The Factory of The Future Qualification for Industry 4.0 Tony Oran Octavio Rojas Vice President Innovation and Technology Director Festo Didactic, Inc. DI-S\Tony Oran Festo Didactic - Global Leader for Technical Education Solutions 1
Festo is a productivity company From Industry — For Industry Partner of technical training and development. Technical Education Didactic Training and Automation Consulting Factory Automation Process Learning Automation systems DI-S\Tony Oran Festo Didactic - Global Leader for Technical Education Solutions 2
Festo Industrial Customers in Indiana – Sampling of 100+ For Industry, By Industry 3
Festo Industrial Customers in Alabama – Sampling of 100+ For Industry, By Industry 4
Industry 4.0 and Digitalization The fundamental change
From Industry 1.0 to 4.0 | Emphasis of the particular industrial revolutions Technical Organizational Technical Organizational inventions inventions inventions inventions 6
Industrial revolutions | First industrial revolution - The steam machine Historical facts: • 1705: First steam machine developed by Thomas Newcomben • 1769: Essential improvement and patent registration by James Watt • Start of industrialization Ideas: • Providing of higher energy quantities • Location-independent generation of energy • Distribution and transmission of energy over long distances 7
Industrial revolutions | Second industrial revolution - The conveyor belt Historical facts: • 1834: First electrical motor developed by Hermann Jacobi (twenty-five times higher cost than steam engine) • 1866: Invention of dynamo by Ernst “First organization, then automation!” Werner von Siemens • 1908: Installation of conveyor belt by Henry Ford Ideas: • Production of Ford Model T as mass product • Understanding of scale effects and consistent usage • Collaborative work organization • Implementation of automation 8
Industrial revolutions | Third industrial revolution - Automation Historical facts: • 1949: First NC controlled tolling machines by John T. Parson • 1950s: Toyota (Lean) Production • 1961: First industrial robots • 1969: First PLC • 1970s: CAD (Computer-Aided Design) • 1983: CIM (Computer Integrated Manufacturing) • 1992: “The second revolution of automotive industry” by Womack, Jones and Roos Ideas: • Manage customer markets • Manage high quality requirements • Delivering a high amount of product variants • Customer-orientated solutions 9
Fundamental paradigm shift in Industry 4.0 3.0 4.0 Third industrial revolution Fourth industrial revolution The use of computers and robots leads Industry 4.0 describes the networking of people, to greater production automation. machines, and products – in real time, via the Internet. Central control Decentralized self-organization through ad-hoc networking Established value chains Virtual ad-hoc organizations Production system operation is planned in advance Autonomous, self-organizing production units Products are passive objects in the processing operation Active production process supported by intelligent products Source: Forschungsunion Wirtschaft – Wissenschaft 10
Cyber Physical Manufacturing Industry 4.0 11
Cyber Physical Manufacturing Industry 4.0 Technology Evolution Source: Accenture. Figure 3 – The Combinatorial Effect of Technology 12
Industry 4.0 Advanced Manufacturing Evolution Source: Overview of Smart Manufacturing 2018 - Dr. Thorsten Wuest 13
Core elements of Industry 4.0 “...who am I ...” “...what can do I ...” “...what am doing I ...” Augmented / Virtual Reality Big Data Condition Monitoring Communication standard Extended reality / computer-assisted Unspecific search for correlations and Permanent or periodical measurements of Standard in the communication of • expansion of reality perception patterns in available but unstructured data. physical variables. CM is considered as a machines (M2M) Securely exchanging Currently mainly realized by smart The goal is to detect unexpected building block of Smart Maintenance. structured data. • connections Basis for optimization glasses Machine-to-Machine RFID ERP/MES Cyber-physical-systems Communication Radio Frequency Identification (RFID) is a ERP takes over the task of planning, Merging of physical and virtual systems. technology for the identification of products controlling and coordinating all resources They have their own intelligence in the form M2M communication denotes the automated as well as a medium to store data. It is in a company. MES performs the detailed of microcontrollers and software, which data exchange between machines. Machines possible to read and write data from/on the planning of production processes and allows them to connect to the outside world must be networked and ready for data RFID tag. resources. via sensors and actuator. exchange. 14
Virtual Reality 15
Augmented Reality 16
Cyber-physical-systems 17
Identification systems - RFID Machine-to-Machine Communication 18
ERP/MES 19
Artificial intelligence / Machine learning The amount of data we produce every day is truly mind-boggling. There are 2.5 quintillion bytes of data created each day at our current pace, but that pace is only accelerating with the growth of the Internet of Things (IoT). source 20
Big Data 21
Communication standards 22
Seamless integration – from top floor to shop floor ERP SCM PLM PLAN MAKE DELIVER INTEGRATION ERP Manufacturing Integration & Intelligence Business Logic Services Industry 4.0 Real Time Composition Visualization MES Environment » Manufacturing Quality Engine industries KPIs/Metrics/Alerts 1 SCADA / HMI Data Services » Things and devices on the shop floor Plant Historian Machine Layer DCS/PLC SMART industrial THINGS via OPC SMART industrial DEVICES Plant Connectivity SCADA/HMI M2M MES LIMS/Inspection/ Wireless Equipment Testing Plant Data Integration Environmental Plant DB Collection Building Management 23
TOP FLOOR TO SHOP FLOOR INTEROPERABILITY Training Scenarios Tutorials E-Learning Tec2Screen Workbook Seminar Webinar Gaming Media and Blended with link to Course Outlines Learning Multi-Media Factory Software CAD/CA Smart SAP4School ORACLE AR Learning M Maintenance CAD AI Arrangements Mindsphere CAM ML Manufacturing Execution System (MES4) INTEROPERABILITY HMI Other Solutions 24
Making the future adaptable in the Technology Plant Learning at the Festo Technology Plant — Scharnhausen, Germany Production plant of the future for valves, valve terminals and electronics Automated and flexible Highly flexible, energy-efficient assembly lines Flexible, flowing production An optimised flow of information and materials Optimised energy consumption Energy network for buildings and production processes Learning taken for granted Training factory as practical, integral constituent 25
Networked production architecture of the future Unified data formats and standards for efficient engineering processes Plug and produce components: Virtual emulation: “I am finished.” facilitate the exchange of defective this will enable automatic production units and the reuse of start-up and reconfiguration. individual units for new products. Condition Monitoring: the filter reports a contamination level of 95%. “I continue on to station 2.” 26
Festo Industry 4.0 Certification Program From fundamentals through Advanced Industry 4.0 Three Levels with horizontal and vertical stacking Level 3: Industry 4.0 Specialization Level 2: Advanced Mechatronics Level 1: Fundamentals Flexibility 27
Festo Industry 4.0 Certification Program Content Landscape Level 3: Industry 4.0 Advanced Smart Advanced HMI Advanced PLC Cyber-Security Product ID Maintenance Robotics Level 2: Advanced Mechatronics Product ID Applied Applied Applied Applied Applied PLC Fundamentals Fluid Power Mechanical Systems Robotics Industry 4.0 Level 1: Fundamentals Electricity Fluid Power Mechanical PLC Robotics Industry 4.0 Fundamentals Fundamentals Systems Fundamentals Fundamentals Fundamentals 28
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