The Fourth Industrial Revolution has begun. What is it about. What SMEs have in this revolution. WIll jobs decrease. Will Skill requirements increase. And what is this Cyber Physical Production Systems.

1. Keynote Address:
Industry
4.0:
the Internet of
Things
Smart Factories
From to
JAYESH C S PAI
MSME TOOL ROOM, KOLKATA

2. © DFKI GmbH
The German Future Project: Industry 4.0
 Industrial production is the backbone of Germany‘s economic
performance:
Exponential growth of data
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.

3. This is how we see our world

4. This is how we should see our world

5. From Industry 1.0 to Industry 4.0: Towards
the 4th Industrial Revolution
First
Mechanical
Loom
1784
mechanical production
water and steam
End of
18th
Centu
ry
t
Degree of Complexity
1. Industrial Revolution
facilities powered by
Industry 1.0

6. From Industry 1.0 to Industry 4.0: Towards
the 4th Industrial Revolution
First
Mechanical
Loom
1784
water and steam Industry 1.0
End of
18th
Centu
ry
Start of
20th
Centu
ry
t
Degree of Complexity
2. Industrial Revolution
mass production based on
the division
of labour powered by
electrical
energy
Industry
1. Industrial Revolution
through introduction of
mechanical production facilities
powered by

7. From Industry 1.0 to Industry 4.0: Towards
the 4th Industrial Revolution
of production Industry 3.0
First
Mechanical
Loom
1784
water and steam Industry 1.0
Start of
70s
End of
18th
Centu
ry
Start of
20th
Centu
ry
t
Degree of Complexity
3. Industrial Revolution
electronics and IT and heavy-duty
industrial robots for a
further automization
2. Industrial Revolution
through introduction of mass
production based on the division
of labour powerde by
electrical
energy
Industry 2.0
1. Industrial Revolution
through introduction of
mechanical production facilities
powered by

8. From Industry 1.0 to Industry 4.0: Towards
the 4th Industrial Revolution
001010100
100101010
of production Industry 3.0
First
Mechanical
Loom
1784
water and steam Industry 1.0
Start of
70ies
End of
18th
Centu
ry
Start of
20th
Centu
ry
today t
Degree of Complexity
010001101
010010101
4. Industrial Revolution
based on Cyber-Physical
Production Systems
Industry
3. Industrial Revolution 4.0
through Introduction of
electronics and IT for a further
automization
2. Industrial Revolution
through introduction of mass
production based on the division
of labour powerde by
electrical
energy
Industry 2.0
1. Industrial Revolution
through introduction of
mechanical production facilities
powered by

9. The Industrial Revolution

10. Industrial Revolution Hearths
• The iron industry was first to
increase production through
extensive use of (James)
Watt’s steam engine, plus
other inventions.
• The textile industry followed.
• From these two pioneering
industries, new industrial
techniques diffused during the
nineteenth century.
Fig. 11-1: The Industrial Revolution originated in areas of northern England. Factories often
clustered near coalfields.

15. Towards Intelligent Environments based on
the Internet of Things and Services
Smart Factory
5) Intelligent
Environments
4) Embedded Computers
Smart
1) Central Computer 3) Smart Phone 90% of all
computers are
embedded
2) PC, Notebook Smart Card
1) Central Computer 3) Smart
Phone
1 Computer
Many Users 1 User Many Computers, 1 User
2) PC, Notebook Smart Card
1941 1960 1980 2000 2020
1 Computer
1 User Many

16. Future Project Industry 4.0
Internet of Things
Vision: Internet der Dinge
Intelligent Intelligente Umgebungen
Environments/Smart Spaces
Digital z.B. Smart City
City
500 M€ for 3 Years
National Program:
250 M€ Funding of
Ministry for Research and
Ministry for Economics
Evolution from
Embedded Systems
to Cyber-Physical
Systems
Embedded Systems Cyber-Physical Systems
Cyber-
Physical
Systems
Smart
Factory,
Smart Grid
Networked
Embedded
Systems
Intelligent Street
Crossing
Embedded
Systems
Airbag

17. Iron Man Suit

18. Talos in Greek mythology

19. Liquid Armor
It is liquid under low or normal pressure and solid under high pressure. This
liquid is made with polyethylene glycol and the solid part is made of nano-particles
of silica. This liquid is soaked into all the layers of a Kevlar vest.

24. Industry 4.0: Smart, Green, and Urban Production
Smart Production
High-precision, superior
quality production of high-mix,
low volume smart
products
Green Production Urban Production
clean, resource-efficient,
and sustainable
Smart Factories in the city
close to the employees‘
homes

25. What is Smart Manufacturing?

26. A future vision
Smart Manufacturing is:
…the integration of data…
…with process expertise…
…to enable “evidence based” management…
…of manufacturing.

