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© Fraunhofer IFF
IDENTIFICATION TECHNOLOGIES AS AN ENABLER FOR INDUSTRIE 4.0
Sebastian Häberer
Chon Buri, February 2019
© Fraunhofer IFF
Employment
Researcher, Fraunhofer Institute for Factory Operation and Automation IFF, Magdeburg
Bachelor’s candidate, Corporate Industrial Ergonomics, Volkswagen AG, Wolfsburg
JOIN intern, Research & Development, DHL Solutions & Innovation, Troisdorf
Student assistant and intern, Fraunhofer Institute for Factory Operation and Automation IFF, Magdeburg
Education
Training and Certification in MTM-Practitoner
Bachelor of Science (B.Sc.) and Master of Science (M.Sc.) in Logistics Engineering Management, Otto von Guericke University Magdeburg, with specializations in:
Logistics planning and virtual reality
Supply chain management (SCM) and networks
Résumé
Industry expertise
Automotive (supplier)
Logistics
Service
Professional expertise
Logistics planning and organization
Process planning and optimization, restructuring
Demand and capability analyses
Project management and steering
Key projects
Development of a standard that assesses physical stress of untimed work
Supervision and refinement of a delivery concept based on the crowd principle
Development of an integrated approach to implement hybrid assembly systems
SME 4.0 competence center Magdeburg
Expertise
Sebastian Häberer
Current Position
Expert Engineer,Logistics and Factory Systems Business Unit
Fraunhofer Institute for Factory Operation and Automation IFF Magdeburg
Person
© Fraunhofer IFF
Industrie 4.0-CheckUp Training of Trainer ProgramRoadmap for the implementation of Industrie 4.0
https://www.youtube.com/watch?v=3rG9-gUhcJA&list=PLIIjFDzTdgkPBOAtujEqZ4jSS8QFjem5l
© Fraunhofer IFF
The Fraunhofer Institute for Factory Operation and Automation IFFWhere do we come from
Fraunhofer Institute for Factory Operation and Automation IFF
Located in Magdeburg, Germany
200 Researchers
€ 20 Mio Research budget p.a.
International experience on six continents
© Fraunhofer IFF © Fraunhofer IFF
© Fraunhofer IFF
The Fraunhofer Institute for Factory Operation and Automation IFFProviding a system perspective on the factory
Fields of Research
Resource Efficient Production and Logistics
Smart WorkSystems
ConvergentSupplyInfra-structures
Logistics and Factory Systems
Material Handling Engineering and
Systems
Measurement and Testing
Technologies
Robotic Systems
Virtual Engineering
BiosystemsEngineering
Convergent Infrastructures
Fraunhofer IFF Business Units
© Fraunhofer IFF
Tactile sensors Tactile sensors for safety and haptic interaction Applied all around the platform, linear axis and as bumper
With integrated damping material
As input device for simple and intuitive movement of platform and linear axis
The Fraunhofer Institute for Factory Operation and Automation IFF Safe Human Robot Collaboration
© Fraunhofer IFF
The Fraunhofer Institute for Factory Operation and Automation IFFUsing smartphones as spectral sensor
Objective: Making spectroscopy available for wider applications
HawkSpex Mobile App uses adjustable illumination of mobile display and front camera to record spectral image
Using purpose built machine learning models to analyze properties
Application area:
Agriculture and food processing
Cosmetics and fashion retail
Quality control and product authentication
New value adding business models
© Fraunhofer IFF
The Fraunhofer Institute for Factory Operation and Automation IFFEuropean level coordination of SME support - Digital Innovation Hubs and Competence Center for SME
VDTC officially recognized as a European Digital Innovation Hub providing companies with cutting edge support towards Industrie 4.0
Supporting international networks to increase access to knowledge
DIH as one-stop-shops for companies, especially SME, to improve their competitiveness through digitalization
VDTC as a central actor in a network of regional stakeholders to promote and support digitalization in Saxony-Anhalt and beyond
Digital
Innovation
Hubs
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Development of markets
Pro
du
ctvo
lum
ep
er
va
ria
nt
Product variety
1850
1913
1955
1980
2000
e.g.. 3D-Print
e.g. BMW online carconfigurator
„People can have the Model T in any colour - as long asit´s black“
Henry Ford (1913)
e.g. VW beetle
Source: According to Yoram Koren: The Global Manufacturing Revolution; Source: Ford, beetleworld.net, bmw.de, dw.de
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Volatility increases flexibility requirements
Production CustomerSupplier
Internationalization of procurement markets
Increasing product complexity
Short-term orders
Increasing number of variants and customized products
Extremely short delivery
times
Order decline or
order increase
Drastically
shortened
product life cycles
Increasing intensity of competition
Small lot sizes
shortage ofresources
