Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen. Towards Positive Impact Factories IoT as an enabler

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1 Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen Towards Positive Impact Factories IoT as an enabler Prof. Dr.-Ing. Christoph Herrmann Sustainable Manufacturing in IoT Era

2 Technische Universität Braunschweig Founded 1745 ca. 19,500 students 3,750 university staff 1,800 scientists 223 professors 120 institutes 65 degree programs 10 central service units 6 departments 8% 7% 6% 5% Anteil am BIP 4% 3% 2% 1% 0% [Eurostat 2002] R&D-Density in European regions (share of GDP). The region of Braunschweig (7,1%) is ahead of North Finland (4,2%) and East England (3,9%) Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 2

3 Agenda 1 Digitalization 2 From Bad to Positive Impacts 3 Building Blocks for The Positive Impact Factory 4 ICT and IoT enabling the Positive Impact Factory Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 3

4 Industry 4.0 The Fourth Industrial Revolution Degree of complexity First Industrial Revolution based on the introduction of mechanical production equipment driven by water and steam power Second Industrial Revolution based on mass production achieved by the division of labor concept and the use of electrical energy Third Industrial Revolution based on the use of electronics and IT to further automate production Fourth Industrial Revolution based on the use of cyber-physical systems First mechanical loom, 1784 First conveyor belt, Cincinnati slaughterhouse, 1870 First programmable logic controller (PLC) Modicon 084, 1969 Late 18 th century Beginning 20 th century 1970s Today [DFKI 2011] Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 4

5 Digitalization Cyber Physical Production Systems Cyber Physical Production System Physical Digital Twin (Factory, Machine, Process, Learning ) Smart Products Smart Data/ Machine Learning Cyber Industral assistance systems Multi-modal input analysis Multi-modal presenstation of results Learn-/ Productionmode [Microsoft BING 2016] Collaboration & Interaction [DFKI 2012, acatech 2013] Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 5

6 Digitalization Cyber Physical Production Systems Automation Pyramid Automation Diabolo ERP Enterprise ERP MES Plant MES SCADA Shop Floor Information Model Real-time critical SPS I/O signals Control Field Automation Production Process Traditional information model from automation technology Data is exchanged between systems on the different layers via gateways Information model as connection to MES Layers from automation technology are dissolved Data exchange in vertical and horizontal direction [VDI/VDE 2013, Vogel-Heuser 2014, Trends+Innovation 2015] Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 6

7 Digitalization Cyber Physical Production Systems Automation Diabolo Cyber-Physical Systems (CPS) ERP MES Information Model Automation Production Process Information model as connection to MES Layers from automation technology are dissolved Data exchange in vertical and horizontal direction [VDI/VDE 2013, Vogel-Heuser 2014, Trends+Innovation 2015] Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 7 Real-time critical control near the processes and distributed Utilization of decentralized services requires new human-machine-interfaces (HMI) New layers above the ERP are added Different OEM and users are integrated

8 Agenda 1 Digitalization 2 From Bad to Positive Impacts 3 Building Blocks for The Positive Impact Factory 4 ICT and IoT enabling the Positive Impact Factory Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 8

9 From Bad to Positive Impacts The current thinking about Factories Bad Factory Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 9

10 From Bad to Positive Impacts The current thinking about Factories Image Sources: 1. static.panoramio.com; 2. maverickbiofuels.com; 3. captainkimo.com; 4. IWF; 5. beobachter.ch; 6. english.cri.cn; 7. ctvnews.ca; 8. cdn.ientry.com; 9. daviscos.com; 10. paritynews.com ; 11. robots.com; 12. i.huffpost.com; weebly.com; 14. czech.homestead.com Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 10

11 From Bad to Positive Impacts Efficiency and Effectivity How to reach positive impacts? Factory Impacts Technology s-curve concept acc. to Foster (1986) positive limit of effectiveness technology potential neutral technology potential today limit of efficiency Effort today negative Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 11

12 From Bad to Positive Impacts Examples of Fields of Action From bad to positive impacts examples: Energy & Resource Demand Bad Impacts - + Positive Impacts Particle Emissions Bad Impacts - + Positive Impacts Working Conditions Bad Impacts - + Positive Impacts Image Sources: static.panoramio.com; oag.ca.gov, captainkimo.com; solar-fabrik.de, paritynews.com; onlinecareertips.com Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 12

13 Agenda 1 Digitalization 2 From Bad to Positive Impacts 3 Building Blocks for The Positive Impact Factory 4 ICT and IoT enabling the Positive Impact Factory Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 13

14 Enabling The Positive Impact Factory Building Blocks Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 14

15 Agenda 1 Digitalization 2 From Bad to Positive Impacts 3 Building Blocks for The Positive Impact Factory 4 ICT and IoT enabling the Positive Impact Factory Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 15

16 Enabling The Positive Impact Factory Energy Transperency in Production Energy Transperency in Production Identification of non-value-creating energy demand Effective analysis and evaluation of energy demand data Decision support on the shop floor Process best practices to reduce cost and process times while maintaining quality [IWF mit uns digital, 2017] Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 16

17 Enabling The Positive Impact Factory Power Autonomous Sensor Systems Power Autonomous Sensor Systems Miniaturised power autonomous sensor systems No intereference with the production system Monitoring of machine data, energy demand, environmental data Human-machine-interaction supporting energy management and maintenance [ESIMA, 2016] Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 17

18 Enabling The Positive Impact Factory Matrix production concept Self-Organising Matrix Production Concept Agent based simulation for system planning and control Highly flexible - synergetic use of the matrix production systems by different products Cycle time independent Large cycle time spreads possible System stability by redundancy Products and production processes are connected and can take actions [IWF] Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 18

19 Enabling The Positive Impact Factory Energy flexibility Energy Flexibility in Production Systems Align electricity demand of a factory to supply All planning stages considered in holistic approach Goal: Real-time manufacturing control through modular system design tool with energy and material flow dynamics Multi-indicator evaluation Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 19 [Beier et al. 2017]

20 Enabling The Positive Impact Factory Industrial Symbiosis Energy Flexibility in Production Systems Industrial symbiosis describes the utilization of output flows (waste) as resource input to other companies Market place system needs to dynamically connect all resource flows and decentral data input For the realization of the simulation data input from a high number of physically distributed entities and decentralized computing is required Transport means and companies are modelled as autonomous agents Elaborated from Low (2015) Prof. Dr.-Ing. Christoph Herrmann Positive Impact Factory Slide 20

21 Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen Towards Positive Impact Factories IoT as an enabler Prof. Dr.-Ing. Christoph Herrmann Sustainable Manufacturing in IoT Era