneur:

Head of

Royal Glass Factory

Researcher:

Discovery of »Fraunhofer Lines«

in the sun spectrum 1814

Inventor:

New methods of

lens processing

Fraunhofer building

Hansastrasse in Munich, 2015

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 5

München

Holzkirchen

Freiburg

Efringen-Kirchen

FreisingStuttgart

PfinztalKarlsruheSaarbrücken

St. IngbertKaiserslautern

DarmstadtWürzburg

Erlangen

Nürnberg

Ilmenau

Schkopau

Teltow

Oberhausen

Duisburg

EuskirchenAachenSt. AugustinSchmallenberg

Dortmund

PotsdamBerlin

Rostock

LübeckItzehoe

Braunschweig

Hannover

Bremen

Bremerhaven

Jena

Leipzig

Chemnitz

Dresden

CottbusMagdeburg

Halle

Fürth

Wachtberg

Ettlingen

Holzen

Oldenburg

Freiberg

Paderborn

Kassel

GießenErfurt

Augsburg

Oberpfaffenhofen

Garching

Straubing

Bayreuth

Bronnbach

Prien

Dubai

Bangalore

Jakarta

Peking Seoul

Tokio

Boston

Plymouth

East LansingSan José

NewarkMaryland

Kairo

Ampang

Santiago de Chile

Singapur

Cambridge

Brüssel

Porto

Wien

Bozen GrazBudapest

Wrocław

Göteborg

Thessaloniki

Sydney

London

Glasgow

Salvador

Sendai

Paris

Representat ive

Subsidiary

Center

Senior Advisor

Project CenterSão Paulo

Campinas

Stellenbosch

€€

Fraunhofer IAO Joint Office at Cluj-Napoca, Romania

Since January, 2014

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 6

Centre for Virtual Engineering

Interaction LabLight Fusion Lab

Center for

document and

workflow

management

Usability Lab

Model Factorym-Lab: Mobile

Software

Applications

3D Interaction Lab Immersive

Engineering Lab

Cloud laboratory with

“Cloud Workpad”

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

„

Slide 7

Motivation

„Factories are complex Products“

[Westkämper, 2005]

Mission

Implementation and Validation of the

industrial Paradigm

Goal

Continuously integrated process development

and factory planning as well

as factory operation and maintenance

beginning from the product design

Approach

Networkable methods and planning tools for

competitive and high performance factories

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 8

Cooperative Planning Table3

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 9

Smart Warehouses

Material Machines Parts Smart Transport Systems Smart Assembly Lines

Sensor Data, …

Worker

Tools

……

Cyber-Physical-based

ERPDigital

Factory

Context- and user aware

applicationsMES PDM

Tasks, Jobs, …Production Orders Product Data Factory Data Current Context Data

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Employees in Germany

(2014)*

* Quelle: Statistisches Bundesamt, Stand 05/2014 ** Quelle: Statistisches Bundesamt, Stand 01/2014

manufacturing

industry

building industry

services industry

agriculture and

forestry

7,7 mio.

2,4 mio.

30,3 mio.

0,7 mio.

Sum 41,1 mio.

machine engineering

17%

automotive

engineering

14%

metal products

9%

Electric

equipment

7%

Other 53%

Employees in the industries in Germany (2014)**

industries

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Depending on…

Relocation volume

Pace of development in the BRIC countries

Chances of low-cost automation

Expenses for logistics …

Forecast for the futureRange of the forecast for the future****

today

* Statistisches Bundesamt, Stand 05/2014

** Prognos

*** Global Insight

**** McKinsey/ ProLabour

BRIC Countries: Brazil, Russia, India and China (BRICS +South Africa)

- 1,5 Mio.

+1,5 Mio.

Vigorous production location ensures sustainably

jobs in Germany.

2014*

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

1. Industrial revolutionBy introducing mechanical

plants with the help of hydraulic

and steam power

2. Industrial revolutionby introducing mass production

based on the division of labor

by means of electric energy

3. Industrial revolutionby using electronics and IT

for the further production

automatization.

