MANUFACTURING WORK IN TRANSITION: INDUSTRY 4.0 AND …INDUSTRY 4.0 AND SMART FACTORIES Fraunhofer...

© Fraunhofer IFF, Magdeburg 2015 , Univ.-Prof. Dr.-Ing. Michael Schenk

MANUFACTURING WORK IN TRANSITION: INDUSTRY 4.0 AND SMART FACTORIES

Fraunhofer IFF - Smart Work System

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Fraunhofer IFF - Industry 4.0 CheckUp 3

OVERVIEW - Industry 4.0 and Smart Factories 2

Fraunhofer IFF - Your Technology Partner 1

Fraunhofer IFF - Lets Work Together

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© Fraunhofer IFF

Fraunhofer in Germany


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1. Fraunhofer IFF: Your Technology Partner Interrelated Specializations for Fields of Research

Convergent Supply Infra- structures

Smart Work Systems

Resource Efficient Production and Logistics

Measurement and testing

Assistance and training systems

Robotics

Logistics zones

Process engineering

Specializations Fields of Research

Dig

ital

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little, medium, great relevance of a specialization for a field of research




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Fraunhofer IFF - Industry 4.0 CheckUp 3

Overview - Industry 4.0 and Smart Factories

1 Fraunhofer IFF - Your Technology Partner


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Industry 4.0: Prepare to Evolve Evolution Instead of Revolution

Source: Deutsches Forschungszentrum für Künstliche Intelligenz. 2011.


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Industrie 4.0 – Industrial Ecosystems: What the future factory will be?

Vision: • Total flexible Production, • Self-optimisation and self-configuration of production, • Massive decision support to humans by Big Data and VR, • Decentralized decisions, • Real time monitoring of physical processes, • Modularity of production units, • Full interoperability (also cross-organizational) • Internal and cross-organizational services are offered and utilized

Drivers: • Evolution of cyber-physical systems

• by Internet of Things • by tools to develop Virtual Reality • by Big Data

• Aging population and high salaries require more efficient production

Critical: • Common standards and norms • Common platforms


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Industry 4.0 Potential Savings

Source: Bauernhansl, Thomas: Die Vierte Industrielle Revolution – Der Weg in ein wertschaffendes Produktionsparadigma. 2014

Costs Impact Savings

Inventory costs Reduction of reserve inventory Elimination of bullwhip effect (Burbidge and Forrester effect)

30 to 40%

Manufacturing costs

Improvement of OEE Process control loops Improvement of vertical and horizontal staff flexibility

10 to 20%

Logistic costs Increased level of automation (milk run, picking, etc.)

10 to 20%

Complexity costs Expanded performance margins Reduction of trouble shooting

60 to 70%

Quality costs Near real-time quality control loops 10 to 20%

Maintenance costs Optimization of spare part inventories Condition-based maintenance (process and measured data) Dynamic prioritization

20 to 30%


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Industry 4.0 Some German-Chinese Cooperation Issues

Due to existing economic integration between Germany and China cooperation on Industry 4.0 is mandatory for competitiveness of both economies .

Aging population and rising labor costs force Chinese manufacturers to implement Industry 4.0 solutions.

Germany is China’s preferred partner. Germany has the advanced technology needed for Chinese Industry 4.0.

The greatest danger for Germany to cooperation with China is the loss of sensitive data in China due to Chinese State data control and its use as an instrument of protectionist industrial policy.

German and Chinese policy makers target currently Industry 4.0 cooperation pilot project that are to be defined and will serve as information input for further policy actions. (common standards etc.)




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Fraunhofer IFF - Industry 4.0 CheckUp

2 Overview - Industry 4.0 and Smart Factories

1 Fraunhofer IFF: Your Technology Partner


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Industry 4.0 CheckUp: Prepare to Evolve Approach

Situation Analysis

Identification of existing technologies

Analysis of running processes

Classification of production facilities in a stage of Industry 4.0

Ascertainment of necessary documents and data

Interviews with Experts

On site surveys of experts using prepared interview guideline

Identification of current weaknesses

Analysis of innovation capability (staff, organization, equipment)