Unsafe replenishment
time
Source: www.mlive.com Source: en.wikipedia.org
© IFA Rotorion© BMW
© Bimmertoday
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Requirements of future-oriented production solutions
Connection and integration Digital value chain
Changeability Dynamic process optimization
Source: Bildquellen: acatech; MuM; Bilfinger; M&R
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Potential Savings
Costs Impact Savings
Inventory costs Reduction of reserve inventoryElimination of bullwhip effect (Burbidge and Forrester effect)
30 to 40%
Manufacturing costs Improvement of OEEProcess control loops Improvement of vertical and horizontal staff flexibility
10 to 20%
Logistics costs Increased level of automation (milk run, picking, etc.) 10 to 20%
Complexity costs Expanded performance marginsReduction of trouble shooting
60 to 70%
Quality costs Near real-time quality control loops 10 to 20%
Maintenance costs Optimization of spare part inventoriesCondition-based maintenance (process and measured data)Dynamic prioritization
20 to 30%
Source: Bauernhansl, Thomas: Die Vierte Industrielle Revolution – Der Weg in ein wertschaffendes Produktionsparadigma. 2014
© Fraunhofer IFF
Multiple entry of data
Coordination problems
Information deficits defies information
Overload of information
Incorrect information
IT solutions
Information losses during shift transfer
Manual data input
High time expenditure
Deficits in the flow of information
Identification technologies as an enabler for Industrie 4.0Increase productivity potential through digitization
operating objectives
Long durations
Delivery problems (scheduling difficulties)
High waiting and lay times
High stocks
Little flexibility
Late troubleshooting
…
Deficits in the material flow
Disturbances in the material flow can often be explained by poor information flow
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Data flow in the production process
Data fusion Data analysis
Model Simulation
Bandwidth
Monitoring
Trends,
Forecast
Decision support
Data entry
Sensors Digital Factory
Data storage
Data protection Amount of data
Preprocessing
real-time Know-how
Visualization
Products, Processes, Facilities
OptimisationRegulation
Interfaces
Automatization
Standards
Key issues / technologies
Networking topics
Existing solutions
Development needs
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0The biggest challenges on the way to the digital industry
Skilled workers qualification Missing standards
Data security Investment costs
Source: MittelstandDigital 2017, BMWI
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Forecast of different Industrie 4.0 Road Maps
Laboratory solutions
Primary Showcases or laboratory solutions in
development
Isolated / selected pilot applications
In the coming years, mainly technology-
driven isolated / plug-in solutions will
be developed
Ready adoption of standard solutions
The market penetration of
isolated solutions merge to
combinations of many solutions
through existing channels
Over the life cycle of the production machines, Industrie 4.0 will take
place holistically, provided the machines,
infrastructure and employees are able to do
industrie 4.0
Transition to true industry 4.0
New factoriesGreenfield
Existing factories
Brownfield
Source: Zollenkop/Lässig (2017), Pg. 67
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Promoting a holistic perspective on Industrie 4.0 - Good-practice recommendations
Industrie 4.0 is not only about modernizing equipment
Improved digital data collection
Better exploitation of data
Fusing different data sources
Modern equipment produces data and needs data
Companies need to take account of this new paradigm
Process ownership and employee competences for decen-tralized decision-making
Employee digital skills and appropriate assistance systems
Innovation-, personnel-, and change management aspects
Digital business model adaptation© Neugebauer, Reimund; Hippmann, Sophie; Leis, Miriam; Landherr, Martin (2016): Industrie 4.0 - From the perspective ofapplied research. 49th CIRP Conference on Manufacturing Systems (CIRP-CMS 2016). Available online at www.sciencedirect.com
© Fraunhofer IFF
Traditional
Strategic
Approaches
Identification technologies as an enabler for Industrie 4.0Digital innovation - Fundamental changes in the strategic context
vs.
Test
&
Learn
“Move fast and break
things”
Uncertain environ-ments
No respect for
incumbency
Speed
Agility
Always in prototype
stage
Constant user
feedback
Win the customer
everyday a new
Centra-lization
Hierarchical Decision-making
Long-term planning
cycles
Incumbancyas market
barrier
Focus on legacy assets
Strict focus on ROI
Top-down
Depart-mental
silos
© Fraunhofer IFF
AIMS: Smart Factory and Smart System
Information and communication technologies connect all areas:
Components and objects are information carriers.
