Mô tả:
Sustainable Manufacturing and Factory
Planning
Industry 4.0
13.04.2017
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
© IWF TU Berlin
Page 1
Content
Industry 4.0 – Definition – Benefits
Examples and Case Studies
Status of Implementation
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 2
Content
Industry 4.0 – Definition – Benefits
Examples and Case Studies
Status of Implementation
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 3
Next Evolution
2. Industrial
Revolution
3. Industrial
Revolution
Use of electronics and IT
for further automation in
Implementation
of production
division
of
labor
Implementation
of production supported by
mechanical
production electrical Energy
facilities
supported
by
Water- and steam power.
1. Industrial
Revolution
1952
Numerical control
1769
mechanization
1870
division of labor and
mass manufacturing
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
1969
Microprocessors in
Production
Digital penetration of the
whole Production Chain
1973 - 1985
Computer Integrated
Manufacturing (CIM)
2012
Cyber-physical
Systems
(Industrie 4.0)
Quelle: In Anlehnung an BITKOM, VDMA, ZVEI: Plattform Industrie 4.0; Fotos: © Fraunhofer IPK
Digital integrated, intelligent Production
Industry 4.0 – The 4th Industrial Revolution?
Page 4
Mass Manufacturing
z. B. BMW Online Car
Configurator
1955
1980
2000
z. B. Global Processmanagement at KSB
1913
„People can have the Model T
in any colour − so long as it‘s
black.“
Henry Ford (1913)
1850
z. B. Additive Manufacturing
Product Variety
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 5
In Anlehnung an: The Global Manufacturing Revolution; Quellen: Ford, beetleworld.net, bmw.de, dw.de
Production Output
per Variant
Increasing Complexity lead to new value chains
The 4th Industrial Revolution: Industrie 4.0
Economic
Production is highly flexible, highly productive (up to +40 %)
Value creating processes are optimized on-demand and in real-
time
Existing infrastructure can be upgraded gradually
Environmental
Resource-efficiency (up to -50 %) and compatibility with urban
life
Social
Adaptive and intelligent assistance systems support the
employee in his enlarged range of tasks
Work-life-balance and a human-oriented work organization
Pace of production adapts to human requirements
From centralized control to decentralized self-organization
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 6
Industrie 4.0 Involves a Fundamental Paradigm Shift
Smart products will actively support the manufacturing
process
Autonomous, self-organizing production units will replace
passive manufacturing systems operated according to preplanned criteria
Orders will autonomously negotiate their own way through
dynamic value chains
Individual availability calendars will replace inflexible fixed
working hours
Ad hoc networking of manufacturing facilities and businesses
Pace of production adapts to human requirements
From centralised control to decentralised self-organisation
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Image source: Hewlett-Packard
Page 7
The Smart Factory: A Network of Smart Objects
Area 3
(e.g. Smart Traffic)
Connection to the internet
Area 2
Smart Data and
Smart Services
(Smart Factory)
Smart Spaces:
Contextual
information
Smart Products
Smart Products
(Security Area 1)
(Security Area 1)
Supply of
Smart Services
Smart Objects:
Machines and products
in the factory
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 8
Industrie 4.0 Enabling Real-time Value Networks
Integrating IoT
Ad hoc networking
Quality of service
Traceability and liability
Image source: Hewlett-Packard
Smart grid, smart truck,…
Contracting
Monitor, predict
and act in real time
Who owns what data?
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 10
The way to Industry 4.0
Yesterday:
Product Identification
Readable Information Devices
Barcode
Identification of Products and Tools
Today:
Product Memory
Read and Write Information
RFID-Transponder
Traceability and Documentation of Production
Tomorrow:
Product / Production Intelligence
Computation at product side
Products are taken all information for production inside
eGrains
Objects communicating, cooperating and decide
Objects can localize themselves
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 11
“Industry 4.0” – The fourth industrial revolution?
The term Industry 4.0 stands for a level of evolution of the third industrial revolution
embodying a new level of organizing and managing the entire value chain along the
products’ life cycle.
The vision itself is an intelligent, real-time-networking factory. Humans only configure
and monitor the planning and management.
Basis for Industry 4.0 is the ad hoc availability of all relevant information and the ability
to enable an optimized flow of value creation for the company at any time.
Industry 4.0 thereby provides companies with the opportunity to control the
complexity consisting of individual products, short development and delivery times and
also short-term changes.
