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Progress within the network The Industrie 4.0 system from SmartFactory KL
Welcome to the future of industrial production
02 VISION
Industrie 4.0 – Progress within the network
Germany is the land of engineers and inventors. Even more, unlike most other developed economies, Germany is still a country of production. Vehicles, machines and medical devices made in Germany have an excellent reputation worldwide and are important pillars of the German economy. But other nations are catching up and force us to defend our lead. Industrie 4.0 is the right concept to successfully redesign the future of industrial production and to ensure the competitiveness of the production site Germany in the long term. SmartFactory KL is committed to paving the way for the intelligent factory of tomorrow. As the leading competence center and manufacturer-independent platform for demonstration and research, we develop innovative factory systems in which the vision of Industrie 4.0 is already becoming reality. The mandatory requirement for this is interoperability. Because consistent standards for manufacturer-independent compatibility between the individual plant modules and complete plants are the central requirement of the fourth industrial revolution. In a network with renowned partners
from industry and research, we are working on new concepts, standards and solutions which form the basis for a highly flexible automation technology. This year, we will present the developed, industrialsuited and completely modular Industrie 4.0 plant at the Hannover Messe. Together with our ever growing partner circle, the focus especially lies on the topics Predictive Maintenance, failure-proof maintenance, employee support and scalable, modular automation. Consistent standards which were defined in the SmartFactory KL consortium facilitate the aggregation and collaboration of individual production and infrastructure modules as well as IT services – technical requirements with which the producing companies can meet the demands of tomorrow. And this is only the beginning. We have great plans for the coming years. With more new research and development projects, we will further our common vision of the intelligent factory. We can‘t do this alone, we need your ideas, solutions and competencies as partners at SmartFactory KL. Join us!
Prof. Dr.-Ing. Dr. h.c. Detlef Zühlke Chairman of the Board Technologie-Initiative SmartFactory KL e.V. Scientific Director, Innovative Fabriksysteme (IFS), DFKI
„There are no national borders for Industrie 4.0, because the concept of cross-linked production will only work world-wide. On a global level, there is not only competition but also a high interest in learning from each other. Extensive success will only happen if international compatibility and consistent standards are defined.“
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INDUSTRIE 4.0
How can the availability of plants be maximized?
How can a production line be set up or converted within a short period of time?
How can the worker be supported in the future production environment?
The Task: Standards for Industrie 4.0
Simply include automation and IT modules and immediately integrate them into the production process: with standardized interfaces and state-of-the-art information technology, the intelligent company facilitates a highly flexible automated production according to the motto “Plug&Produce”. This is how companies adjust to significantly different general conditions. Significantly shorter life cycles, increasing individualization of products and world-wide growing cost pressure demand new, interconnected answers. The developed demonstrator which SmartFactory KL has realized with 18 partners in the industry will show what productivity potential the intelligent factory of tomorrow has to offer. The partners have developed production modules and the superordinate infrastructure, and provided important IT systems. Independently constructed
modules integrate into the process in an interoperable and seamless way. This also includes systems which perfectly support the human as an actor in the environment of Industrie 4.0. Manufacturer-independent standards, from consistent mechanical measurements and connections to common communication protocols, form the basis for consistently modularized factories. With the connection to manufacturer-independent infrastructure solutions as well as neighborhood detection of the production modules by means of RFID, a flexible production network is being created according to the Plug&Produce principle. Defined standards for information technology, such as for information protocols and the description of product memories, create the preconditions for an intelligent production flow.
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Intelligent, modular – ready for use in industry: The Industrie 4.0 system from SmartFactory KL
10 INDUSTRIE 4.0
The Crosslinked Production
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With the world’s first manufacturer-independent Industrie 4.0 production plant, SmartFactory KL shows that batch size 1 with set-up time 0 is already possible today. The highly convertible production is based on consistent standards, Plug&Produce and modularly integrated IT systems. This way, companies image shorter innovation cycles and an increasingly strong customer-oriented value.
order situation and the customer’s request. The modules can be put together in new configurations at any time. The efficient, flexible infrastructure which takes over essential supply and management functions for the production modules minimizes this configuration effort. The infrastructure is thus the connecting lifeline between the production modules, which otherwise act completely autonomous.