They communicate with humans and machines, exchange data.
They actively support the production process.
Mobile assistance systems support people.
Real-time analysis of data from components and machines is used for decision support
Identification technologies as an enabler for Industrie 4.0Work system of the future - IT becomes the driver
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Five Key Characteristics of a Smart Factory
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Holistic Approach for Smart Factories: Interaction Model
Theories Experiments
Technologies
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Automatic identification as a key technology - Definition of Terms »Identification«
Identification is the application of methods and tools to uniquely recognize a person or an object.
Identification requires characteristic features or a so-called identifier as an artificially assigned feature.
Example "Human eye“:
Task: Identification of a person
Characteristic: Iris of the human eye
Procedure: Image processing
Source: Sweeney, in RFID für Dummies, 2006
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - Vision of the Auto-ID application
Development of an "Internet of Objects" (Internet of Things, IoT)
In a highly linked process, objects can be repeatedly detected and captured.
The data collected in real time can then be used without delay in the existing logically meshed network of the intranet, databases and applications.
Source: Sweeney, in RFID für Dummies, 2006
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0 Functions and added values - Automatic identification systems
Artificial identifier
Optical Character Recognition (OCR)
Barcode System
Smart cards
Radio Frequency
Identification (RFID)
Natural identifiers (biometry)
Fingerprint
Language
Eye
Surfaces
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - Comparison of RFID with conventional identification
Characteristic Barcode-Technology RFID-Technology
Transmission optical electromagnetic
Data capacity low high
Shape and size determinateindividually
customizable
Sight required not required
Harmful environmental influences
dirt, moisture, heat metal, liquid
Data security low high
Bulk reading not possible possible
Read distance low (< 25 cm) high (< 15 m)
Costs low high
Source: IndiaMart, Source: VDA.
© Fraunhofer IFF
Challenges
Avoiding interference
Removal tag to reader
Data security and quantity
Costs
Recycling
Potential
Fast, clear, electronic identification
Bulk reading
Data on the object
Identification technologies as an enabler for Industrie 4.0Functions and added values - Advantages of dynamic Auto-ID solutions using RFID
22%
34%
30%
7%
18%
17%
50%
51%
0% 10% 20% 30% 40% 50% 60%
1
2
3
4
5
6
7
8
Most common reasons for using RFID
Source: Internet der Dinge, Hsg.: Bullinger, ten Hompel
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - passive and active transponders
passive
the signals emitted by the reader are received, modulated and reflected back
power transmission wireless via reader
active
the radio signals are generated in the RFID tag itself
own energy supply
adjustable "flashing rate", i.e. frequency of the radio signal
Locating and combination with sensors possible
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - Advantages of dynamic Auto-ID solutions using RFID
Data can be changed through the use of rewritable transponders
High storage capacity:
passive: approx. 64 KByte
active: several Mbyte
Bulk acquisition - acquisition of all information from the tags located in the read/write field
Reading speed allows reading of data in motion
Reading distances up to several meters
no visual contact necessary for read/write operation
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - RFID - Different principles of action
LF, HF (antenna = coil): load modulation / attenuation modulation
UHF (antenna = DiPole): Transmit - Reflect / Mirror
Characteristic LF HF UHF
Frequencies 125 kHz 13,56 MHz 868-915 MHz
Operating principle
Opportunities
Readable distance
Up to approx. 1m EU: 3-4mUSA: Up to 8m
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - Power supply for transponders
Passive RFID transponders are powered by the radio signals of the interrogator.
Coil - Induction - Charge capacitor – reply
RFID transponder with own power supply (higher ranges, considerably higher costs)
Challenge - battery life
Active RFID-transponders
Own energy source both for the supply of the microchip and for the generation of the modulated return signal
Depending on the permissible transmission power, the range can be kilometers.
Semi-active RFID-transponders or Semi-passive RFID-Transponders
More economical
Without own transmitter (only modulated backscattering)
Range to a maximum of 100 m, depending on power and antenna gain of the transmitter
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - Bluetooth Low Energy compared to RFID
Criteria Bluetooth Low Energy Passiv UHF-RFID
Frequency range ~2,4 Ghz 868 – 915 MHz
Range approx. 10m up to10mNear-field applications can be used in a targeted manner
Power supply about button cellin the future via Energy Harvesting if necessary
Tags passive - power supply via reading field
Maintenance cost High due to required battery change low
Additional features Combination with sensors well possible - continuous measurements possible
Passive tags with sensor functions successively available on the market - Sensor measurement only during the reading process
Costs Beacons/Tags > 5 € depending on field of application from < 0,10 €
Costs reading hardware
Hardware especially in consumer electronics -Industrial electronics so far only rarely with BLE support
Hardware especially in the field of industrial electronics
Standardisation no industry standards / norms so far Extensive standardization (e.g. according to VDA)
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - Advantages and disadvantages of RFID tagging
Advantages
No line-of-sight required to ensure certain stability against contamination, concealment, ...