27. Smart Connections
Your Smart Factory
Business Systems
Customers
Real time information
flows
Reporting on availability,
traceability
& movement of products
Distribution
Centres
Suppliers
The Smart Grid
Other Network Partners
OEM
Demand
Mass customisation
Traceable
Recyclable / remanufactured
Optimise resource and energy use vs. production
Optimise production and minimise cost
Close links into supply
chain/networks
Optimise production
performance
Create agile networks able to respond to
Rapid demand changes
Higher product availability & lower
inventories

28. Internet of Services
Internet der Dienste
© DFKI GmbH
The Internet of Things and Services as a
Basis for the Smart Factories in the Industry 4.0
Products
Plattform
Internet of Things
Smart
App
Smart
Material
App
Plattform
Semantic PLM-, SCM-,
CRM-, QMS- and
ERP-Services Smart
Fact
ory
App Plattform
Cyber-Physical
Production System

29. Pipelines of Smart Factories for Industry 4.0
based on Secure Networks of Clouds
…
Machine 1
Secure Cloud
Networks
Smart
Products
Smart
Materials
Smart Factory 2…N
Smart Factory 1
M2M-Comunication
Smart … Smart
Machine N
Application Plattform
for Machines
Cyber-Physical
Production Systems
CPPS

30. Raising the Level of Abstraction
If Smart Manufacturing is such a
smart idea why aren’t companies
already doing it?

31. What is
Smart Manufacturing?
Business (Collaboration, Broader Metrics
Real-time Decisions)
Technology
(Horizontal & Vertical
Pervasive)
Workforce
(Innovation &
Broad-Based)
Organizational
Mindset

32. 21st Century Smart Manufacturing
Data
Analyze
Model
• Demand-dynamic economics keyed
on the intelligence of the ‘customer’
• Coordinated enterprise responses
throughout the entire
manufacturing supply chain
• Predictive, preventive
• Integrated computational materials
Apply
engineering
• Performance-oriented enterprise,
minimizing energy and material
usage and maximizing
environmental sustainability,
health and safety and economic
competitiveness
Dramatically intensified application of
manufacturing intelligence using advanced
data analytics, modeling and simulation to
produce a fundamental transformation to
transition/new product-based economics,
flexible factories and demand-driven supply
chain service enterprises

33. SMLC Priority: Situational Awareness performance tools across the enterprise to manage dynamic
production, use, and storage of essential resources (energy, water, air)
Supply Chain
Distribution Center
Customer
Business
Systems, ERP
an interconnected world…
voice, data, mobile, etc.
Smart Grid
Smart Factory
Modern, smart factories will be interconnected
with supply chain, distribution and business systems

34. SMLC Priority: Production and Demand-Dynamic Supply Chain Efficiency - At Scale Virtual Supply Chain Planning, Computational
Materials Engineering and Product Tracking & Traceability Tools
Manufacturing Plant
Supply Chain
• Customers “pushing” demands
• Flexible production of smaller
volumes of custom products
• Less vertically integrated
• More information driven
and automated
Customer
Distributor
Farming
Mining
SMLC Priority:
New Productivity/Efficiency Metrics – Change from output/input
productivity measures to customization, flexibility,
responsiveness, energy performance and reuse

35. Smart Manufacturing is the Application of a Manufacturing Industry Internet
Supply Chain
Distribution Center
Customer
Business
Systems, ERP
Smart Grid
Smart Factory
New Degrees of freedom for
Performance, efficiency and productivity
Anticipate, plan,
manage risk
across
suppliers
Merging actionable
business &
Operations
information
New forms
equipment
benchmarking
Tracking &
traceability
New real-time global
performance
metrics

36. Attributes of a Smarter Manufacturing Sector
Old Traditional Factory
• More jobs: labor-intensive
• Lower output and productivity
• Lower quality products
• Lower paying unskilled jobs
• Higher risk working conditions
• Higher environmental impact
• Higher production costs
• Rigid, high-volume production
• Longer time-to-market
• Socially optimized (Six Sigma)
New Smart Manufacturing Plant
• Less jobs: automation-intensive
• Higher output and productivity
• Higher quality products
• Higher paying skilled jobs
• Safer working environment
• Less waste, resource use
• Lower production costs
• More flexible customization
• Faster time-to-market
• IT-optimized (models, simulation)

37. As Factories Get Smarter, More Jobs Surround Them
21st Century Manufacturing Ecosystem
Much Greater 3x to 15x+ Economic Multiplier -
Smart Manufacturing: The Essential Nucleus For SME’s & The Service Economy
Smart Factory
100% automated
Intel Chip FAB –
Some engineers and
technicians
Small Businesses
Innovation and
specialties
25% automated
75% labor
Medium-size
Manufacturers
Components and
other suppliers
50% automated,
50% labor
Education, Health Care and
Government
Services & Support Community colleges and
Financial, IT Services,
Consulting, etc.
100% labor
Universities, healthy
knowledge workers,
public-private
partnerships

72. Products with Integrated Dynamic Digital Storage,
Sensing, and Wireless Communication
ÞThe product as an information
container
Capabilities
I was
produced on
30 April 2010
and shipped
– The product carries information on 3 May 2010
across the complete supply chain
and its lifecycle. Grasp at
ÞThe product as an agent the middle
– The product
affects ist
environment
2 mins open
ÞThe product as an observer Please close!
– The product
monitors itself
its environment
and