The SmartFactory KL network partners have developed nine production modules with specific production capabilities according to standards that were defined together. Due to the modular conception, the demonstrator images different production scenarios depending on the
The product itself also contributes to flexible, customer-oriented production processes. Through an integrated RFID tag, each product controls its own production by transmitting the product specification to the single production modules for individual processing.
Workpiece carrier with plastic bottom
The process structure
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The STORAGE MODULE by Pilz serves as an intelligent automated memory for the workpiece carriers: sensors register each carrier when passing the module and identify it by means of RFID technology. If the workpiece carrier is empty, it is removed from the production flow with a gripper and then stored. If the central server reports a new order to the module and thus the need for an additional carrier, the module starts circulating an empty workpiece carrier from storage.
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During the process, the module ENGRAVE BOTTOM by Festo initializes the digital production memory by RFID with a production order. The production order is loaded from the Web server of the superordinate ERP system per http-protocol by means of a specially developed Web Client. In accordance with the production memory, an individual engraving is added via a CNC engraving control.
Reading and writing the digital production memory
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The CLIP MODULE by the company Bosch Rexroth mounts a retaining clip on the plastic bottom. Open interfaces facilitate horizontal and vertical networking. For example, the consistent access from the initial commissioning, operation and diagnostics with the smart device to the integration into IT processes.
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The central mounting of the two housing parts takes place in the module FORCE FITTING by HARTING. The base plates with the retaining clip is mounted with the cover, according to the client’s wish in one of two colors. The HARTING module puts the lid on the base plate with a robot and embosses both parts together.
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A function-expanding ROBOT MODULE, which was realized by SmartFactory KL and which provides additional lids in different colors, can be docked to the module Force Fitting. Furthermore, a neighborhood detection at the back of the module automatically verifies if the function extender is available. The robot
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Retaining clip is mounted onto the plastic bottom
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Force fitting of the base plate with the retaining clip and the cover
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Individual laser engraving on the top side 6
can take the other colors out of a storage and transmit them to the module Force Fitting lid. It is automatically reported back into the order entry if and for which service the function extension is added. Accordingly, the order entry can reflect the possible product variants, which are suitable for the respective plant topology, for selection.
docked to this module and present another function. It can insert another give-away into the completely assembled business card holder. For this, the robot takes the product out of the LAPP module and inserts a business-card shaped give-away into the clip. The finished products are reinserted into the LAPP module and processed further.
charge each product at the production step to be replaced and to replace it by a manual assembly order. This way, a failure-proof maintenance and a scalable automation of the production line is flexibly possible.
The module LASER MARKING by the company PHOENIX CONTACT puts an individual engraving (batch size 1) on the top side of the business card holder by means of a laser engraving system. The engraving shows the name and a digital business card with an engraved QR code. This data can be flexibly changed upon the client’s request up until the process step.
The WEIGH MODULE by Mettler Toledo provides the in-process quality control at the end of the production line. The integrated high-precision scale determines the weight of each product with an accuracy of 1 mg. By comparing the individual product weigh with the stored reference weight it can be determined whether or not all components are installed and thus the giveaway is completely produced.
A MANUAL WORK STATION, which was realized by the company MiniTec, is connected to this process. An ergonomical, perfectly adjusted work station with many entry possibilities for technology carriers offers the possibility to support employees with assembly tasks with many variants up to batch size 1 by means of Internet and communication technologies. Augmented Reality Technologies, developed by SmartFactory KL, accompany individual assembly steps or the complete production process. Augmented Reality – the connection of real-time pictures with recommendations for actions – offers many advantages, especially for training processes and assembly with many variants. Through an
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The module QUALITY CONTROL by LAPP KABEL takes on two tasks: the end control of the product by means of a high-resolution camera as well as the output of the completed business card holder. The described function-extending robot module can also be
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The BRIDGE MODULE by the companies TE Connectivity and MiniTec offers the possibility to replace any other module in the production process. A short program selection enables the module to dis
Manual assembly with support of the employees
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Flexible manual work station for manual assembly tasks
integrated RFID reading and writing device, the employee can read out the current production progress of the product as well as the client-specific information. Augmented Reality Technologies will support the implementation of the variable tasks. During complex and high-variable maintenance and repair tasks, “mobile smart devices” such as tablet PCs, smart phones, smartwatches and smartglasses guide the employee through his tasks.