User memory (data volume high as required)
Pile and load recording (truck) possible
Disadvantages
High investment and operating costs
Interference from the environment possible (metals, shielding, moisture)
Reading range depends on technology (limited frequencies)
Specific technology and qualification requirements
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - Opportunities for electronic identification
Chances
Transparency
(Process) efficiency
Precision
Speed
Unification and standardization
Technological advantages
Initial investments are necessary, but can pay for themselves quickly
…
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - Risks of electronic identification
Product-related ("contamination" of the product or raw material)
Process related (effort, costs, security,...)
Technology-related (performance, compatibility, reliability, ...)
Employee-related (acceptance, manageability, ...)
Specifics of automotive processes
Heterogeneity of actors, products, expectations, ...
Technical Restrictions
investment cost
Missing standards and/or heterogeneous interfaces
unwanted process transparency, which leads to a lack of acceptance
Business models of IT providers (cheap software vs. expensive adaptations, integration, updates)
Attempts by the industry to put the "new" digital technologies on existing processes and not to tackle process changes (that would be necessary). This still results in complex processes that require a great deal of effort when trying to map them into IT-supported processes.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Functions and added values - Application of CPS in production - Vision
Smart containers CPS - Workpiece carrierSmart product
CPS – Machine tool CPS Production islandPlanning and control of production processes -Management Cockpit
Source: Fraunhofer IFF/Daimler
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0System components and process integration - Effect structure of an RFID application
Component Features and Functions
Transponder Stores uniquely identifiable number code
Air interface Magnetic field (inductive coupling) or electromagnetic waves (backscatter coupling)
Detection device (reader or read / write device)
Reading the number code (data acquisition); Describe the transponder; with antenna
Local Interface Between acquisition device and IT system (database)
Software for data processing Decryption of data transmitted by the reader & matching with stored information
transponder
Air interface
Reader
Middleware Application server
antenna
data data
data
Energy
Source: Schumann, Melski, Grundlagen und betriebswirtschaftliche Anwendung von RFID, 2006.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0System components and process integration – Steps among the integration
Mounting
Initialization
Reading
Writing (Optional)
Identify
Data processing
1
2
3
4
5
6
Physically linking the label with the object
Initial assignment of data (object identification data processing system)
Reading the marking data in a defined process step
Updating the identification data in a defined process step
Assignment of data (computer system, transponder)
(Further) -processing and storage of data (DP systems)
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Technology and Standards - Function UHF RFID system
Functions:
Power supply, read/write process
frequency range : 0,3 … 3 GHz
Permitted frequencies (ISM bands):
433,920 MHz,
869 MHz,
915 MHz,
2,45 GHz
Typical reading ranges : 3 … 6 m
IT System
Storage chip
directional characteristic aerial
Transponder not readable
Reader(if necessary with multiplexer)
Reader-
Antenne
Source: FORSCHUNGSBERICHT RFID-MachLog - Methodik für UHF-RFID-Machbarkeitsstudien, TU München, 2011.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Technology and Standards – International Standards
Source: Lehrstuhl für Fördertechnik Materialfluss Logistik, TUM.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Technology and Standards - Technology and standardization of AutoID applications Automotive
The VDA has developed numerous standards for the use of RFID in the automotive industry:
VDA 5500 - Fundamentals of RFID Use in the Automotive Industry
VDA 5501 - RFID in container management in the supply chain
VDA 5509 - AutoID/RFID application and data transfer for tracking parts and components in vehicle development
VDA 5510 - RFID for tracking parts and assemblies
VDA 5520 - RFID in Vehicle Distribution
In addition, some group standards already exist that further underpin the VDA standards (e.g. use of user memory).
The VDA standards recommend the parallel use of RFID with optical coding and plain text information:
Backup-Methode
Avoidance of technology-related media breaks
Support of step-by-step migration from optical codes to RFID
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Technology and Standards - Norms and standards for Auto-ID applications
Data management (format, ...)
