FoodFactories of the Future

How Industry 4.0Technologiescan improve your business

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Introduction.

Peter WienzekDipl.-Ing. MBM

Business DevelopmentManager Systems

Smart Factories

ifm electronic

ifm electronic gmbhFriedrichstr.145128 Essen / GermanyPhone +49 201 2422-1260Fax +49 201 2422-1345Mobile +49 171 632 8550E-Mail peter.wienzek@ifm.comInternet www.ifm.com

Position sensors

Process sensors

Sensors formotion control

Industrial communication

Connectiontechnology

Industrial imaging

Identificationsystems

Safety technology

Conditionmonitoring systemsIO-Link

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Power supplies

Software

Accessories

Systems formobile machines

HistoryIndustriesHome Customer Quality Innovation Products

CloudServices

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What is most important?

• Constantproduct quality inyour process

• Higherefficiency =Cost reduction

• Environmentaltasks =savings onutility bills

• MoreTransparency inProduction Maintenance

• Future:CPF?Cyber-Physical-Factory

Industry4.0

Internet of ThingsIndustrial control system

Digital modeling and fabrication

Industrial InternetIntelligent Maintenance Systems

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syst

em

SCA

DA Big data

Popular keywords

IoT

M2M Cyber Physical Systems

PLC

Picture source: http://www.uberb2b.com

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"PLC

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"automation + IT"

Steps of industrial manufacturing

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Morefactory automationtechnologies infoodplants

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Example:Robots inFilling Area

• Moreautomation means more efficiency in:• Filling,packaging,conveying...

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Moreinformation from yoursensors

Continuous Development to BIG DATA.

1969

1970

1980

1990

2000

2010

ifm introduces the firstelectronic flowmonitors, start of thefluid sensors range.

0,18 Terabyte/pa

1,3 Terabyte/paUnique in the market – theecomatmobile Basic controllerconcept for simple mobile machines. Its three modules –BasicRelay, BasicController, BasicDisplay – allow anycombination.

Identification systems from ifm: optical (reading 2D codes) andvia radio (RFID).

3,9 Terabyte/pa

The third dimensionat a glance. Visual assessment ofdistance, level orvolume withthe efector pmd3d 3D vision sensor.:

Introduction ofinductive andcapacitive sensorsby the ifm foundersRobert Buck andGerd Marhofer.

Presentation of ifm's firstown control systems forindustrial use, and laterfor mobile vehicles.

efector octavis vibrationdiagnostic system. New ways in condition-based maintenance. Nominated for theHermes Award 2004.

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Moreinformation from yourproduction

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Industrie4.0– ITvs.Production?

IT-experts say:l 94%:„Networkingbetween Automation- and IT-World (Hard-,Softwareand

Telecom)is overwhelming enterprises.“l 71%:„Enterprisesunder-estimate the costs for data collection and data

storage.“

Production experts say:l 90%:„efficient data exchange is most important for Industrie4.0“

l Machine data 72%l Process- and quality data 70%l For SupplyChain58%

l 84%:„Connectivitybetween machine and ERP is the key factor.“

„We are sitting onamountain of data today butare notcapable of using thesedata structured and networked to optimize our process control.“Headof Production

Quelle:VerbandderdeutschenInternetwirtschaft(www.eco.de), PWC-Studie„Industrie4.0– ChancenundHerausforderungenderviertenindustriellenRevolution(n=235),Industrie4.0Monitor2013,BARCSurvey„BigDataUse Cases2015“,BusinessImpact04/2015,01/2016

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0

10

20

30

40

50

60

1992 2002 2007 2014 2019

0,1TBproSek.

2,0TBproSek.

15,9TBproSek.

50,6TBproSek.

TB/s

Datenvolumenweltweiter

InternetverkehrgesamtinZB(Mrd.TB)

1,2ZB 7,9ZB 40ZB

Raw Datavs.Information

95%of machine data today are „DarkData“– Contentunknown and therefore useless

Quelle: BARC Survey „Big Data Use Cases 2015“, Business Impact 04/ 2015, 01/2016

To findthe needle you need thehaystack...TheCLOUD?

To find the needle, you need the haystack .To find the needle, you need the haystack .

To find the needle, you need the haystack .

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WhatdoestheifmCloudlooklike?

SaaS– SoftwareasaService• Globalavailability and support 24/7• Fastimplementation – with or without ERPconnectivity (SAP)• Always up-to-date– industrial application packages• No investment innew software (WYSIWYG)• Highsecuritylevel– evenwithcriticaldata(e2eencryption)

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ifmCloudApplications

RemoteServicesOEMs

Remotemachines /plants

MobileMachines,Vehicles

ifm Cloud:SmartData

Cloud-APPseg.

