the smart factory and the evolution towards industry 4.0

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The Smart Factory and the evolution towards Industry 4.0

Christian Schregel

Chief Evangelist Industry 4.0

Industry 4.0 Competence Center, CE

Frank L. Blaimberger

Head of Services & Tools

A Division of Factory Operations


Industry 4.0 Competence Center


The path to Industry 4.0

Digital Transformation

has high relevance for

future business model

Digital Transformation

is high priority

Executive Council

topic

Strategy is defined

in detail, a roadmap

is available

Top-3 hurdles:

• Lack of IT skills and resources

(64%)

• Lack of standards for M2M and

IoT (57%)

• Compliance regulations (53%)

and High Security Demands

(52%)

The path towards the 4th industrial

revolution is an evolutionary one

Agree

Disagree

0% 50% 100%

Agree

Disagree

Source: IoT in German Manufacturing Industry, PAC GmbH on behalf of Fujitsu (n=160), 2017


Smart Business

Models Cross-Company

EcosystemsEfficient

Operations

New Production Principles

Data-driven Enhancements

Horizontal Integration

Partner Management

Reduce to Max

Fast IT ready

Evolution of Fujitsu Smart Factory at Campus Augsburg


The Story So Far ….

Easy

Difficult

Complex

KaikakuKaizenWork Load2000 2011 20191985 2016

Complicate

WorkLoad


Areas of Smart Factory Based Solutions

Digitalization and Transformation

Worker‘s Place

Assistance SystemsBridging Digital Gaps

Technologies to support and enhance @ Shopfloor and Office


eInk @ Shopfloor

Substitution of Printing Materials

Printer, Paper Rols, Labels, Blades, etc.

Environmental protection (zero emission)

Dynamic Information Distribution

Last minute change ‘on the run’

Information distribution based on status

Display of Additional Content

Warnings, Changes, Instructions, etc.

Code Labels

Hidden control information


Smart Button @ Shopfloor

Digitally Integration of…

Legacy devices

Appliances w/o digital interfaces

Secured ‘black boxes’

Inexpensive goods

Non electrical production related elements

Commodity Technology

Standard wireless technology WiFi 802.11xx

Low efforts of integration into corporate infrastructure

Seamless integration into already existing supply data flow


Dynamic Test Control

Process Control Test Controlling

Locked / Closed Q-Loops Dynamic „Q-control loops“

„Linestop“- Function

Assembly & Soldering AOI & ICT Test

Intelligent, Dynamic Test Proceedings Separation of test steps

Automatic controlling of test depth and test details


APS-Connect

Context Based Instruction Display Multi-Use capability

Context based filtered / visualization

Smart Instruction Separation

Timing Dynamic flow per single product

Automatic product recognition

Flexible material assignments

Interactions Push services for support and material supply

Bi-directional information flow

Data Interface for Quality Tools

APS: Worker’s Place Control Area


Dynamic Light @ Workbench

Need Based Driven

Content driven illumination assistance

Support for employees with special needs

Increase of ergonomically issues, based on product / configuration related operation

Economical

Power down after operation

Multi functional desk approach to reduce non functional space


Adaptive Testing Event assistance Dynamic test control Problem visualization Multiple operation / less invest

Quality Improvement Online problem solver Process instruction Escalation assessment Trigger on event

Predictive Maintenance Improve OEE Production stabilization Resource allocation Avoid unnecessary waste

Operator Support Context based Instruction Quality increase

Agility and fast

reaction

Digital Supply Chain Paperless Kitting: eInk eKanban Transparency along supply chain “Pull” control

Client Interface Cloud based App Seamless DataFlow towards

customer Data value for clients Desk view load

Shopfloor

Management Worker’s place control Real time data Mobile App

Power / Energy

Management Peak reduction Energy cost saving Consumption supervision

Current Smart Factory Readiness Level


Future Challenges ….

