Bosch: Next Gen Manufacturing and IT
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Next-gen Manufacturing and perspective from Bosch
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Bosch: Next Gen Manufacturing and IT
- 1. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Next Generation IT in Manufacturing Speaker: Philips Dayanidhi Head - Manufacturing Vertical SAP Practice 1
- 2. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing 2
- 3. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Overview Facts & figures Locations DomainsOfferings 1998 Year of foundation 13000 100% Subsidiary of Bosch Associates 7 4 Countries Development Centres 6 Sales offices Avionics Healthcare Automotive Manufacturing Engineering $500 Mio Revenue Level 5 Level 3 ASPICE CMMI Business Services Enterprise Facts & figures 2013 data 154 Patents filed 3
- 4. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Agenda 4 Mega trends Discussions Industry 4.0 IoTS and Bosch New trends in Manufacturing IT
- 5. Confidential | RBEI | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Connected World… The World is Changing…. Event : Pope Elections. St. Peter’s Square, Vatican City 5
- 6. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing 6
- 7. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Big Data 7 Key role in Manufacturing IT solutions for maximizing manufacturing potential
- 8. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Agenda Mega trends Discussions Industry 4.0 IoTS and Bosch New trends in Manufacturing IT 8
- 9. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing 9
- 10. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Industry 4.0 - Evolution 1.0 2.0 3.0 Smart BuildingSmart Grid Local Communication: Fieldbus within factoryAuto ID: unique worldwide, online Online System: Machines, Vehicles, Tools Internet: Service Platforms 4.0 Internetting of all Things and Cyber-Physical Systems First mechanical loom 1784 First assembly line Slaughterhouse in Cincinatti 1870 First Programmable Logic Controller, Modicon 084 1969 10
- 11. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Industry 4.0 refers to the technological evolution from embedded systems to cyber-physical systems. Industry 4.0 represents a paradigm shift from “centralized” to “decentralized” production - made possible by technological advances. Industry 4.0 connects embedded system production technologies and smart production processes. 11
- 12. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Whether ERP or MES or Manufacturing intelligence layer will establish themselves as the dominant software system force in production environments ? Scenario 1 : ERP software will be directly linked to process control systems at the production level, thereby eliminating the need for ERP software. Scenario 2 : Conversely, MES software functionalities being provided by the ERP Scenario 3 : New role of Manufacturing integration with ERP and MES between plants thereby strengthening the information flow in realtime between enterprise and production Convergence of manufacturing systems in a intelligent manner 12 What does Industry 4.0 mean to IT in Manufacturing ?
- 13. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Agenda Mega trends Discussions Industry 4.0 IoTS and Bosch New trends in Manufacturing IT 13
- 14. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing 14 and The Provider & The Operator – Practitioners perspective..
- 15. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing 15 Internet of Things and Services Domain IT/ Software Creativity Shift “Smart Manufacturing” to “Manufacturing Smart” Enabling business success in the connected world IoTS and its play in manufacturing..
- 16. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing 16 RFID based Manufacturing 1.5 million RFID bookings per month 1 booking every 2 seconds (24/7) Realized benefits of 1M Euro annually By moving to smaller lot sizes and inventory reductionRAN – RFID Automotive Network with Partners
- 17. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing 17 Machine request for Materials in Production Machine communicates for its own material by its own for the next production Zero inventory in production No waiting time for material in production. Smooth supply of materials in production Realized benefits of 10% productivity improvement By moving to smaller lot sizes and inventory reduction
- 18. Confidential | RBEI | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Predictive Maintenance Principles and Offering Real-time gathering of machine data and conditions Software-based analysis of machine data to produce fault predictions Agile modeling and execution of (partially) automated maintenance processes to prevent impending faults Flexible integration into existing business IT (e.g. SAP work order) 18
- 19. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Agenda Mega trends Discussions Industry 4.0 IoTS and Bosch New trends in Manufacturing IT 19
- 20. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing New Manufacturing Enterprise IT Architecture 20 Enterprise-wide network TCP/IP, Ethernet Manufacturing Intelligence Layer Tight integration, Visualization, manufacturing analytics , realtime information flow, technology enablement in production Enterprise-wide network TCP/IP, Ethernet Business Logistics [ERP/SCM/CRM/BI/BO] Macro Planning, Logistics process, Shipping, Receiving, Inventory, Finance and Controlling Manufacturing site 1 Manufacturing site 2 Manufacturing site 3
- 21. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing 21 Bosch is currently running some 50 connected industry pilot projects We have introduced aspects of connected industry at our own plants, including standardized data exchange between companies Bosch offers software and hardware solutions for connected industry applications “At Bosch, we’re not just making connected industry a reality, it already is – and its future is bright around the world” - Werner Struth, member ,Bosch Board of Management
- 22. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Next Generation IT in Manufacturing Agenda Mega trends Discussions Industry 4.0 IoTS and Bosch New trends in Manufacturing IT 22
- 23. Confidential | RBEI/BSS | 11/02/2015 | © Robert Bosch Engineering and Business Solutions Limited 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 23 Next Generation IT in Manufacturing
Editor's Notes
- Statistics and information about the connected things in 2015. this gives the indication about how the world is moving towards connecting things which includes the machine and products in manufacturing.