• LRSMARTOBSERVERMachine dataacquisition forprocess control anddiagnosis

• LRDEVICE:RemoteServicesandspareparts ordermanagement withSAPintegration

LR-Box:SmartDataPre-processing andSecuritymanagement

BigData

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Example for Cloud-APPs

LRSmartObserver• Facebookof sensors:Allrelevantmachine data inone cockpit:• Process data,alarms and charts

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OEMwith• 2.000Serviceengineers• 5.000independent system integrators

RemoteServiceswith LRDEVICE

Parametrizing,Templatesfordata sets,Readhistorian etc.

Data-collectors(IPCs)

SystemintegratorOn-sitewith PC

Latest Firmware

RemoteServiceTechnician

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Energy Savings inyour Plant

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EDM – Application Monitoring Energy Consumption

UserBenefits:

● Energycostperproducedpiece

● Energycostmonitoringforcompressedair

● Optimizationandincreaseofefficiencythoughimprovedtransparency

● Quickandsimpleinstallation

CompanyIT

Counter(OSD150)

Energyconsumption

(Janitza / Socomec))

Compressed Air(SD Family)

Compressed Air(SD Family)

Energy Meters(Janitza /

Socomec))

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EDM – Energy Data Acquisition

● Datacapturingvia● IOLinkSensors

(Temperature,pressure,flow,pieces/counter,etc.)

● TCP/IP(intelligentsensorsforelectricalenergy)● ModbusTCP(intelligentsensorsforelectricalenergy)● S0Impulse(energysensorswithimpulseoutput)● Connectivitytomachinecontrolspossible● Connectivitytoexistingsensors/infrastructurepossible

● Dataprocessing● Sensordataaredecentralizedconvertedtoprocessvalues● Calculationofheatquantityfromflowrateandtemperatures

● Futureproofconcept● Dataacquisitionexpandabletothecompleteplantandcompany● Transferandhandlingofthedatainthecloudpossible

PieceCounter

CompressedAir

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EDM – Energy Data Reporting

● CostmonitoringVisualizationofenergycostperproducedpiece

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Condition Based Maintenance

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RemoteCBM

VibrationsensorsTemperature sensorsInductive sensorsEvaluationUnit

LR Agent CP

Water pumps

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Solutionpackagesforfoodapplications

CorporateITNetworkMaintenance

Parameters, EventsDiagnostics, Identification etc.

PC,Server

CBM = Vibration Analysis

ifmStandardSolutionPackagesavailablefor

• Pumps• Fans (Cooling, Ventilation)• Material Handling Robot• Hydraulic Systems (Water, Oil)• Motors, Gear boxes (Conveyors)

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Examples:lRemoteServices with IO-Link-Sensors(Identification,Parameterising,Diagnosis)

lRFIDand Multicode-Readersfor Traceabilityand Assembly of the whole SupplyChain

l3D- and 2D-SensorsforQualityMonitoringand Historian

lEnergy management for Powermeters,compressed airand leakage monitoring

lCondition Based Monitoring for Motors,Gearboxes,Fansand Pumps.

MainAreasof I40Applications

GEAcustomer site

HANA CloudIoT

Evaluation unit

PLCs

ERP

M-Guard

LRAgentembedded

Ethernet

Ethernet

Data

Mission Control Center

IPC unit

Application Decanter OEM

Decanter

RemoteServicesone step ahead

Remote

Industry 4.0- integratedRemoteServices,Maintenanceand Repair

§Planning of AfterSales capacity worldwide§Easyconnection to customer‘s IT-systems§Protection against plagiarism§Automated ordering of spareparts§Highly improved quality management§Improved documentation for warranty situations§Possibility of operating,insurance and financing models

Application

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Conclusion:FoodFactories of the Future

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Transparency,Flexibility,Individualization andIntegrationare key principles

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Context of Industry 4.0along the ValueChain

R&D Sales Supply Chain Manufacturing Aftermarket Service

Smart Products

Predictive Maintenance

Adaptive Logistics

DigitalProduct Memory

EnergyManagement

Remote Service Management

Resilient Production

Track & Trace

Performancebased Contracting

Smart Data

Source: SAP

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For ifmIndustry 4.0means:

... the right information

... at the right time

... at the right recipient

= Solutions from sensor to ERP (SAP) and back ...27.07.17 Industry 4.0 31

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Industry 4.0– 3steps

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Collecting information(read from the PLC by means of the LR AGENTs ordirectly from the sensors,identification / image processing systems by means of theLR AGENT EMBEDDED (Iot core)

Bundling and distributing informationby means of IO-Link, Ethernet, the Y path and theconnectivity agents

Machines act autonomously / automaticallyon the one hand via the real-time network e.g. when themachine is switched off, on the other hand by linking andanalysing information on computers and servers ... to SAP and back