Briefly intro and some more background information.

1. Digitalization
Value-Adding Industry
Copyright by Hans-Dieter Wehle, 2019
hdw@idhorb.de

2. INDUSTRIE 4.0
Definition
▪ Digitalization of Industry: connecting machines,
storage systems and equipment (CPS – cyber-
physical systems)
▪ Vertical (company departments) and horizontal
(various business partners across the value chain)
integration
▪ Intelligent machines with independent
information exchange
▪ Smart Factory: clearly identifiable and
localized products
▪ Controlling and optimization in real-time
INDUSTRIE
4.0
Intelligent products
M2M Sensors and actuators
Data
protection
Information
security
Real-time data
IPv6
Apps
Big
Data
Mobile devices
Mobile
communications
Broadband
Vision
(VR/AR)
HMI
Low cost
automation
Plug &
produce
Social
machines
Embedded
systems CPS
Smart
factory
Robust
networks
Cloud
computing
IT security
by hdw,2019

3. INDUSTRIE 4.0
DEFINITION
To configure networked manufacturing systems that
approach different case scenarios with alternative
strategies
The regulatory framework of vertical integration is
the factory. In the future Smart Factory,
manufacturing structures will no longer be concrete
or predetermined. Instead, IT configuration rules
will be defined, from which an automated case-
specific structure (topology) will be created.
Vertical Integration and Networked Manufacturing Systems
SERVERSERVER
SERVER
by hdw,2019

4. INDUSTRIE 4.0
Horizontal Integration Across Value Chain Networks
supplier
manufacturer
DEFINITION
The term "horizontal integration" is commonly
understood as optimized material and information
flowing from various suppliers in a value chain to
and from consuming companies.
The ttp system (eSCM) manages all the material
requirements of the delivery stage to put together
provision plans and pass on necessary information
in real-time to the supplier network so that
producers have the right components at the right
time and the right place.
by hdw,2019

5. INDUSTRIE 4.0
Integration Topology
I4.0
I4.0
Readaccess
Writeaccesswith
approvalpoint
I40 Network
Communication hub
I40I40I40
I40I40
I40I40
I40I40
I40 I40
I40 I40
Communication with standardized services based on
standardized semantics
Private
I4.0 service system
Read access to standardized I4.0 service
system with possibility of self-exploration and
adaption
I40 machine-to-machine
communication
Storage of data in a standardized
syntax and semantics
Value creation by software
service systems and their
interrelation
Production network
Traditional or future I40
production network
I40I40
Production optimization
Logistic optimization
Weather forecast
Payment services
Search engines
Third-partyservices
Write access to the I40 service
system with approval point
Devices
Machines
and cells
Plants
I40
by hdw,2019

6. INDUSTRIE 4.0
Horizontal and Vertical Integration
HorizontalIntegration:
▪ Networking between manufacturing sites
▪ Customer involvement in the process
▪ Exchanging information throughout the
value chain
▪ Intelligent system communication in
demand, production and logistics
Vertical Integration:
▪ Networking within the company from the
manufacturing level to the field level
▪ IT systems communicate at all levels
PRODUCTION
PLANNING
(ERP)
PRODUCTION
CONTROL
OPERATING DATA
MANAGEMENT
(MES)
OPERATING AND MONITORING SYSTEM
(HMI/SCADA)
MACHINE AND SYSTEM CONTROL
(SPS)
INPUT/ OUTPUT SIGNALS
(ACTUATORS/ SENSORS)
MANUFACTURING/ PRODUCTION PROCESS
HorizontalIntegration
VertiCalIntegration
Field level
Process control level
Operation control level
Manufacturing level
by hdw,2019

7. INDUSTRIE 4.0
Manufacturing Environment
Recognition and interaction
REAL ENVIRONMENT
Development and process
HUMANENERGY/
ENVIRONMENT
WORKING
ENVIRONMENT
MACHINE PRODUCT
LOGISTICS
SERVER COMPUTER
SENSOR/
ACTUATOR
Local communication Middleware Cloud/ services
by hdw,2019