73. Service-oriented planning of plant systems
Hardware-independent planning of plant systems
ERP Enterprise
Resource Planning
MES
Manufacturing
Execution System
Field Layer
Service Library
Sensor-Service Valve-Service Pump-Service Control-Service Communication-Service
Industry 4.0: All-IP Factories, no chaos of field buses, Internet-based
Factory Networking based on IoS and IoT
Abstract Service
hardware-independent
Device Control
hardware-dependent

74. The SmartFactory Shop Floor: Wireless,
RFID-, Sensor- and Service-based Architecture
discrete handling proce
continuous flow proce
process process
bottling, handling, labeling, QC, p
packaging…
colored soap production
Live Webcam: http://www.smartfactory.de/webcam.de.html

75. Data Mining and Knowledge
Smart Factories
Manufacturing stores more data than any
other industrial sector.
Close to two exabytes of new production
data were stored in 2010 from multiple
sources:
Discovery in
•
instrumented production machinery
•
supply chain management systems
• product life-cycle systems
New ICT Coordination Action of EU:
BIG: Big Data
Public Private
Forum

76. Human-Centered CPS-based Assistance
Systems for the Smart Factory
Physical
Assistance by
Exoskeletons
Industrielle
Assistenz-systeme
Mobile,
Personalized,
Situation-
Adaptive,
Tutoring Systems
Context-adaptive
Assistance for
Fault Diagnosis
AR/VR/DR-Assistance
in
Complex Work
Processes
Multimodal
Human-Machine
Interaction
Location-based
Maintenance and
Planning
Assistance

77. App Stores for the Smart Factory: Downloading
Tailored User Interfaces for User Groups:
Elderly, Trainees, Disabled, Supervisors…

78. Location-based Industrial Assistance Systems in Smart
Factories for Resource Efficiency Improvements

79. Advanced Industrial Assistant Systems Based
on Augmented Reality Technologies
Industrial Environment
Industrial Worker
with Google Glasses
Mobile, Interactive and
Situation-Aware
Tutoring
Tools

80. Augmented Reality Systems Supporting Maintenance Staff

81. Industry 4.0: Robots are no Longer Locked in
Safety Work Cells but Cooperate with Human Workers
Today
Tomorrow
A new generation of light-weight, flexible robots collaborate with
humans in the smart factory

82. DFKI’s Fembot AILA: Using the Semantic Product
Memory for Adaptive
Grasping and Smart Product
Assembly
Stereo Cameras in the Head and a 3D
Camera on the Torso for Approaching
an Object
Reading
from the
Size, Weight and Lifting Points
Product Memory with an
antenna in the left hand – the Robot
gets instructions from the product
bpreoindguced in the CPPS

83. W3C Standards as a Basis for the Project of
the Future Industry 4.0
Product Memory
Standardization
EMMA:
Multimodal
Industrial
Assistance
Systems
Industry 4.0
Smart Factory
OMM:
Semantic
USDL:
Semantic Services
in Cyber-Physical
Production Systems

84. The Software-defined Car: Customizing
a Car Environment
Android Market
through Apps
1110100101011011011011000100000100100
0011110100100110101001001001001010101
0101011000100010010010100101000100010
1001110100000000000000000000000000000
1100100101001010000010011111110101011
0001001001001001001010100100111011001
010101101001001001010010010010010010
001001001011111111101010111011111110011
0101111111010000000000001001001000010
1000000000100000000010010101010100100
App Store
Intelligent
User
Interface
Apps
Motor
Managem
ent
Apps
Driver
Assistan
ce
Apps
Green
Driving
Apps
10010101101110100010100
10010010010001000111101
0010111111110111111111111
10001011100111111101000
101001111011110001111111
10
1001101111101001001010
10010010010011101010100
0010011010010010010001
1
0010000000000010001000
00010010001001001010100
11010101110100100100100
101011001101011101001010010010111111001111001 1 0
11111111101000010101001000000001001001010011111
10110101010011111011101
0100100100100100100100
11111000000000010010110
1 1
01010000100101001111010
1001000110110

85. © DFKI GmbH
BMW Apps: Integrating the Most Recent
Web Services Into the Car Environment
Source: BMW

86. Conclusions
1. High-precision, superior quality production of high-mix, low volume
smart products are the future of Europe’s successful export-oriented
economies like Germany.
2. 80% of the innovations in manufacturing are based on ICT. They will
lead to Smart Factories, Green and Urban Production.
3. The fourth Industrial Revolution will be based on cyber-physical systems,
the Internet of Things and the Internet of Services. It will generate
enormous BIG data streams that can be harvested and analyzed for
resource-efficient and ultra-high quality production.
4. CPS-based industrial assistant systems are needed to support, help
train the next generation of workers in smart factories.
and
5. Augmented and dual reality systems allow individualized workflows and
fast learning of new production processes.

87. Tha
nk
yo
u
ve
ry
mu
ch
fo
r
yo
ur
attenti
on.