4. Industrial revolutionon the basis of cyber-physical

systems

The end of

18th century

Beginning of

20th century

End of the

70s of the 20th century

today

De

gre

e o

f

co

mp

lex

ity

Industry1.0

Industry 4.0

Industry 3.0

Industry 2.0

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

„

Quellen: 1) www.acatech.de/cps; 2) Gausemeier:

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Quellen: 1) www.pro-smart-metering.de 2) blogs.bournemouth.ac.uk / nullbarriere.de3) Geisberger, Broy (Hrsg): agenda CPS/; www.7-forum.com 4) robotik.dfki-bremen.de

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

more inter-

connected

object than

people on the

earth

world population (bn)

interconnected objects per person

interconnected objects (bn)

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

New technologies

Economical fields of application

Profitable business models

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Preparations (acatech, German research union)

19.12.2011

1st tender (BMBF)

Workshops of German research union

Industry 4.0-implementation forum and start of the 2nd tender (BMWi)

02.10.2012

15.09.2012

start of the first three lead projects

Preparation of further tenders (BMBF, BMWi)

06.02.2013

3rd tender (BMBF)

07. 2013

Lead-Study available

www.produktionsarbeit.de

02.2015

> 6 lead projects (BMBF)

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Prof. Wahlster

•Prof. Spath/Bauer

Prof. Bauernhansl

Prof. ten Hompel

Prof. Reinhart

Prof. Broy

Prof. Kagermann

Prof. Fundel

Hr. Feld

Hr. Dr. Ferber

Hr. Respondek

Hr. Dr. Holfelder

Hr. Dorst

Hr. Glatz

Hr. Dr. Mittelbach,

Hr. Dr. Diegner

Fr. Dr. Kurz

Hr. Dr. Wittenstein/Spath

Hr. Bauer

Hr. Prof. Post

Hr. Sachse

Hr. Dr. Rode

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

„

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

„

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

–

–

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Self-organized and flexible capacity in Cyber-Physical-Systems

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Please switch off!

Hopper is empty, replenish please! Capacity fully booked till

Friday!

I have to be at outgoing goods in 2 hours!

Customer‘s order: 50 gearboxes till Monday

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

I can work on Saturday

I ll do the replenishment of the hopper.

Saturday will be impossible for me.

Interconnected humans and objects decide in cooperation

Please switch off!

Hopper is empty, replenish please! Capacity fully booked till

Friday!

I have to be at outgoing goods in 2 hours!

Customer‘s order: 50 gearboxes till Monday

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

„

Self-organized employment control in real-time as a competitive advantage

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

(Source: Anderl, TU Darmstadt)

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Finland

• FIMEC PPP Programmes

(MANU, S-Step, SIMP,

S4FLeet)

• Industrial Internet Business

Revolution

• IoT pilot factoryPoland

• INNOMOTO

• INNOLOT

• Digital manufacturing

for the SMEGermany

• Industrie 4.0

• Smart service world

• Autonomik for I4.0

• itsOWL

• Allianz Industrie 4.0 BW

Austria

• Produktion der Zukunft

• IKT der Zukunft

Greece

• Operational program in

region Western Greece

Italy

• Industria sostenibile

• Fabbrica intelligente

• Ass. Fabbr. Intell. Lombardia

Spain

• Estrategia Fabriccacion

Avanzada

Portugal

• Produtech

France

• Usine du Futur

• FoF Ile-de-France

Belgium

• Made different

• Flanders Make

• iMinds

UK

• High value

manufacturing

• Action plan for

manufacturing

(Scotland)

Sweden

• Production 2030

• IoT

Netherlands

• Smart industry

EU-level Initiatives

• PPPs: FoF, SPIRE

• I4MS

• Smart Anything

Everywhere

• ICT PPPs

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

‚

€ € € € €

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

2015 2018 2025 2035

Methods for new business models

Methods for value adding networks

Automation of value adding networks

Integration of real and virtual world

Systems engineering

Sensor data analysis and data based process control

Intelligence – flexibility - adaptivity

Multi modal assisting systems

Acceptance of new technologies and design working systems

Wireless communication for Industrie 4.0-use cases

Security and safety

Industrie 4.0-Plattform, reference architecture, shared SOA

Horizontal

integration over

value adding

networks

Continuous

development of

basic technologies

Engineering over

the entire life cycle

Vertical integration

and linked prod.