8. IMPACT
INDUSTRIE 4.0
by hdw,2019

9. IMPACT OF INDUSTRIE 4.0
Impact on Businesses and Workers
▪ localized and identifiable intelligent products allow for more
knowledge about manufacturing processes
▪ inter-company networking
▪ flexible fine-tuning processes with continuous collection of
current internal and external data
▪ competitive advantages
▪ individual customer requirements and stronger customer
integration
Businesses Workers
▪ additional requirement for employees (IT know-how)
▪ greater involvement in innovation processes
▪ new human-machine interaction with less location-based factory
work, but with more virtual, mobile work
▪ support of smart assistance systems
▪ qualification and training
▪ more self-reliant autonomy and decentralized management forms
▪ more room for decision
SOCIAL
MEDIA
Global
facilities
Augmented
operators
Smart
products
Virtual
productions
by hdw,2019

10. ACTIONS FOR
BUSINESSES
INDUSTRIE 4.0
by hdw,2019

11. ACTIONS FOR BUSINESSES
General Features for Implementation
NEW SOCIAL INFRASTRUCTURES: education and training, introducing new assistance systems
ENGINEERING:Product Life Cycle Management (PLM) supported across whole value chain
VERTICAL INTEGRATION: network of production with real-time requirements
HORIZONTAL INTEGRATION: inter-company networking and collaboration
TECHNOLOGICAL REQUIREMENTS: network communications, broadband network, cloud computing, data analytics,
cybersecurity, secure terminals and machine-to-machine solutions
physical cyber
by hdw,2019

12. RECOMMENDED FOR BUSINESSES
Practical Suggestions for Companies
WorkDesign:
Participative work design; develop a socio-technical approach with
guidance and practical guides; Exchange/ dialogue within and
outside the organization on progress, problems, solutions
Security:
New knowledge pool created for new security concepts of complex
systems; existing concepts with new enhancements; security
certificate created for machines, processes and products with
application, list of measures and weaknesses; user-friendly
applications; protection against plagiarism and piracy (balance
between trust and transparency)
ELECTRICITY
BUILDINGS
LOGISTICS
PRODUCTS
SMART
FACTORY
MOBILITY
by hdw,2019

13. RECOMMENDED FOR BUSINESSES
Practical Suggestions for Companies
Resource efficiency:
Calculation and assessment of additional resource consumption
and conservation; consideration of KPI (Key Performance
Indicators) and others to assess productivity
Managingcomplex systems:
Training and continuing professional development; gaining new
insights into the control and integration of complex systems
through examples such as a mutual exchange (e.g. forums) among
the staff
ELECTRICITY
BUILDINGS
LOGISTICS
PRODUCTS
SMART
FACTORY
MOBILITY
by hdw,2019

14. RECOMMENDED FOR BUSINESSES
Regulatoryframework:
Documentary evidence; new contract models for protecting trade
secrets or distributing profits (set exact definitions); provide legal
basics
Trainingandcontinuingprofessionaldevelopment:
Learning technologies (e-learning); aid learning by work
organization: training concepts, analytical leadership concepts;
promote interdisciplinary research and collaboration
Practical Suggestions for Companies
ELECTRICITY
BUILDINGS
LOGISTICS
PRODUCTS
SMART
FACTORY
MOBILITY
by hdw,2019

15. ADVANTAGES AND DISADVANTAGES
▪ individual customer requirements
▪ flexible production
▪ relief to employees – work-life balance
▪ new value: new B2B services
▪ increased competiveness
▪ identifying and developing productivity and resource
efficiency
▪ handling new national and global challenges
ADVANTAGES DISADVANTAGES
▪ lack of data protection
▪ easy manipulation of remote manufacturing systems
▪ a disadvantage for rural areas is the lack of broadband
connections
▪ continuous provision and maintenance of necessary
infrastructures
▪ high and expensive technical standards
▪ additional requirement for employees (IT know-how)
VS
by hdw,2019

16. FUTURE OUTLOOK
Survey on the Challenges of Implementation – Views of Businesses
Standardization
Process/ Work organization
Available Products
New business models
SECURITY KNOW-HOW protection
Available Specialists
Research
Training and continuing professional development
Legal Framework
52,80%
46,40%
35,30%
30,60%
28,10%
25,20%
23,00%
15,10%
10,80%
by hdw,2019