Cost Sensitive

Reduce to the Max

Ready to change IT accounting schemes

(e.g. pay per use)

Fast IT ready

Scalability and automation capability to

decrease costs and expenditure

Smart

Industry 4.0 / IoT Ready

To support and deploy new production principles

and technologies

Enhancements

e.g. being ready for Smart Analytics / AI

Comprehensive

Partner-Management

Embrace new partner and collaboration models

Fujitsu’s Live UseCase

Demonstrate manufacturing capability

towards customers


Enabler for Cyber Physical Systems – Tool as a Service

Request for Data

Receive Value

Fujitsu ‘Cyber Security’ Layer

Factory Platform @ Fujitsu Cloud (K5)

Data Regression Reconcile

Smart Analytics & Prediction

Smart Devices e.g. Sensor Grids

IoT Apps

Fujitsu Augsburg

Customer

Data Stream

Supervision Monitor

Fujitsu Gateway Appliance / Edge Computing Operation


Co-Creation Approach, e.g. Intelligent Dashboard

Fujitsu Campus Augsburg

Partner

Requirements

Customizing / Consulting

Colmina @ K5

Smart Factory

Fujitsu Global Product / Solution Portfolio Partner Co-Operation


Industry 4.0 Solution Stack

Engineering Manufacturing Operation & Maintenance

Process FacilityProduct Design Factory Design EnvironmentProduct Worker

Consulting & Managed Security Services

Collaborative Engineering

Industrial Analytics

Industrial-IoT & Edge Computing

Fujitsu Industry 4.0 – Co-Create Industrial Value NetworksTransparency, Interoperability and Innovation in internal and cross-organizational Value Chains


Product Lifecycle Management, based on transparent Value Chain

Innovation Management Machine Utilization Quality Assurance Business Planning

Product Design WIP Management Supply Chain Traceability MRO-Optimization

Process Automation Demand Forecast

Process Analytics

Worker Assistant Solution

Predictive Analytics Condition Monitoring

Location Based Solutions

Asset Tracking & TracingSolution Offerings


Process Automation Demand Forecast

Process Analytics

Worker Assistant Solution

Predictive Analytics Condition Monitoring

Location Based Solutions

Asset Tracking & Tracing

Process FacilityProduct Design Factory Design EnvironmentProduct Worker

Consulting & Managed Security Services

Engineering Cloud Orchestration

Design & Simulation Tool Integration

Design-Data Management


Fujitsu Industry 4.0 – Co-Create Industrial Value NetworksTransparency, Interoperability and Innovation in internal and cross-organizational Value Chains

Industrial Reporting Smart Analytics & Machine Learning

Big Data

IoT Platform Event Processing Platform Process Automation Platform

RTLS / AIT Edge Computing UI-Applications

Devices / Sensors / Tags / Beacons Industrial IoT Gateway PAN/ LAN / WAN / Mobile

Product Lifecycle Management, based on transparent Value Chain

Innovation Management Machine Utilization Quality Assurance Business Planning

Product Design WIP Management Supply Chain Traceability MRO-Optimization

Engineering Manufacturing Operation & Maintenance

Industry 4.0 Solution Stack


Smart Quality Control with AI

• Ultrasonic quality inspection generates massive amount of blade scanning data

Deep learning solution automates the scan data evaluation process

High gains in time efficiency by enabling skilled operators to focus on the important part of the data


Industry 4.0 Show Case

K5 GERSensor Data

Access

Dashboarding

&

Alerting

Machine Sensor Data

Motor current flow Data

Dashboarding

Alerting

Predictive

Data generation/Digital Twin• Native data from robot arm

• Add. Sensors:

• Temperature

• Vibration gearing box (microphone)

• Acceleration, Gyroscope via Smartphone

Micro Services• IoT Data GW

• Dashboarding and EPP

• Data visualization on AR via table/HMD

Data for animated Twin

Customer Product DataCustomer Product

Analytics results on Twin

Production Machine

Analytics Services• Predictive Analytics

• Dashboarding

• AI Sound analyse including machine learning

pattern definition (SWP)


Industry 4.0 Competence Center Team

Andreas Rohnfelder

E-mail: [email protected]

Head of Industry 4.0 CC

Wieland Kordas


Christian Schregel


Industry 4.0 Evangelist

Leopold Sternberg


Program Manager


Frank Zedler


Program Manager

Industrial-IoT & Edge

Computing

Program Manager

Industrial Analytics

mailto:[email protected]

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