- Mega trends in the world from 2013, in which mobility and big data is playing a vital role in the manufacturing boundary. As part of modernization of manufacturing these 2 technologies play a key role in the transformation.
- Evolution of Industry 4.0 which is similar initiative in US which is called a “Smart manufacturing”
- What it means for the manufacturing sector? Entire processes are going to get connected to communicate by itself with the value chain. Eg. Trucks and machines will communicate to inform about the status and any deviation so that it can get corrected automatically.
- Meaning of Industry 4.0 and what is expected from I4.0.
- I4.0 what it means in manufacturing, whether ERP, MES and manufacturing intelligence layer which is going to provide strong integration for the connected industry.
- 1. Bosch perspective: we have the advantage in the market as we provide the solutions and products as well as we also operates with the same. Which gives us the bigger benefit of Practitioner. In out manufacturing setups we started using the same and started realizing the benefits also.
- What is meant by IoTS, how it is going to help the manufacturing set up? What are the new business models evolved because of IoTS. This is leading to transformation of shift of manufacturing set up and processes in the supply chain to give better improvement in the productivity and results in customer satisfaction and securing brand in the global market. No more “Smart Manufacturing” it is about manufacturing smart!!
- Some examples of I4.0 solutions already implemented in Bosch : 1. RFID based process for the outbound logistics and production to ensure and benefit zero stock. JIT/JIS production and supply of components to OEM’s. which ensures smooth flow of material to the customer location.
- Example 2 : Machine request material for it’s own production. Material arrives at the specific location when it is required as per the production plan.
- The aim is to prevent costly downtime and optimize maintenance and repair costs through better planning . How it works: networking of enterprise resource planning systems , machinery databases and personnel planning. Bosch Software Innovations is working on a solution to integrate data and processes so that machine errors predicted before its occurrence and maintenance can be planned in advance as a result. ? Networking via the Internet: Using sensors status data of machine components at run time , which shall be transmitted over the Internet to the software. Based on defined rules, the data should be analyzed and made accurate predictions about faults and failure points in time . The corresponding measures are not taken in time by means of techniques of process management before production falters Service Portal : ? About a service portal , the results obtained are centrally monitored and organized follow-up. In combination with information from ERP systems or other third-party systems such services for remote maintenance and offered as trays of technicians can be scheduled on-site. Ziel ist es, teure Stillstände zu vermeiden und Wartungs- und Reparaturkosten durch eine bessere Planbarkeit zu optimieren. Funktionsweise: Vernetzung von Warenwirtschaftssysteme, Maschinendatenbanken und Personalplanung. Bosch Software Innovations arbeitet an einer Lösung, um Daten und Prozesse so zu integrieren, dass Maschinenfehler schon vor ihrem Auftreten prognostiziert und Instandhaltungen infolgedessen vorausschauend geplant werden können. Vernetzung über das Internet: Mit Hilfe von Sensoren werden zur Laufzeit Zustandsdaten von Maschinenkomponenten erfasst, die über das Internet an die Software übermittelt werden. Anhand definierter Regeln werden die Daten analysiert und so präzise Vorhersagen über Störungen und Ausfallzeitpunkte getroffen. Die entsprechenden Maßnahmen werden mittels Techniken des Prozessmanagements rechtzeitig eingeleitet, bevor die Produktion ins Stocken gerät! Service Portal: Über ein Service Portal werden die gewonnenen Ergebnisse zentral überwacht und Folgemaßnahmen organisiert. In Kombination mit Informationen aus Warenwirtschaftssystemen oder anderen Drittsystemen können so Dienste zur Fernwartung angeboten und beispielsweise Einsätze von Technikern vor Ort geplant werden.
- Ne manufacturing enterprise architecture which gives the higher benefit and maximize the manufacturing potential. Critical point is to have a strong layer for the manufacturing system integration between plants and the enterprise data. This allows the enterprise the get the relevant meaning information at the real time for taking right decisions at the right time. Key focus on the integration between systems and plants for critical information, where the tight and stable integration is a must. This layer ensures the integration between enterprise systems , MES systems which in turn integrated with the controller layer and machine devices layer. Key architecture decision to enable the production to manufacture smart, and making right decisions with respect the manufacturing processes for improving the productivity.
- Key highlight projects running in Bosch within the I4.0 spectrum.