[Basque industry 4.0] The fourth industrial revolution based on smart factories

Industrie 4.0:The Fourth Industrial Revolution

based on Smart Factories

Bilbao, October 15, 2014

Professor Wolfgang Wahlster

CEO of DFKI

Saarbrücken, Kaiserslautern, Bremen, Berlin, Osnabrück

Phone: +49 (681) 85775-5252/4162

Fax: +49 (681) 85775-5383/5341

Email: [email protected]

WWW: http://www.dfki.de/~wahlster

© W. Wahlster

Towards Intelligent Environments based

on the Internet of Things and Services

90% of all

computers are

embedded

5) Intelligent

Environments

4) Embedded Computers

3) Smart Phone

Smart Card

2000 202019801960

Smart Factory

1) Central Computer

2) PC, Notebook

1 Computer

Many Users1 Computer

1 User

1941

Many Computers, 1 User

© W. Wahlster

Context- sensitive

and Location-Based

Smart Services

Cross-linking of

Assets and Products

in the Factory Internet

Capturing

Context Information

Digital Product

Memories

TrustedCloud

M2M

Communication

Between Intelligent

Objects

The Internet of Things in the Smart Factory:

A Network of Intelligent Objects

© W. Wahlster

Evolution from

Embedded Systems

to Cyber-Physical

Systems

500 M€ for 3 Years

National Program:

250 M€ Funding of

Ministry for Research and

Ministry for Economics

Future Project Industrie 4.0 of

German Chancellor Dr. Angela Merkel

Eingebettetes

System (ES)

Intelligente Umgebungen

z.B. Smart City

Vision: Internet der Dinge

EmbeddedSystemsAirbag

Cyber-Physical Systems

Smart Factory, Smart Grid

Networked Embedded

SystemsIntelligent Street Crossing

National Roadmap

Embedded Systems

Agenda

Cyber-Physical Systems

Intelligent Environments/Smart Spaces

Digital City

Internet of Things

© W. Wahlster

today (Industrie 3.0):

tomorrow (Industrie 4.0):

Machine plus Software

Software plus Machine

ICT as Innovation Motor No. 1

and Advanced Manufacturing

The Role of Software for Industrie 4.0

© W. Wahlster

From Industrie 1.0 to Industrie 4.0:

Towards the 4th Industrial Revolution

tEnd of

18th

Century

Start of

20th

Century

First

Mechanical

Loom1784

1. Industrial Revolutionthrough introduction of mechanical production facilities powered by

water and steam

2. Industrial Revolutionthrough introduction of mass

production based on the division

of labour powerde by

electrical energy

3. Industrial Revolution through Introduction of

electronics and IT for a

further automization

of production

Deg

ree o

f C

om

ple

xit

y

Start of

70ies

4. Industrial Revolutionbased on Cyber-Physical

Production Systems

today

010001101001010100100101010010010101

Industrie 1.0

Industrie 2.0

Industrie 3.0

Industrie 4.0

© W. Wahlster

Industrial production is the backbone of Germany‘s economic performance:

jobs direct: 7,7 Million. indirect: 7,1 Million, every second job

more than als 158 € Billion trade surplus from export of industrial products

(export : machine tool industry, automotive industry)

Disruptive Paradigm Shift in Production based on the Future Internet

1. M2M and All-IP Factories are shifting from central MES to decentralized

item-level production control

2. The embedded digital product memory tells the machines, which production

services are needed for a particular emerging product.

