The Power of Manufacturing Ecosystem · Konzernstrategie 2016-2020 KUKA Konzern | CEO | Dr. Till...

Page: 1 Smart Products & Smart Production | Dr. Christian Schlögel | 09/2016 | www.kuka.com

The Power of Manufacturing Ecosystem

Rohit Pant Vice President

Head of Central Industrie 4.0 Team

www.kuka.com

Konzernstrategie 2016-2020

KUKA Konzern | CEO | Dr. Till Reuter | 24. September 2015 | 2

KUKA 2020 Plan

Revenue

4 - 4,5 Mrd. €

EBIT-Margin

> 7,5% Revenue

2,1 Mrd. €

2020 2014 2014

http://www.kuka.biz/

www.kuka.com



Strategic focus points of KUKA in 4 phases

2009 – 2011

Focus Europe & Automotive

Stabilization:

Financing

Cost reduction

Efficiency

2012 – 2014

Enhancing product portfolio

Quantec

Agilus

KR C4

Roll-Out LBR iiwa

Operational Excellence

Growth in General Industry

Divisions

2018 – 2020

Leading global solution provider

for robot based

automation

Key Role in mega trend

Digitization / Industrie 4.0

2015 – 2017

Market focus

China and Localization

Strategic Markets E-Commerce,

Consumer Goods, Electronics

Additional potential in

combination of production- and

warehouse-logistics

Innovation Leader


www.kuka.com



KUKA – One stop shop for solutions

Integrated Software solutions for Applications

Product Cell Solution

Swisslog KUKA Industries KUKA Systems KUKA Robotics

Robotics-

Know-how

Integration-

Know-how

Line- and Manufacturing Process-

Know-how

Global market approach by using industry focus



Industrie 4.0 in action

Digitalized small manufacturer

Digitalized engineering

IoT Business

Models

Manufacturing in 2020 – very different to today‘s world

Autonomous mobile Robots

Collaborative Robots

Smart production / logistics

Mechatronics 2.0

Data Analytics as value driver


I4.0 Strategy


Stages of Industry 4.0 – Think Platform

DECISIONS

Change Movement Optimization

DATA

Data Acquisition Digital events Analog events

INFORMATION

Presentation Organization Gives Meaning

KNOWLEDGE

Application Analytics Learning

Industry 4.0 Stage 1 (Enabler) Industry 4.0 – Stage 2 Industry 4.0 – Stage 3

WISDOM

Understanding Interpretation Actionable

we are here



We are able to offer a complete stack combined with domain knowledge & machines covering both areas of smart tools services and smart production & logistics services

• Apps & Cloud-Services Eco System • Digital production & Logistics / Smart Products focus • Technology Components • Industry 4.0 Middleware

• Industry 4.0 ready Intelligent Machines • Domain Process Content • Market specific KUKA Apps

Central Industry 4.0 team

• Evangelization, I4.0 Program coordination • Enabling New Business Models • Coordination of KUKA Apps & Cloud Services • I4.0 PreSales

Eco-System Partners

Holistic Industry 4.0 offering

KUKA Industrie 4.0 Organization


KUKA is shaping the factory of the future. KUKA is currently working on components, cells and solutions that enhance the ability of bringing the customers the products they want in the time they expect them. Furthermore, KUKA will enable data accessibility of any device in the shop floor.

KUKA strongly contributes to shaping the factory of the future.

Throughout the entire value chain, KUKA can offer solutions that suite the customers’ demands.


Our responses and contributions Human Robot Collaboration (HRC)

The LBR iiwa.

A new era of sensitive robotics is beginning.

• The LBR iiwa is a work colleague – completely safe, with a sensitive touch.

• In all seven axes, the LBR iiwa has integrated torque sensors implemented, using safe technology.

• The need for a safety fence is eliminated.

• Hand in hand for greater productivity.

• Lowest tolerances, high path accuracy.

• Green light for innovative automation solutions.


Our responses and contributions Mobile robotics & platforms

Freedom of movement in every order of magnitude

Mobile resources enhance production flexibility & enrich Industrie 4.0 concepts


Our responses and contributions Adaptive manufacturing – Matrix production

Matrix production

Highly flexible production is becoming reality.

• Matrix production is characterized by flexibly configurable production cells, which are linked together.

• Automated guided vehicles (AGVs) automatically load the production cells with the necessary tools and grippers.

• The matrix production concepts enables extremely versatile production on an industrial scale.


What do we focus on?