Technical Capabilities for Industry 4.0

Compilation and assessment of existing technological solutions

Identification of innovative technical solution for Industry 4.0 –

Recommendations for future actions

Smart Factory

Industry 4.0








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Smart Work System Humans in Production: Motivation

1/3 of all absences are due to musculoskeletal and mental disorders

in lost output

Sicherheit und Gesundheit bei der Arbeit, baua 2012

Every

worker in machinery manufacturing is between 45 and 55 years old. Statistisches Handbuch für den Maschinenbau, Ausgabe 2012, VDMA Volkswirtschaft und Statistik.

of industrial companies cannot find skilled technical labor

VW

Up to

of modules are assembled manually at VW

Percentage of the labor force over 50

Today

2025

Demografiemanagement 2011, Pricewaterhouse-Coopers AG Wirtschaftsprüfungsgesellschaft, 2012. DIHK-Arbeitsmarktreport 2013


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Smart Work System Matching Humans and Machines

+ Senses and intelligence

+ Flexibility + Dexterity + Creativity + Ability to learn

+ High consistency + Endurance + Precise power + Media resistance + High speed

+ Combination of high performance and human senses

+ Easier work + Higher quality

Humans Machines Human-Machine

Interaction

Safety Protection of humans from machines

Security Protection of machines from humans

© Fraunhofer IFF, Magdeburg 2015

Univ.-Prof. Dr.-Ing. Michael Schenk

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Work areas Shared by Humans and Machines Safe cooperation between humans and machines Projection and camera-based sensor system generates optical safeguarded

zones display of robot status, instructions

for procedures, etc.

Smart Work Systems-Fraunhofer IFF Research Workplace Monitoring for More Safety

© Fraunhofer IFF

Immediately recognizable safeguarded zones

Ergonomic interaction



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Automation and Application Industry Ascertainment of Thresholds for Safe Human-Robot Collaboration Fraunhofer IFF Load Study Systematic collision tests with human subjects for the

first time ever (medical supervision, ethics commission consent)

Determination of biomechanical thresholds (pain, slight swelling or hematoma )

Findings will be incorporated in international standard TS 15066

Smart Work Systems-Fraunhofer IFF Research Safe Human-Robot Interaction

© Fraunhofer IFF

Determination of maximum biomechanical loads for collisions without injury

Study of injury-related parameters



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Zero-defect manufac-turing

Machine Manufacturers Diversity of models and high complexity of jobs in assembly operations Visual assistance and inspection systems for the assembly of clamping systems Virtual templates to position and align

components Augmented reality: Information supplied by

camera images of the assembly scene, overlaid with 3D CAD models

Upgradable with an inspection assistant

Smart Work Systems-Fraunhofer IFF Research Visual Assistance and Inspection Systems

Shortened assembly time 20%

Reliability in the process chain


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Smart Work System Consistent and parallel design of products and production system

Quelle: Fraunhofer IFF

Simultaneous engineering and design of products , manufacturing and production facility based on virtual models

Ready to use plants are planned in record time









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Technology development cooperation's on Smart Work Systems

Cooperation on designing Industry 4.0 strategies for Companies (Industry 4.0 CheckUp)

Together with BTU establishment of a Industry 4.0 Model-Factory to:

• Show of select Industry 4.0 technologies, systems and methods under real conditions of use.

• Provision of General trainings to companies on Industry 4.0 potentials.

• Provision of assistance to companies when they are developing manufacturing processes, optimizing processes or selecting software and hardware components by development of user based scenarios to validate solutions.

Technology Partner Fraunhofer IFF Visions on Industry 4.0 cooperation's with Hong Kong & China


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Technology Partner Fraunhofer IFF Let us research your application together!

Fraunhofer Institute for Factory Operation und Automation IFF

Sandtorstrasse 22 39106 Magdeburg

Germany

Phone: +49 391 4090-0

[email protected] www.iff.fraunhofer.de

© Fraunhofer IFF

© Fraunhofer IFF

Kay Matzner Dipl.-Vw

Logistik- und Fabriksysteme

Telefon +49 391 4090-159

Fax +49 391 4090-432

[email protected]

mailto:[email protected]

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MANUFACTURING WORK IN TRANSITION: INDUSTRY 4.0 AND …INDUSTRY 4.0 AND SMART FACTORIES Fraunhofer...

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