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 12
Potentials for Quantitative Benefits by Industry 4.0
Reduction of production resources
Reduction of work-in-progress
Increase of capacity utilization
Reduction of processing time
Increase of production output
Reduction of production costs
Reduction of efforts for coordination /
communication
Time savings on production planning and
management
Source: SOPRO, Analysis in a Gas Turbine Plant
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 13
Production Days
Benefit of Throughput time – from sample dataset
80
70
60
50
40
30
20
10
0
69,7
58,7
55,8
46,9
41,4
33,1
30,7
21,2
45,3
29,6
36,2
27,3
Product Group 1 Product Group 2 Product Group 3 Product Group 4
Manual Planning
Planning with MES
Ideal - Simulation
Source: SOPRO
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 14
Sources and Effects of Industry 4.0
Faster Processes and optimized
Changeability
Complexity Reduction in the aspect of
Man-Machine-Interaction
Reduced Costs of information handling
Using
networked intelligent
Systems
Acatech
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Page 16
Detail – Vertical Integration across the Automation Pyramid
TodayTomorrow
– Transparency
is required
– How about the costs?
- Integration
by „Process-eGrains“
Self Configuration
Many
Interfaces
ERP
Deeper
Self Organisation
Integration causes longer time
for implementation
MES
Immense Costs for introduction and
maintenance
SCADA
These Principles are valid for Process Design and Implementation
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
ERP – Enterprise Resource Planning
MES – Manufacturing Execution System
SCADA - Supervisory Control and Data
Page 17
Classical Process Chain of Industrial Production
A Product is created
Demand for flexibility and
transparency leads to central
integration of IT
Many interfaces between
levels lead to high efforts
and complexity
Planning and managing
along the automation pyramid
Integration of changes into
the normal process appears
very complicated
ERP
Current data quality is
MES
critical – manual
adjustments take a long time
SCADA
PDM
Service
Management
Sensors
Product
Development
Provision of
Raw Material
Production
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Assembly
Packaging
Storage/Dispatch
Use
ERP – Enterprise Resource Planning
MES – Manufacturing Execution System
SCADA - Supervisory Control and Data
PDM – Product Data Management
Page 18
Classical Process Chain of Industrial Production
What changes because of Industry 4.0?
Direct real-time networking of
production elements among themselves
(products, orders, employees, operation
systems):
Reduced complexity for employees
Planning and managing
along the automation pyramid
despite individualized production
PLM
Less interfaces – less effort
ERP
Planning and management do not
ERP ERP
hinder the processing
MES
MES MES MES
Quick feasibility checks for new
SCADA
requirements
SCADA SCADA SCADA
PDM
ERP MES
ERP PLM
ERP
Development
Provide
Raw Material
Sensors
SCADA
MES
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
MES
ERP
ERP
SCADA
PLM
SCADA
Produce
PLM
Service
Management
PLM
Assembly
Packaging
Storage/Dispatch
ERP – Enterprise Resource Planning
MES – Manufacturing Execution System
SCADA - Supervisory Control and Data
PDM – Product Data Management
Use
Page 19
The next Step: Outsourcing of the Production – IT into the Industrial –
Cloud
Higher performance
Easier data protection
System performance is
better adjustable
Cheaper components
ERP MES
ERP PLM
MES
MES
ERP
ERP
SCADA
PLM
ERP
Development
Provide
Raw Material
Produce
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Assembly
Packaging
Storage/Dispatch
ERP – Enterprise Resource Planning
MES – Manufacturing Execution System
SCADA - Supervisory Control and Data
PDM – Product Data Management
Use
Page 20
Connection to the “Internet of Things”, Processes and Services for direct
and flexible Controlling and Management
Order spare parts
Instruct assembly service
Feedback of mistakes
ERP MES
ERP
MES
MES
ERP
ERP
SCADA
ERP
Development
Provide
Raw Material
Produce
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
Assembly
Packaging
Storage/Dispatch
ERP – Enterprise Resource Planning
MES – Manufacturing Execution System
SCADA - Supervisory Control and Data
PDM – Product Data Management
Use
Page 21
IPK Developments in Industry 4.0 – Research and Partners
Managementcockpit
Self organized
Manufacturing
Design und Engineering
e-Industrial
Services
Manufacturing Control
Web Factory
Machinery and Atomization
1997
2001
Technische Universität Berlin
Institute for Machine Tools and Factory Management
Univ.-Prof. Dr.-Ing. Holger Kohl
2009
2015
Page 22
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