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Infrastructure: The Common Lifeline
To be able to combine production modules universally and with minimal configuration effort to a production process, an efficient, flexible infrastructure is necessary. It takes on the essential supply and management functions for the production modules. This includes energy supply, data routing and comprehensive control of the safety functions. The infrastructure is thus the connecting lifeline between the production modules, which otherwise act completely autonomous. The infrastructure is set up modularly and enables the manufacturer-independent connection of the production modules. Thus, it increases the flexibility in the structure of Industrie 4.0 plant and saves expensive infrastructure planning, for example for the energy network.
Plug&Produce by means of a consistent supply through an infrastructure backbone
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The first generation is an infrastructure box developed by the SmartFactory KL. By now, this concept is used by different partners and further developed to specific products.
Vendor-specific Infrastructure boxes enable a standardized connection of the production modules. Plug & produce becomes reality.
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The HARTING technology group presents another development level of the in-house infrastructure box, which is equipped with efficient hardware and software. In-house plug connectors ensure a secure and standardized connection. An integrated touch control designs the operation of the infrastructure box intuitively.
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PHOENIX CONTACT has also presented a compatible in-house development of the infrastructure box. Among others, comprehensive interoperability is ensured by the compatible, industrial plug connector by PHOENIX CONTACT. Furthermore, the infrastructure box shows a module-independent measurement data recording and intelligent evaluation including plant evaluation. This way, the objective of an energy-efficient production can be easily tracked.
The infrastructure box, which was developed by TE Connectivity, ensures high energy efficiency as well as hasslefree production processes. For this purpose, the plant modules are permanently monitored through the infrastructure box by TE Connectivity. The data communication with the control level is performed through an industry switch – which is also integrated into the box – by the leading IT manufacturer Cisco.
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Belden/Hirschmann and Weidmüller also take on their own infrastructure boxes. The communication modules by HIRSCHMANNTM enable a crosslink between the process control, control technology and actuator/sensor technology; the in-house switches ensure efficient communication, while the firewall solution implements state-of-the-art security and firewall functions. The integrated energy measurement by means of Weidmüller components make an energyefficient connection of the production modules possible.
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Vertical Integration: Real and Virtual World
Industrie 4.0 stands for a close connection of automation technology and IT systems, a consistent vertical integration. The synchronization of the real and the digital world creates high transparency and opens potentials for computer-assisted optimization. Information on production modules and products is continuously recorded in real-time and forwarded to modularly connected IT systems. This digitally available information forms the initial situation for disruptive business models, such as data-based services for business process integration, Predictive Maintenance, remote diagnostics and maintenance. In cooperation with automation technology and IT providers, the SmartFactory KL network has already realized a series of solutions.
implementation of the visions in the context of Industrie 4.0 of a Smart Factory. It is the intention to recognize the necessary real requirements of modern production in order to establish according software standards for efficient production.
The “digital image” of the Smart Factory – in the form of a unique and flexible dashboard by the company IBM – combines data from production modules, infrastructure boxes and IT systems, in order to answer questions on quality, continuity or anomalities of the production. Process data of the jointly defined OPC UA information model were recorded, enriched and saved in a structured way in a data historian. From this, analytical results are derived in order to avoid botSteer complex processes tlenecks, rejects, rework and downtime. Process data and results of the analytics are communicated farther efficient and transparent in order to achieve operational excellence, transpar Industrie 4.0 means way more than only the tran- ence in real-time, proactive repair and quality sition to flexibility and automation of production. assurance. The exemplary use of cognitive procedures This requires a lot for the production, but also from the supports the human expert and makes the idea of a comprehensive business processes. In the future, the “cognitive factory” tangible. planning processes have to be able to efficiently integrate decentralized partial planning. The integrated The maintenance and service aspects for operatERP SYSTEM by the company proALPHA keeps the ing a plant like this are provided by SAP, leveraging processes, which keep becoming more and more com- business processes that are secure with low operating plex, transparent in the Industrie 4.0 demonstrator. The costs. Massive amounts of data can be analyzed in realsolution is able to create an integration between the time, maintenance status and plant efficiency levels of the classic automation pyramid. reports can be generated, and service orders can be created. The direct transfer and analysis of data (plant Proactively optimize productivity status, operational measurement data such as pressure, temperature, humidity, etc.) from the production It is the goal of iTAC to implement Internet-capa- floor to the device cloud make it possible to automatible MES standard solutions, which enable an cally trigger repair and service orders. Through this
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cloud connection, component manufacturers and plant operators can collaborate directly, offer services, or consume services on any device in any plant across a secure network without disruption.