Prof. Bauernhansel

Smart Factory

Smart Production

Smart/ Connected

Product


Embedded Systems + Connected to the Internet + Machine2Machine Connectivity - Wireless/wired Communication - Sematical description

= CPS (Cyber Physical System)

Smart Production & Logistics

Smart Tools Smart Products uses produces

Examples Smart Factory Smart Warehouse

Robots, AGVs, Laser, Welding Machines,… Cars, Phones, Smart tools when they are getting produced

Customer of services

Production provider Machine vendor Consumer, Business customer

Used at Factory (Factory view) Factory (Single tool view) Home, Factory

Typical services

Line optimization, MES, Autonomous production

Remote Mgmnt, Alerting, Usage profiles, SW Updates via Appstore, Service Upsell, Cloud based control

Services to guide production, Remote Mgmnt, Alerting, Usage profiles, SW Updates via Appstore, Service Upsell

Some terminology first


Get an holistic view about your customers

Product Product +

Connected Experience

Proactive service

M2M Connection

Usage analytics

Efficiency Updates

24x7 Diagnostics

Remote Management

Benchmarking

Skill Extensions Energy

Management


What is the key to success?


Acceptance of Smart production relies on improvement of OEE

(example McKinsey)


Usage of existing I4.0 technologies will increase OEE (McKinsey study)


Let us build an manufacturing cloud ecosystem

Edge CLOUD

KUKA.Connect User Production Company A

Manufacturing Appstore User Product Company 1

User Product Company 2

User Product Company 3


Technology Stack View


KUKA Edge Cloud Gateway Real-time edge computing

IT

OT

Edge


23

Federation of

Fog Nodes

Machines

and Things

Nebbiolo Cloud Management

Nebbiolo Fulfillment Center

•

•

•

•

•

•

•

•

Opportunity with Machine

Mounted Fog (MFN)

The MFN will be central controlling instance of a machine.

It combines real time controls, HMI, connectivity to higher level

controls, service connectivity and hosting of machine vendor specific

applications.

40

1. A flexible hardware architecture manifesting in a family of Fog

Nodes

2. A rich software stack on each node, enabling fast, secure,

solution deployment

3. An advanced end-to-end management of distributed

networking and computing systems, assets, software and

applications

Nebbiolo’s Fog Computing Platform Components


• Originally created for KUKA Industry’s Remote Service product CRSM

• Several 100s out in the field already

• CRSM to be integrated into KUKA Connect

• SW upgrade of brownfield facilities possible

KUKA Edge Gateways for Brownfield enabling of existing KUKA customers (Data collection & remote service)


Human Human/machine interface

Set value

Actual value

Stan

dar

diz

ed

Co

mm

un

icat

ion

Marketplace: • Sell & Extend • Build up Ecosystem • Services, SW Updates & Skills

Cloud platform: • Enable & provide technologies • Customer strategy • Generic cloud services for Smart tools

& production

Cloud services: • Manage & optimize • Assets & Lines • Domain cloud services for AGVs,

robots, production & logistics

Real time fog node/Edge Cloud: • Connect, Collect & Aggregate, Control • Sensors & Machines • Data-Hub & distributed control

Holistic view on KUKA Industrie 4.0 solutions

Any asset of interest

Apps for all layers

Robot / Tools and process - Machine UI - Easy2Use - Skills & Capab.

Edge/Fog

Additio-nal data

SCM

…

Analytics platform Cloud platform

Cloud services

Marketplace

Your Tools

Your Tools


KUKA cloud

Customer any cloud Additional customer

data

KUKA Edge Cloud Gateway • Fog Operating System • Engineered for real time control • High availability & scalability • Security standards

Additional Vendor data

Internet Internet

OPC UA

LAN/UMTS

KUKA offers the platform to streamline data of any machine through the KUKA cloud to analyze through personal apps.

Marketplace: Cloud platform: Cloud analytics:

Cloud infrastructure featured by KUKA

Your Tools


Schematic Cloud Architecture Layers

Edge Cloud

IoT Middleware

Big Data Analytics Object Layer

Connyun Frameworks

Mapping Asset

Management Remote Mgmnt

Condition Monitoring

Augmented Reality

Protocols (OPC-UA, AMQP, RESR, MQTT..)

Device Management

Remote Access

Realtime (Sensor integrat.)

