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Industry 4.0 pai

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Fourth Industrial revolution - Cyber Physical Production Systems - Internet of Things and Factory of the Future

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Industry 4.0 pai

  1. 1. Keynote Address: Industry 4.0: the Internet of Things Smart Factories From to JAYESH C S PAI MSME TOOL ROOM, KOLKATA
  2. 2. © DFKI GmbH The German Future Project: Industry 4.0  Industrial production is the backbone of Germany‘s economic performance: 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. Exponential growth of data
  3. 3. This is how we see our world
  4. 4. This is how we should see our world
  5. 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 t DegreeofComplexity 1. Industrial Revolution facilities powered by Industry 1.0
  6. 6. From Industry 1.0 to Industry 4.0: Towards the 4th Industrial Revolution First Mechanical Loom 1784 Industry 1.0water and steam End of 18th Centu Start of 20th Centu t DegreeofComplexity 2. Industrial Revolution mass production based on the division of labour powered by electrical energy1. Industrial Revolution through introduction of mechanical production facilities powered by
  7. 7. From Industry 1.0 to Industry 4.0: Towards the 4th Industrial Revolution Industry 3.0of production First Mechanical Loom 1784 Industry 1.0water and steam Start of 70s End of 18th Centu Start of 20th Centu t DegreeofComplexity 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 powered by electrical energy Industry 2.0 1. Industrial Revolution through introduction of mechanical production facilities powered by
  8. 8. From Industry 1.0 to Industry 4.0: Towards the 4th Industrial Revolution 001010100 100101010 Industry 3.0of production First Mechanical Loom 1784 Industry 1.0water and steam Start of 70ies End of 18th Centu Start of 20th Centu today t DegreeofComplexity 010001101 010010101 4. Industrial Revolution based on Cyber-Physical Production Systems Industry 4.03. Industrial Revolution through Introduction of electronics and IT for a further automization 2. Industrial Revolution through introduction of mass production based on the division of labour powered by electrical energy Industry 2.0 1. Industrial Revolution through introduction of mechanical production facilities powered by
  9. 9. The Industrial Revolution
  10. 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.
  11. 11. SELLING PRICE - COST PRICE = PROFIT
  12. 12. Towards Intelligent Environments based on the Internet of Things and Services 4) Embedded Computers Smart Factory 1) Central Computer 90% of all3) Smart Phone computers are embedded 2) PC, Notebook Smart Card 1 Computer 1 User Many Users Many Computers, 1 User 20201960 20001941 1980 5) Intelligent Environments 4) Embedded Computers Smart 1) Central Computer 3) Smart Phone 2) PC, Notebook Smart Card 1 Computer
  13. 13. Vision: Internet der Dinge Intelligente Umgebungen z.B. Smart City Future Project Industry 4.0 500 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 Cyber-Physical SystemsEmbedded Systems Intelligent Environments/Smart Spaces Digital City Cyber- Physical Systems Smart Factory, Smart Grid Networked Embedded Systems Intelligent Street Crossing Embedded Systems Internet of Things
  14. 14. Iron Man Suit
  15. 15. Talos in Greek mythology
  16. 16. 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.
  17. 17. Industry 4.0: Smart, Green, and Urban Production Smart Production High-precision, superior quality production of high- mix, low volume smart products Urban Production Green Production clean, resource-efficient, and sustainable Smart Factories in the city close to the employees‘ homes
  18. 18. What is Smart Manufacturing?
  19. 19. A future vision …the integration of data… Smart Manufacturing is: …with process expertise… …to enable “evidence based” management… …of manufacturing.
  20. 20. 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 Internet of Services
  21. 21. 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
  22. 22. Raising the Level of Abstraction If Smart Manufacturing is such a smart idea why aren’t companies already doing it?
  23. 23. What is Smart Manufacturing? Business (Collaboration, Broader Metrics Real-time Decisions) Technology (Horizontal & Vertical Pervasive) Workforce (Innovation & Broad-Based) Organizational Mindset
  24. 24. 21st Century Smart Manufacturing Data Analyze Model Apply • Demand-dynamic economics keyed on the intelligence of the ‘customer’ • Coordinated enterprise responses throughout the entire manufacturing supply chain • Predictive, preventive • Integrated computational materials 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