Flexible production according to the Plug&Produce principle The Connected Factory Architecture by CISCO connects intelligent networks, server architectures and Unified Communication with the objective of uniting IT and automation technology. This creates the preconditions of a modern Industrie 4.0 environment in the company. The interaction between the CISCO technologies facilitates application in the area of preemptive maintenance, multimedia remote access to plants and remote maintenance concepts.
Interdisciplinarily planning automation technology 20 EPLAN Software & Service takes on engineering in the Industrie 4.0 demonstrator. The automation technology of the single production modules has to
be treated interdisciplinarily, since it is mandatory for structure, efficiency and operational security of Cyber Physical Systems (CPS). The control technology documented in EPLAN is used as continuous, consistent data basis in the complete supply chain and over the complete product life cycle. It is the objective to already consider findings from the complete supply chain as early as in the engineering phase or in the PLM process (product lifecycle management). The generated documentation is suitable, for example, for professionalized maintenance scenarios or the optimization of the energy balance.
Concept for the certification In order to transport the vision of Industrie 4.0 to reality, TÜV SÜD is working on creating a concept for a modular certification methodology for flexible plant structures. The security-related and legal questions contained herein have not been considered enough so far and pose a potential threat. The certification method developed by TÜV SÜD experts contains a concrete, analytical approach which makes the advantages of Industrie 4.0 possible to successfully implement in operational practice.
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From Data to Information to Knowledge
The following scenario clearly shows the advantages of the modular structure, the scalable automation and the deep integration of IT systems into the process.
Increased consumption data Through the implemented Data Monitoring Tool, the different module data can be viewed in real-time and evaluated by means of different algorithms. During this evaluation, it is noticed that the energy consumption data of an actor in the clip module have increased. By means of a comparison with the manufacturer information and experience values on this actor, an outage can be predicted about 200 operation hours in advance. By means of an adjustment with the orders and the predicted delivery time for the necessary replacement parts, the service provider of the module plans a suitable repair point in order to prevent the outage and to perform the repair with as little loss as possible. The appropriate repair technician receives all necessary information directly and is informed of the upcoming appointment. The necessary replacement parts are provided automatically.
Plug&Produce If it is time for the repair, the responsible repair technician removes the clip module out of operation and pulls it from the production line. The module is replaced by the available bridge module. The neighbor modules first close the gates to discharge the clip module from operation, and re-open the gates after recognizing the bridge module. During initial operation, the bridge module receives the information to replace the step „Apply spring“ by the repair technician.
Scalable automation From now on, the bridge module discharges all products which request the order „Attach spring“ via the RFID production memory. The technician in the production environment can perform this step as well as all other production steps manually at the manual work station. He removes the discharged product, reads the RFID tag at the manual work station and receives support with the assembly tasks by means of Augmented Reality. When the task is complete, the RFID production memory is rewritten and the product is reintegrated into the process through the bridge module. The other tasks can continue to be performed automatically. It is thus possible to perform failure-proof maintenance of the clip module and to flexibly adjust the production line to the requirements.
Repair By means of Augmented Reality Technologies, which give the repair technician recommendations for action through his Smartglasses, the repair process can be performed quickly and error-free. The defective actor is removed from the module and replaced by the reordered actor. As soon as the module is connected to the plant network again, it is possible to directly transfer the configurations from the old actor to the new actor by means of continuous engineering. The configuration effort will thus be reduced to a minimum. After this process has been completed, the repair technician will exchange the clip module in the production line with the bridge module. The production process continuous fully automatically.
20 PARTNER
Many Partners, One Common Project: Progress within the Network!
Festo is the world leader in automation technology and world market leader in technical training and advance training. Pneumatic and electric drive technology by Festo stands for innovation in the industry and process automation - from the individual product to the readyto-install solution. Innovations for highest possible productivity of the customers, worldwide presence and close system partnership with the customers are the trademarks of Festo. The company employs 17,800 employees in 61 countries all over the world www.festo.com
The realization of Industrie 4.0 demands ideas and collaboration, as well as the eagerness to experiment and willingness to learn. Because in order to develop the intelligent factory of tomorrow, new technologies and concepts are needed, which can only be developed, tested and implemented jointly in a strong network. For this reason, various partners, which are among the leaders in their respective fields, are involved in the realization of the first manufacturer-independent Industrie 4.0 plant.