3. Green and urban production based on cyber-physical production systems

4. Apps for software-defined products and smart product services

Germany is preparing the 4th Industrial Revolution based on the

Internet of Things, Cyber-physical Production Systems, and the

Internet of Services in Real industry. © PG Kommunikation der Forschungsunion

The German Future Project: Industrie 4.0

© W. Wahlster

Dynamic

Value Chain

Networks

Shorter

Product Lifecycles

Increasing

Product Variability

Volatile Markets

and Cost

Reduction

Pressure

Lack of Skilled

Workforce

Aging Society

Later Retirement

Resource-

Efficient and Clean

Urban

Production

Batch Size 1, Mass

Customization

Low-volume High-

mixture Factories

Socio-Economic Drivers of Industrie 4.0

© W. Wahlster

Outline of the Talk

1. From Embedded Systems to Cyber-Physical Systems in the Smart Factory

2. The Role of Digital Product Memoriesfor Mass Customization

3. Semantic Web Services in Decentralized Cyber-Physical Production Systems

4. The Importance of Skilled Workers: Industrial Assistance Systems

5. The Role of New Standards for Industrie 4.0

6. Conclusion

© W. Wahlster

Industrie 4.0: The Fourth Industrial Revolution

© W. Wahlster

Make to OrderSmart Shop:

Innovative Retail SoftwareSmart Factory:

Innovative Factory Software

Future Project:

Internet of Services Future Project:

Tailored production:566 billion

variants of custom-mixed cereals

from:

Digital Production with Batch Size 1

Internet of ThingsActive Product MemoriesService-based manufacturing control based on CPSS

Using Internet portals to configure and order a personalized product

© W. Wahlster

Mass Customization of Bottles: Tailored

Digital Decoration by Parallel Jet Printing

© W. Wahlster

Mass Customization of Perfumes and

their Packaging

• Customer can create her own

perfume from millions of

possibilities via a web portal

• Smart Factory can produce

36 000 Unique Perfume

Packages per day

• 24 hours after the order via the

Internet has been completed

the individualized product is

ready for shipment.

Since the customer of an individualized product, that she has designed by

herself, does not accept long delivery times, the product should be produced

close to the customer - > advantage for local European production industry.

© W. Wahlster

Interoperability for M2M-Communication

in Industrie 4.0

µ webserver32bit ARM processor

8MB SDRAM

100Mbit Ethernet &Wi-Fi

LINUX on DIGI Connect

OPC-UA(Open Process Control

Unified Architecture)

Server for M2M

The heart of an industrial CPS: XML-based Web server or very

fast binary communication based on the TCP protocols

© W. Wahlster

Smart

ServicesProduction

Production

Planning

Product

DesignProduction

Engineering

The Semantic Product Memory Is Continiously Updated and Serves as a Lifelog

of the History of an Individual Product

• Maintenance

• Context Conditions

• Security

• Location

• Status

Cyber-Physical System (CPS)

Physical Production

ComponentActive Semantic Product

Memory as a Digital Model

• Embedded

Components,

• Interfaces

• CO2 Footprint

• Materials

• Handling

Includes Information about …

+

Active Semantic Product Memories for

Industrie 4.0

adapted from Siemens

© W. Wahlster

Products with Integrated Dynamic Digital

Storage, Sensing, and Wireless Communication

Capabilities

The product as an informationcontainer

– The product carries informationacross the complete supply chain and itslifecycle.

The product as an agent

– The product affects its environment

The product as an observer

– The product monitors itself and itsenvironment

Grasp at

the middle

2 mins open

Please close!

I was

produced on

30 April 2010

and shipped

on 3 May 2010

© W. Wahlster

Semantic Product

Memory Chip in the

backcover plastic

frame with product

specification

Bluetooth circuit

board with key-

finder logic

packaged inside

a plastic shell

Personalized

keychain with custom

metal tag on the front

produced by an

engraving machine

The Smart Keyfinder with its Semantic

Product Memory Chip

© W. Wahlster

0

0

0

Service Offers

Context

Information

Concrete Process Description

Service Disco-

very and Selection

Dynamic

Service

Orchestration

Knowledge Base of Semantic

Service Descriptions

Service Usage

Smart Product

Abstract

Process

Description

Smart Factory

The Service-Oriented Architecture of Industrie 4.0

© W. Wahlster

From bits and bytes

To semantic services

Via functions

SOAPprod_Core

common

ontology

knowledge

based

ElectricalEngineering

driven by

SoftwareEngineering

driven by

Semantic Technologies

driven by

From Bits and Bytes to Semantics

Adapted from D. Zühlke

© W. Wahlster

Semantic Description of all Factory

Components as Services in OWL-S Ontology

Adapted from Losykll 2013

© W. Wahlster

Machine 1 Machine N

… …

Emerging Product 1

… …

…

Semantic Product Memory

• Top Shell Selection• Circuit-Top Shell Packaging• RES-COM Engravature• Top and Bottom Shell Assembly