Time Series Inbound API Device Management

Inbound / Outbound API

Alarming

Big Data Engine

Dashboarding Object Model

Service Abstraction

Anomalie Detection

SW Distribution

Visualization Correlation

XPert Service

History Fwk

KUKA.Connect KUKA.Connect Factory KUKA Robot Simulation

New Services

SW Updates New

Product capabilities SW Updates

Connyun Appstore

KUKA Marketplace

SpareParts

KUKA Robot Spec. Services

Xpert Robot

Line Optimization

Partner Tools Spec. Services

XPERT Partner Tools

Connyun Smart Tools Suite Xpert Line


I4.0

In

fras

tru

ctu

re

Fog Computing Fog Computing TSN Fog Computing Distributed Control

Asset Management

Dashboards Big Data Correlations Machine Learning

3D Vision Extended Object Recognition

MES&LES Basics MES&LES Extended

Condition Monitoring Predictive Maintenance

Augmented Reality

Zero Touch

Asset Efficiency

Remote Mgmt.

Data Acquisition

Knowledge Mgmt.

Amazon Microsoft On Premise

I4.0

Sm

art

Pro

du

ct

Data Acquisition Alarming Application Service Layer Process Data Standardization

I4.0

Sm

art

Pro

du

ctio

n

/Lo

gist

ics Mobile Data Mgmnt Digital Shadow

Digital Process Parameter

Com Ctrl

Preview Roadmap serving both scenarios: smart production services and smart tools services

2016 2017 2018


Outlook (KUKA.Connect for KUKA Robots)

Product Launch Dec

KUKA Connect 1.0

KUKA Connect + 1.0

KUKA App Framework 1.o

Product Launch

KUKA Service 1.0

KUKA Maintenance 1.0

Connect 2.0

KUKA Connect + 2.0

Service 2.0

Maintenance 2.0

SimConnect1.0

OnDemand 1.0

Maint 1.x Maint 1.x

Serv 1.x Serv 1.x

App 1.x App 1.x App 1.x

KC+ 1.x

KC 1.x

KC+ 1.x

KC 1.x

WCTC

KTPO

Augsburg

HMI IMTS IoT Solutions World Congress

KUKA AppStore and Community

Asset Information

Service History

Usage Data

Energy Consumption

Xpert System

Smart Ticketing

10/2016 12/2016 6/2016 3/2017 10/2017 6/2017


Deployment Models


Edge CLOUD

Device 1

Device 2

Device 3

Device 4

Device 5

Things

Public Cloud

Private Cloud

Edge Cloud Digital Twins

KUKA.Connect

KUKA Smart Production & Smart Tools Cloud

Services Product Resumes

iBase SAP

XPert

Ticketing

Scenario: Hosted Cloud for Production and/or Smart Tools Usage

User Production Company A

User Connected Product Company 1



Edge CLOUD

KUKA.Connect

Device 1

Device 2

Device 3

Device 4

Device 5

KUKA Smart Tools Cloud

Things

Public Cloud

Private Cloud

Edge Cloud

Services Product Resumes

iBase SAP

XPert

Ticketing

Digital Twins



Customer Production Cloud

Scenario: ‚Customer Cloud‘ as single line data hub and dependent comp-clouds

User Production Company A


Edge CLOUD

KUKA.Connect

Device 1

Device 2

Device 3

Device 4


Things

Public Cloud

Private Cloud

Edge Cloud Digital Twins

Scenario: Constructing ‚your‘ Cloud in an embedded ecosystem

User Production Your customer

Your

Device

User Connected Product Your company

Your Device

Services

Product Resumes

SAP

Ticketing

Your Business IT Your

Device

Your Device


Use Cases


Often you do know too less about your smart product

Smart Products

Where are my assets in which configuration?

Which additional services can I upsell via a digital channel?

Asset Management

Appstore Smart Service Smart Operation

Smart Insight

Smart Optimization

Service Upsell?

Updates Spare Parts

Apps & Optimi-zation

Usage Environ-

ment


Best Fit

Availa-bility?

Perfor-mance?

Energy Consumpt

ion

Material Usage?

Changes?

Optimi-zation

Configuration?

Environ-ment

Asset Data

Production Data

Delivery Configura

tion

Digital Documen

tation

Next Service?

Service History?

Expert Knowledge

Alarming?

Predictive Maintenance

Smart Tickets

Connect 2 Service Mgmnt

Best Practices?