As a specialist for industrial communications technology, Hirschmann™ – a Belden brand – develops innovative solutions oriented towards high customer demands with regard to performance, efficiency and security of investment. Hirschmann™ offers a complete range of Ethernet products for data communication in applications of critical importance to companies. These include Layer 2 and Layer 3 switches as well as security and wireless LAN systems that enable a standardized company-wide communication infrastructure. www.hirschmann.de
The HARTING Technology Group specializes in the areas of electrical, electronic and optical connection, transmission and network technology, manufacturing, mechatronics and software creation and develops tailor-made solutions and products such as plug-in connectors for power supply and data transmission, for industries including mechanical engineering, railway technology, wind energy plants, factory automation and the telecommunications sector. www.harting.de
IBM has become one of the strongest brands in the world by innovations which far exceed technology. IBM offers the complete IT portfolio from one source: from the super computer to software and services to financing. Today, IBM focuses on the growth initiatives Cloud, Big Data and Analytics, Mobile Enterprise, Social Computing, Security and Cognitive Systems and supports companies of all sizes in leveraging the chances of globalization. In the recently opened Watson Innovation Center in Munich, developers, consultants, researchers and designers will work on crosslinked solutions around the topics Internet of Things and Cognitive Computing. www.ibm.com
Cisco (NASDAQ: CSCO), the world-leading IT provider, helps companies seize tomorrow’s business chances today. Unique opportunities are opened up by networking people, processes, data and more. Current information on Cisco can be found at: globalnewsroom.cisco.com/de/de gblogs.cisco.com/de www.facebook.com/CiscoGermany twitter.com/#!/cisco_germany
EPLAN Software & Service develops CAE solutions and advises companies in the optimization of their engineering processes. Customers benefit from increased efficiency in the production process thanks to standardized procedures, automated sequences and continuous workflows. EPLAN delivers tailor-made concepts for introducing and setting up systems as well as integrating them into the IT/PLM system landscape – based on standard engineering solutions. The service portfolio also comprises customizing, consulting and training. www.eplan.de
iTAC Software AG, an independent company of the mechanical and plant engineering group Dürr, offers Internet-compatible information and communication technologies for the producing industry. The company that was founded in 1998 is one of the leading MES manufacturers in Germany. The iTAC.MES.Suite is a cloud-compatible Manufacturing Execution System, which is used worldwide for companies of different industry sectors such as automobile supplier, electronics/EMS/TK, medical technology, metal industry and energy. Further systems and solutions to implement Industrie 4.0 requirements round off the portfolio. It is iTAC‘s philosophy to connect people, data and systems with each other. www.itac.de
Headquartered in Stuttgart, Germany, Lapp Kabel is a leading supplier of integrated solutions and branded products in the field of cable and connection technology. Lapp Kabel’s portfolio includes standard and highly flexible cables, industrial connectors and screw technology, customized system solutions, automation technology and robotics solutions for the intelligent factory of the future. The Lapp Group’s core market is in the industrial machinery and plant engineering sector. Lapp Kabel has more than 40 sales companies, 18 production sites and approx. 100 national partners worldwide. They employ 3,200 people. www.lappkabel.de
22 PARTNER
The proALPHA group is the third largest provider of ERP for medium-sized manufacturing and trading companies in the D-A-CH region. For more than 20 years, proALPHA has offered a powerful ERP solution as well as consulting, support, training, and maintenance services from one source. Among our customers are approximately 1,800 medium-sized companies from various industries in 50 countries, such as plant and systems engineering, electrical and high-tech, metal working, plastics, wholesale, and automotive and supply industries. www.proalpha.de
Mettler Toledo is a leading global manufacturer of precision instruments. The Company is the world’s largest manufacturer and marketer of weighing instruments for use in laboratory, industrial and food retailing applications. The Company also holds top-three market positions for several related analytical instruments and is a leading provider of automated chemistry systems used in drug and chemical compound discovery and development. In addition, the Company is the world’s largest manufacturer and marketer of metal detection systems used in production and packaging.