CNC Milling Machine

Production Service Discovery, Matching and Execution

Production Pathplanning Based on Semantic Product Memories

…

M2M

Communication

M2M

Communication

Active Semantic

Product MemoryActive Semantic

Product Memory

Active Semantic

Product Memory

Emerging Product N

Active Semantic

Product Memory

WorkpieceCarrier N

Active Semantic

Product Memory

WorkpieceCarrier 1

Active Semantic

Product Memory

Key Components of Service-Oriented Cyber-Physical Production Systems

© W. Wahlster

Dynamic Planning Based on Service Compo-

sition in a SOA Architecture for Smart Factories

Fast TrackProduction

Conveyor1.transport(fullSpeed)

Pick&Place.insertBottom (AssemblyPlace1)

Abstract

Process

Specification

AssemblyPlace1.compressPick&Place.insertBoard

(AssemblyPlace1)Pick&Place.insertCap

(AssemblyPlace1)

Green

Production

Minimize CO2

Conveyor1.transport(lowSpeed)

AssemblyPlace2.compress

X


Pick&Place.insertBoard (AssemblyPlace2)

Pick&Place.insertCap (AssemblyPlace2)




AssemblyPlace3.compressAssemblyPlace4.compress

Plug & Produce





© W. Wahlster

The Intelligent Workpiece Carrier:

A Complex Cyber-Physical System

The Taxi to Production Services

© W. Wahlster

Plug&Produce based on Adaptive Service

Ontologies

• Plugin of CPS production

components on a physical,

digital and semantic level

• Automated Expansion of the

Service Ontology

New Assembly Component

is installed on-the-fly


© W. Wahlster

Rasberry PI 1

CPS as an Active Product Memory

for the Emerging Product

Rasberry PI 2

CPS for Processing Sensor Data from

the Additional Sensor Web

Gadgeteer with

Sensors for

Acceleration,

Shock,

Humidity and

Temperature

Classical SPS

WLAN Router

The Retrofitting of Legacy Factories with

an Additional Layer of Cyber-Physical Systems

© W. Wahlster

Mobile, Personalized,

Situation-Adaptive, Tutoring Systems

Multimodal Human-Machine

Interaction

Location-basedMaintenance and

PlanningAssistance

AR/VR/DR-Assistance in Complex Work

Processes

Context-adaptiveAssistance forFault Diagnosis

PhysicalAssistance byExoskeletons

Human-Centered CPS-based Assistance

Systems for the Smart Factory

© W. Wahlster

App Stores for the Smart Factory

© W. Wahlster

Advanced Industrial Assistant Systems Based

on Augmented Reality Technologies

Industrial Worker

with Google GlassesToolsIndustrial Environment

Mobile, Interactive and Situation-Aware

Tutoring

© W. Wahlster

DFKI’s Fembot AILA: Using the Semantic Product

Memory for Adaptive Grasping

Reading Size, Weight and Lifting Points

from the Product Memory with an

antenna in the left hand – the Robot

gets instructions from the product being

produced in the CPPS

Stereo Cameras in the Head and a 3D

Camera on the Torso for Approaching

an Object

© W. Wahlster

o Use of OMM/OMS as a

Active Product

Memory

o Use of Assistance

Functions in Planning

and Production

TestingPack--aging

Rewor-

king

Upper-

ShellBoardBoard

Bosch APAS

(Automatic Production

Assistants)