Use Case: Smart Tools Services

Connected Smart

Products &

Components

Smart Services based on

Data

Usage Data

Service Data

Asset Production

Data

Energy / Safety Data


Big Data Correlations

Remote

Management

Safety Regulations

Digital

Birth Certificate


Location

Information

Smart Service UpSell on Demand based on Data

Faster Diagnosis

Better fitting products

Service upsell

Compliance & Regulations

Reliable Product

Optimized Usage

Higher Uptime

Energy Effic & Safe Product

Offering V1.0

Digital

Knowledgebase

Dynamic Data

Mapping Service

History

Energy

Usage


Things

Private/Public Cloud

Fog Node

Thing Open API

OPC-UA Protocol

Device Mgmnt

Remote Access

Thing Data Model

Asset Data

Appstore

Xpert System

Service History

Dynamic Data

Alarming Remote Mgmnt Mapping

Smart Ticketing


SW Distribution

Anomaly Detection

Connect

Monitor & Detect

Repair & Optimize

Upsell Asset Data Mapping Dashboard Alerting Dynamic Data Remote Management

connyun smart tools services (01/2017) (KUKA & NON KUKA Machines)


Asset Management: the source of all data

Digital Twin

Master Data

Process Data

Service Data Dynamic

Data Confi-

guration Data

Digital Insight Suite - Asset Efficiency

Asset Efficiency

Master Data

Modelling

Location &

Mapping

Digital Birth

Certificate

Documentation

Master Data

Modelling

Location &

Mapping

Digital Birth

Certificate

Documentation

• Definition of all necessary master data attributes per smart product type • Storage in connyun cloud or attached dynamically by API • Possibility to define publich attributes for smart product customers

• Production related data (date, time, factory, production line) • Charges and components • Performed tests and recorded test data

• Information about location of the smart product • Customer defined additional fiels & hierarchy • Mapping view of assets

• Available customer documentation of asset • Delivery configuration • Documentation URL for embedding on customer side


Asset Data Mapping

Asset Management: the source of all data


Smart Operation: Get insight in the usage

Operations Efficiency

Usage tracking

Environment tracking

Material usage

Benchmarking

Digital Twin

Master Data

Process Data


Data Confi-

guration Data

Digital Insight Suite - Operations Efficiency

Usage

tracking

Material

Usage

Environment

tracking

Benchmarking

• Track all available usage data provided by internal and external sensors • Define the frequency and the historization timeframe • Track the related configuration data and process parameters

• Track all available environment data based on sensors • Store these data as tmime series data (compressed)

• Track material usage of smart product if available • Correlate material usage data with order data if available

• Build in factory / in use benchmarks • Select data sets (attributes) for benchmarking • Define own benchmarking KPIs and ranges for tracking


Dynamic Data

Smart Operation: Get insight in the usage


Smart service: move up to help your customer

Service Efficiency

Remote

Management

Service

History

Expert

Knowledgebase

Smart

Service Ticketing

Digital Twin

Master Data

Process Data


Data Confi-

guration Data

Digital Insight Suite - Service Efficiency

Remote

Management

Expert

Knowledgebase

Service

History

Smart

Service Ticketing

• Remote Access to the connected smart products on a global base • Controlled inside – out connection capability • Logging of all interactions during the session

• Service logbook per asset instance • Next service request attached • Connection to related service ticket (if available)

• Issue and solution database of known issues & probability of solution • Extend by going forward • Recommended SW updates to solve issue

• Automated service ticket creation in case of error • Automated solution recommendation in service ticket • Configuration of alarming method


Maintenance Efficiency

Condition

Monitoring

Predictive

Maintenance

Maintenance

Plann. & Schedul.

Root cause analysi. & anomaly detect.

Digital Twin

Master Data

Process Data


Data Confi-

guration Data

Digital Insight Suite - Maintenance Efficiency

Condition

Monitoring

Maint. Plann. &

Scheduling

Predictive

Maintenance

Anomaly

Detection

• Definition of alerting ranges per asset type and asset version • Configuration of alerting method • Logging of critical situations

• Learning of critical patterns • Correlation to necessary actions to overcome predicted critical situation • Configuration of alerting method

• Planning of maintenance cycles per asset type & version static & dynamic • Creation of a service ticket to schedule necessary service action • Open & planned maintenance tags per asset type & version

• Logging of execptional behaviour of systems & services • Configuration of alerting method



Smart Service: Samples

Alerting Remote Management



Smart KPI‘s: Get a fast insight

Analytics Efficiency

Own KPIs

Dashboarding

Statistical

Quality Control

OEE

Own KPIs

• Definition of Dashboards based on available KPI‘s by Usertype & User • Support of web frontends and mobile

• Provisioning of OEE related to the smart product type and version • Availability of production information of customer necessary

• Statistical quality KPIs based on transmitted data • Correlation of service tickets possible