systems

New social

infrastructures of

work

Migration strategy

Industrie 4.0 by design

(Source: Plattform Industrie 4.0)

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Customer

Machine builder

remains lead supplier

and creates new business opportunities

based on real-time data

Manufacturing of

machines and lines

Operation of

machines and lines

Optimization and

added services

Smart

services

Smart

data

Smart

products

Customer

System integrator

in charge of customer

and data interfaces which leads to

‚exchangeable‘ suppliers

System integrator

Supplier 1 Supplier 2 Supplier n

Operation of

machines and lines

Support and

optimization

(Source: Kagermann, acatech)

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 33

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Examples from projects

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Functionalities become services

APPs

Manufacturing Service Bus

Services

Machines, equipment, components, CPS

Integration services

Partners:

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Example for SecurePLUGandWORK

•

•

•

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Current project: SecurePLUGandWORK

Machine1 Machine2 Machinen Digital Factory

Encoder Encoder Encoder Encoder

Secure plug-and-work „integration layer“:authenticates machines and components

Signed and encrypted

communication

MES 1 MES 2 MES m

Decoder Decoder Decoder

= Software component

= Certificate

SecurePlug & Work-equip-ment-

modelincl.

certifi-cates and

digital rights-mgmt.

Field deviceincl. identity

Drive incl. identity

Signed and encrypted communication

Secure plug-and-work “integration layer“:authenticates field devices and components

Spindle incl. identity

SecurePlug & Work-

change manager

Feld-gerät

Component is „unlocked“, onlysigned componentsmaybe integrated

X

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

39

Communication channel to propagate

configuration and runtime data (How?)

+

Description of the content to be

communicated by OPC-UA’s

information model (What?)

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

40

Chemical processes

High complexity

High number of measurement points

Requirements of operator

Online-Monitoring

Detection of failures for maintenance

Detailed information for localization of failures and assistance to fix them

Role based provision (GUI) of results

Solution developed: monitoring suite for predictive maintenance

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

• The following purposes are focused:

– scientifically substantiated guidelines

– involvement and representation of the expertise of the

research partners

– regular publication of partial results

– contributions to the industrial and public debates

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 42

Motivation

„Factories are complex Products“

[Westkämper, 2005]

Mission

Implementation and Validation of the

industrial Paradigm

Goal

Continuously integrated process development

and factory planning as well

as factory operation and maintenance

beginning from the product design

Approach

Networkable methods and planning tools for

competitive and high performance factories

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 43

Grid Engineering for Manufacturing (GEM)

•Modelling, simulation, optimization and

visualization of products, factories and processes

•Networking and distribution of data, models,

tools and computer resources with the support of

grid technologies

Benefits

Increased planning reliability regarding:

Time to manufacture,

Planning costs, time and quality and

Value-adding operation functions

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 45

Simulation techniques

Product ProcessSystem

Specialized application, FEM

Product functionality simulation

Factory performance simulation

System simulation

Process simulation

Investment and performance

planning

Site and network planning

Prozess-

simulation

Prozess-

simulation

Buildings, infra-structure and

media planning

Internal logistics and layout planning

Process, equip-ment and work-place planning

Ramp-up and project-

management

2 3 4 5 6 7

FLM

Factory

data

Factory operation and manufacturing

execution

8

PLM

Product

data

Product development

1 Planning

workflows

GRID

technologies

PLM: Product Lifecycle Management FLM: Factory Lifecycle Management

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 46

Cooperative Planning Table3

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 47

Development of innovative concepts,

approaches, methods and tools for digital,

networked and knowledge-based Manufacturing

Focus on holistic and continuously integrated

design and engineering of:

Smart products, Self-optimized processes,

Self-aware production modules, machines and

equipment along their life cycles

Synchronisation of self-organisation/optimisation

approaches of Industry 4.0 Strategy with the

current developments of integrated intelligent

models Contribution to the implementation of the

Next-Generation PLM Vision

Anthropocentric approach

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 49

FoF.NMP.2013-7 (2013-2016) Robo-Mate

“Intelligent exoskeleton based on human-robot interaction for manipulation

of heavy goods in Europe’s factories of the future –

Robo-Mate”

Industry Workshop – DEMO – 12. Juni, 2015

FhG-IAO:

•Modelling, simulation and optimisation of production companies: INDRA

(FR), COMPA (RO), Fiat (IT)

•Modification of the Human Jack Classic equations, coupling of Exo-skeleton

to Jack – new Manufacturing resource

•Software; Process Simulate, Human Jack Classic (Siemens)

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 50

HORIZON 2020 FoF-5 (2015-2018)

ICP4Life

“An Integrated Collaborative

Platform for Managing the Product-

Service Engineering Lifecycle -

ICP4Life”

FhG-IAO:

•Design and development of Factory

Designer, Customiser and

Simulation Component

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 51

Simulation techniques

Product ProcessSystem

Specialized application, FEM

Product functionality simulation

Factory performance simulation

System simulation

Process simulation

Investment and performance

planning

Site and network planning

Prozess-

simulation

Prozess-

simulation

Buildings, infra-structure and

media planning

Internal logistics and layout planning

Process, equip-ment and work-place planning

Ramp-up and project-

management

2 3 4 5 6 7

FLM

Factory

data

Factory operation and manufacturing

execution

8

PLM

Product

data

Product development

1 Planning

workflows

GRID

technologies

PLM: Product Lifecycle Management FLM: Factory Lifecycle Management

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 52

I4-Factories

The Resilient Factory: characterized by a high level of

agility, adaptivity, redundancy, decentralization and

compliance in order to achieve optimum workload and

capacity at all times.

The situation-based adaptation and continuously

reconfiguration of the manufacturing lines enables the

realization of the Just-in-time production with optimal

capacity utilization, reduced time-to-production, time-to-

quality and time-to-productivity.

I4-Factories

© 2015 Fraunhofer IAO, DM4.0, All rights reservedFactory Context-aware and User-Aware Applications

Factory Context-aware and User-Aware Applications

I4-Factories Approach

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 54

Smart Warehouses

Material Machines Parts Smart Transport Systems Smart Assembly Lines

Sensor Data, …

Worker

Tools

……

Cyber-Physical-based

ERPDigital

Factory

Context- and user aware

applicationsMES PDM

Tasks, Jobs, …Production Orders Product Data Factory Data Current Context Data

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 55

Intelligent Optimization

Strategies

in Uncertain and

Dynamic Environments

D

A AAA

A

A

D

•

•

•

•

•

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

2012-03-21Slide 56

Drillhole misplaced

Capturing with mobile

device

Recording with video,

foto, audio

Material defect

Input mask

Classification matrix

Who is responsible?

Defined roles

Send via microblog

How do I eliminate the

failure?

Documentation with

mobile device

Ramp-Up Wiki

Failure wass not

eliminated

Escalation

Automatic escalation

cascades

Fast and intuitive

capturing

Event classification

Knowledge network

Decentraliced

decision-making

Ad-hoc Knowledge

organization

Failure

Solution

System

Human as universal

sensor

Ramp-ME-Up

NEIN

Nobody accepts task

Fast escalation

Scheduled time

© 2015 Fraunhofer IAO, DM4.0, All rights reserved

Slide 57

I4-Factories

The Resilient Factory: characterized by a high level of

agility, adaptivity, redundancy, decentralization and

compliance in order to achieve optimum workload and

capacity at all times.

The situation-based adaptation and continuously

reconfiguration of the manufacturing lines enables the

realization of the Just-in-time production with optimal

capacity utilization, reduced time-to-production, time-to-

quality and time-to-productivity.

© 2015 Fraunhofer IAO, DM4.0, All rights reservedFactory Context-aware and User-Aware Applications

Factory Context-aware and User-Aware Applications

I4-Factories Approach