Automatic Manually Transport

5 Werker

3 Werker

3 Workers +

1 Roboter

PrüfenVer-

packen

Nach-

arbeit

Ober-

schalePlatinePlatine

Schra

u-

be

n

Unte

r-

schale

PrüfenVer-

packen

Nach-

arbeit

Ober-


Schra

u-

ben

Un

ter-

schale

PrüfenVer-

packen

Nach-

arbeit

Ober-


Sch

rau-

be

n

Unte

r-

sch

ale

PrüfenVer-

packen

Nach-

arbeit

Ober-


Schra

u-

ben

Un

ter-

schale

Variant

1V

ariant

2V

ariant

3

5 Workers

5 Workers

BoardBoardUpper-

Shell

Upper-

ShellBoardBoard

Testing

Testing

Pack--aging

Rewor-

king

Pack--aging

Rewor-

king

Multiadaptive Assembly System for

Highly Flexible Hybrid Job Floors

Low

er

Shell

Low

er

Shell

Scre

ws

Scre

ws

© W. Wahlster

Smart Production

Green Productionclean, resource-efficient,

and sustainable

Urban ProductionSmart Factories in the city

close to the employees‘ homes

High-precision, superior

quality production of high-mix,

low volume smart products

Industrie 4.0: Smart, Green, and

Urban Production

© W. Wahlster

In the US, the great spike in unemployment over the

past five years was disproportionately due to loss of

manufacturing jobs.

Innovation in Germany builds on legacies: in industrial

specializations, workforce skills, and proximity to

suppliers with diverse capabilities.

The potential of German patterns extends well beyond

defending niches against lowcost competition with

incremental advances.

They create new businesses, not usually through start-

ups - the U.S. model - but through the transformation of

old capabilities and their reapplication, repurposing, and

commercialization

President Obama has introduced the

“re-industrialization” strategy for the US

MIT Taskforce on Innovation and

Production ReportsMAKING IN AMERICA

MIT Press, 2013

© W. Wahlster

7

6

5

4

3

2

1Ethernet

IP

OPC UA

SOA Services

RJ45, WiFi…

TCP/IP

OPC-UA

SoA

Communication

Standards

USDL WSDL

Semantic Service Description and

Semantic Product Memory

Standardization

through

Semantic Meta

Description

Languages OWL OWL-S OMM++

HAN-Modular

Mechatronic

Base Standards

2860

EN 62264

Intefaces between Digital Enterprise

and Digital Factory Layer

Standardization

through

Interoperability

Standardization as a Key Success Factor

for Industrie 4.0

© W. Wahlster

The Race for Industrie 4.0 Standards

Leading Provider

of Internet Hardware,

Software and General ICT

No Leading Manufacturing

Industries

Leading Manufacturing

Industries

Leading Provider of

Enterprise Software

Leading Provider of

Internet Hardware

Giant Market for

Manufacturing Industries

Competition

for Standards

© W. Wahlster

From Smart Factories to Smart Products and

Smart Services based on Smart Data

SmartProduct

Smart Factory

SmartData

SmartService

BIG DATA

© W. Wahlster

Bremen

Osnabrück

Saarbrücken Kaiserslautern

Berlin

Cooperation between DFKI and Basque R&D

for Empowering Industry

© W. Wahlster

• Bilbao was the center of Basque Country‘s

Industrial Revolution during the 19th century.

• Industrie 4.0 is the chance for Basque country

to become again a leader in the fourth industrial

revolution.

• Industrie 4.0 can boost both the production of

next-generation manufacturing tools and smart

services based on digitally enhanced physical

products.

• Industrie 4.0 will create new jobs since mass

customization needs the collaboration of skilled

workforce and next-generation lightweight

robots.

Bilbao

The Potential of Industrie 4.0

for the Basque Country

Design by R.O.

Thank you very much for

your attention.

[Basque industry 4.0] The fourth industrial revolution based on smart factories

Engineering

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