From a single module to a complete solution: What started with miniature linear guides in 1986 developed into an internationally renowned full-service provider with more than 350 employees in ten factories and over 60 partners and service points worldwide. The MiniTec modular system with its proven and flexibly deployable components for automation technology and plant engineering is valued and used by leading companies all over the world. www.minitec.de
www.mt.com
Since its foundation in 1972, SAP has become the leading provider of innovative business software that drives profitable growth. Thanks to the applications, solutions, and services provided by SAP, more than 250,000 customers worldwide are able to continuously adjust to new market requirements and sustainably grow their businesses. Industrie 4.0 is an important element of SAP‘s product strategy, which focuses on networking with employees, customers, suppliers, and the Internet of Things. By leveraging new collaboration and networking technology from SAP, companies can vastly improve their operational and commercial processes through new and innovative business models. www.sap.de
PHOENIX CONTACT is the world market leader for components, systems and solutions in the field of electrotechnology, electronics and automation. As an operator and manufacturer of modern production plants with a high degree of vertical integration as well as a supplier of automation products and the related connection and interface technology, PHOENIX CONTACT has a thorough knowledge of the requirements of Industrie 4.0. Because we aligned our business towards ITpowered automation at an early stage, we have many years of experience and contribute this to the committees for Industrie 4.0. With our in-house mechanical engineering section we plan, build and test the intelligent production of tomorrow. www.phoenixcontact.de
Pilz is a complete automation technology supplier. The company covers the whole of automation technology, from sensor technology to control and actuator technology. The product range also comprises relevant software tools, diagnostic and visualization systems and services. Complete system solutions are the result. Pilz solutions consits of both automation and safety functions. One example is the automation system PSS 4000, the central concept of which is to merge safety and automation. www.pilz.de
TÜV SÜD provides quality, safety and sustainability with 24,000 employees at more than 800 locations worldwide. In the sector of Digital Service, TÜV SÜD bundles consulting, training, inspection and certification services around Industrie 4.0. The experts support companies in exploiting the potentials of digital change, identifying weaknesses in IT security in automation and control plants and in developing according protective measures. With an approach that combines security and efficiency, the experts offer comprehensive services for operation security, IT security and analytics. www.tuev-sued.de
Economical, precise, secure and energy-efficient: drive and control technology by Bosch Rexroth moves machines and plant of any size. The company bundles the world-wide application experiences in the market segments if mobile applications, plant engineering and engineering, as well as factory automation for the development of innovative components, tailored system solutions and services. Bosch Rexroth offers its customers hydraulics, electric drives and controls, transmission technology as well as linear and assembly technology from one source. www.boschrexroth.de
TE Connectivity is a global technology company with 80,000 employees, including 7,500 design engineers. We develop, produce and market connection technology and sensor solutions that enable and protect the flow of energy and data in many devices and systems used on a daily basis. In our main markets of industry & energy, the automotive sector, data communication and consumer goods we offer innovative and high-performance products and solutions that are proven in harsh environments. These include plug-in connector systems, antennas, sensors, relays, fiber glass solutions, wire and cable products as well as protective systems. www.te.com
Weidmüller is your partner for Industrial Connectivity. As experienced experts, we support customers and partners all over the world with products, solutions and services in the industrial environment of energy, signals and data. We are at home in your industries and markets and know the technological challenges of tomorrow. We continue to develop innovative, sustainable and valuable solutions for individual requirements. Together, we set standards in Industrial Connectivity. www.weidmueller.de
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Technologie-Initiative SmartFactory KL e.V. Trippstadter Straße 122 67663 Kaiserslautern, Germany P +49 (0) 631 / 20575-3400 F +49 (0) 631 / 20575-3402 M
[email protected] The Technology-Initiative SmartFactory KL e.V. (SmartFactory KL) is a non-profit association registered in the register of associations for Kaiserslautern
Association registration number: VR 2458 Kai Sales tax identification number: DE249965612 Executive Board Prof. Dr. Dr. h.c. Detlef Zühlke, DFKI GmbH (CEO) Andreas Huhmann, HARTING KGaA Dr. Thomas Bürger, Bosch Rexroth AG Dr. John Herold, Belden Electronics GmbH Management Rüdiger Dabelow, DFKI GmbH Source for images: Christopher Arnoldi; Lapp Gruppe/Maiwolf