  25. 25. 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
  26. 26. 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 Customer Distributor Farming Mining SMLC Priority: New Productivity/Efficiency Metrics – Change from output/input productivity measures to customization, flexibility, responsiveness, energy performance and reuse • Customers “pushing” demands • Flexible production of smaller volumes of custom products • Less vertically integrated • More information driven and automated
  27. 27. 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
  28. 28. 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) Attributes of a Smarter Manufacturing Sector
  29. 29. 21st Century Manufacturing Ecosystem Much Greater 3x to 15x+ Economic Multiplier - Smart Manufacturing: The Essential Nucleus For SME’s & The Service Economy 100% automated Intel Chip FAB – Some engineers and technicians Smart Factory Innovation and specialties 25% automated 75% labor Small Businesses Components and other suppliers 50% automated, 50% labor Medium-size Manufacturers Financial, IT Services, Consulting, etc. 100% labor Services & Support Community colleges and Universities, healthy knowledge workers, public-private partnerships Education, Health Care and Government As Factories Get Smarter, More Jobs Surround Them
  30. 30. Products with Integrated Dynamic Digital Storage, Sensing, and Wireless Communication ⇒The product as an information container Capabilities I was produced on 30 April 2010 and shipped on 3 May 2010 – The product carries information across the complete supply chain and its lifecycle. Grasp at the middle ⇒The product as an agent – The product affects ist environment 2 mins open Please close! ⇒The product as an observer – The product monitors itself and
  31. 31. 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
  32. 32. The SmartFactory Shop Floor: Wireless, RFID-, Sensor- and Service-based Architecture continuous flow process discrete handling process bottling, handling, labeling, QC, packaging… Live Webcam: http://www.smartfactory.de/webcam.de.html discrete handling proce bottling, handling, labeling, QC, p continuous flow proce colored soap production
  33. 33. 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
  34. 34. Industrielle Assistenz- systeme Human-Centered CPS-based Assistance Systems for the Smart Factory Physical Assistance by Exoskeletons 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
  35. 35. App Stores for the Smart Factory: Downloading Tailored User Interfaces for User Groups: Supervisors…Elderly, Trainees, Disabled,
  36. 36. Location-based Industrial Assistance Systems in Smart Factories for Resource Efficiency Improvements
  37. 37. Industrial Environment Advanced Industrial Assistant Systems Based on Augmented Reality Technologies Industrial Worker with Google Glasses Mobile, Interactive and Situation-Aware Tutoring Tools
  38. 38. Augmented Reality Systems Supporting Maintenance Staff
  39. 39. 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
  40. 40. DFKI’s Fembot AILA: Using the Semantic Product Grasping and Smart ProductMemory for Assembly Adaptive 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 beingproduced in the CPPS
  41. 41. 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
  42. 42. 1110100101011011011011000100000100100 0011110100100110101001001001001010101 0101011000100010010010100101000100010 1001110100000000000000000000000000000 1100100101001010000010011111110101011 0001001001001001001010100100111011001 010101101001001001010010010010010010 001001001011111111101010111011111110011 0101111111010000000000001001001000010 1000000000100000000010010101010100100 The Software-defined Car: Customizing a Car Environment Android Market through Apps App Store Intelligent User Interface Apps Motor Managem ent Apps Driver Assistan ce Apps Green Driving Apps 10010101101110100010100 10010010010001000111101 0010111111110111111111111 10001011100111111101000 101001111011110001111111 1 01001101111101001001010 10010010010011101010100 0010011010010010010001 1 0010000000000010001000 00010010001001001010100 11010101110100100100100 1010110011010111010010010010010111111001111001 1 00000000100100101001111111111111101000010101001 10110101010011111011101 0100100100100100100100 11111000000000010010110 11 01010000100101001111010 1001000110110
  43. 43. © DFKI GmbH BMW Apps: Integrating the Most Recent Web Services Into the Car Environment Source: BMW
  44. 44. 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.
  45. 45. Tha nk yo u ve ry mu ch fo r yo ur attenti on. THANK YOU METALLIX & JADAVPUR UNI

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