• Definition of own KPIs based on transmitted data • Definition of user type access

Digital Twin

Master Data

Process Data


Data Confi-

guration Data

Digital Insight Suite - Analytics Efficiency

Production Optimization (OEE)

Statistical Quality Control

Dashboarding


Smart KPIs: Samples

Dashboard

Smart KPI‘s: Get a fast insight


Edge CLOUD

KUKA.Connect

Device 1

Device 2

Device 3

Device 4


Things

Public Cloud

Private Cloud

Edge Cloud

Services

Product Resumes

SAP

Ticketing

Digital Twins

Constructing ‚your‘ Cloud in an embedded ecosystem

User Production Your customer

User Connected Product Your company

Your Business IT

Your

Device

Your Device

Your Device


Internal Pilot KUKA Production: inspiration for customers and validation of our solutions

- Cost improvements: ROI < 3 years

- Process and quality improvements

- Scaleable flexible production

- Right data at right time at right place

- Highest safety

- Material supply with autonomous navigation

- 50 robots in 2020

Connected devices:

• all robots in axis 1 line

• SPS

• intelligent screwdrivers

• mobile robot

Features:

• Mapping

• Asset management

• Data acquisition

• Dynamic data

• Remote management

Showcase availability

• Ready for production 11/2016


Status Industry 4.0 implemented and planned solutions in KUKA production

Connection implemented

Connection in progress


Status Industry 4.0 – benefits in KUKA production

1. Real-time device state and operational status 2. Access to device manual 3. Timeline with fault occurrences and maintenance milestones 4. Energy consumption graph 5. Motor temperature graph 6. Robot key performance indicators 7. Robot identification and specification data 8. Time range adjustor for timeline and condition monitoring views. 9. Robot uptime counter. 10. Remote management

Advantages:

- Cost reduction

- Data of whole system in one base online

- Data transparency on shopfloor

- Integration of process data

- Quality and process improvements by effective

analysis

- Gain experience with own products

- Customer reference cases


KUKA.Connect

Bringing the Internet of Robotics to Life


Zero Software Installation


KUKA Connect Ecosystems

Simulation

Service

Open API

Optimization



How to start?


How to start?

Fast

PoC

Design

Pilot

Pilot(s)

live Digitalization

delivered + + =

Requirements, Prototyping &

Stakeholder Testing

Connect Piloting to

Rollout

Success delivered

1 machine visible in the cloud

1 use case ready to rollout

1 use case In production

1 use case defined, agreed & tested


How to start – Steps to a PoC

Technical

Workshop

Design

PoC

Implementation

PoC

Get a better understanding about technical details

Get an alignment about protocols Get an understanding about

northbound and southbound APIs

Build a connected tool PoC as a minimal viable product

Select services out of our toolbox Involve your internal and external

stakeholders Follow the keep it simple principle

Define the necessary implementation support for your

services

Technical understanding

Decide on the scope of PoC

Decide on the necessary support


Summary


• KUKA is one of the leaders in Industrie 4.0

• KUKA and connyun are delivering an end2end solution

• KUKA is building a suite for connected product via connyun

• KUKA is using the solution itself the solution for the robots and stir welding machines

• KUKA is creating an ecosystem of technology partners to make the manufacturing cloud reality

• Your are invited to do a fast PoC to get first hand experience

• We do understand the needs of a machine builder, because we are one

• We are enhancing the solution on a regular basis to move from connect to insight to predictive services

• We are focusing on upsell of services

• We are building the basis for new business models together

Summary – Let us influence the future together

Be part of it!


10 reasons to use connyun

Connect

• Easy, secure, fast connection of your production fleet

• Open your machines HMI‘s for visualization and mobile control

• Secure opening of your closed production environment to the new cloud-based capabilities

Detect

• Asset efficiency as enabler for all shopfloor based processes

• Control the whole life-cycle of your products from design, make, ship, use and maintain

Act

• Embedded Big Data Analytics capabilities

• Extend the capabilities of your machines by community based extensions

Optimize

• Learn from data correlations and multi-vendor benchmarking

• Easy reconfiguration by your fingertips

• Use the automation know-how and IT competence of the world-leading companies behind connyun

Connect Detect Optimize Act


The purest form of madness is to leave everything as it is and still hope that something will change (Albert Einstein)

A wise man at the end of this presentation…


Questions

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The Power of Manufacturing Ecosystem · Konzernstrategie 2016-2020 KUKA Konzern | CEO | Dr. Till...

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