Test procedures and methods
Radio regulations
Communication and network standards
Air interface standards
Data protection/security regulations
Recommendations for use / application standards
Industry specifications
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Planning and operating phases - Technical support and early overall conception
Technical testing in productive operation with IT connectivity
Requirements for total integration
Technical Requirements
Phase 3 – RollOut
Ongoing tasks Support SuppliersAccompaniment Rollouts
Phase 1 – Analysis
Process suitabilityEffort/benefitProject plan
2.1a) Practicability 2.1b) Endurance test
2.2) overall concept
more
pieces
© Fraunhofer IFF
Phase 3 – RollOut
Ongoing tasks Support SuppliersAccompaniment Rollouts
Identification technologies as an enabler for Industrie 4.0Planning and operating phases - Technical support and early overall conception
Procurement of test material and equipment
Climate/life cycle and performance tests for selection of suitable RFID transponders
Identification of components + load carriers (RFID, plain writing, 1D/2D code as backup)
Endurance test in productive pilot application
Evaluation of requirements & specifications for RollOut
Definition of the processes and environmental conditions to be supported (endurance test + rollout)
Definition of the main functions for identification, tracking & tracing, status monitoring, communication (endurance test + rollout)
Definition of IT interfaces (central, decentralized data models), transfer format/middleware (endurance test + rollout)
Determination of RFID standard processes (e.g. bulk detection WE, shoring inspection, sequencing)
Determination of internal number ranges (VDA-compliant)
Definition of the processes and environmental conditions to be supported (endurance test + rollout)
Radio technical feasibility study
Preparation test programs
Hardware selection and testing
Test execution
Evaluation + recommendations for action for project planning Endurance test
Phase 1 – Analysis
Process suitabilityEffort/benefitProject plan
2.1a) Practicability 2.1b) Endurance test
2.2) overall concept
more
pieces
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Roles and tasks involved - RFID stakeholder model
Source: Schumann, Melski, Grundlagen und betriebswirtschaftliche Anwendung von RFID, 2006.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Roles and tasks involved - Correlation between time spent and project success
Focus on contentrank correlationcoefficient 𝜹𝒔 confidence level
Positive influence
Creation of solution concepts and concept alternatives 0,312 99,40%
Analysis of requirements, boundary conditions and conditions 0,291 99,00%
Analysis of the (logistics) process and new process conception 0,280 98.70%
Neutral/ influence not statistically detectable
Identification of the field of application for RFID technology 0,170 55,30%
Finding & coordinating the system components / proof of technical feasibility 0,054 66,30%
Implementation of the pilot operation 0,021 56,40%
Implementation of system integration / system rollout -0,034 60,30%
Project management -0,046 63,60%
IT system development -0,121 82,80%
In-house development of RFID-specific know-how -0,145 86,10%
Planning of the system entry / system roll-out -0,225 66,40%
Negative influence
Analysis of economic activity / creation of business case -0,188 92,10%
Training / qualification of employees (system users, administrators, maintenance,...) -0,225 94,90%
Invest more time!
Invest less time!
Source: RFID-Anwenderzentrum München in Best-Practices beim Vorgehen in RFID-Projekten, Studie 2011.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Requirements and checklists – Demands Cause-effect analysis
Demands
Technique
Merging
Processes
Transponder
Aerial
Read-write device
used in used in
Dynamic investigation
Static analysis
Spacer material
Application material
Air interfaces
resulted in
Technical features
are formulated as a query
lead to lead to lead toincluded
demands
uses
allowresults in results in
Logistics process (process module)
Framework conditions Functions
Cargo Environment Resources
Source: Günthner, Fischer, Salfer; RFID in der Logistik – Werkzeuge zur Identifikation und Nutzung von RFID-Potenzialen, 2009.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Requirements and checklists – Definition of requirements for RFID use in general
Determination of product-related criteria (selection)
For which object, product, assembly, individual part should RFID technology be used (brief description)?
How many objects should be marked with RFID?
How high are the unit costs (value) of the objects to be marked?
In addition to the identification data, should further information be stored on the transponder (locations, certificates, etc.)?
What materials does the object to be marked consist of (plastic, wood, paper, metal, liquids, etc.)?
How often is the object to be marked identified?
What environmental conditions are to be expected with regard to material, temperature, humidity and dirt?
Should the transponder be visible to everyone?
Does the transponder have to be removed from the object at the end of the process?
Is there a required protection class or to what mechanical loads are the objects exposed?
How should a transponder be attached to the objects? (e.g. gluing, screws, ...)
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Requirements and checklists – Distinguishing criteria of the technical solution
Demands
RFIDType
Energy supply
Programmability
Frequency
(-range)
Range / Reading speed
Operating mode
Standardization
Amount of data
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Requirements and checklists – Design context of the technical solution
Type Energy supply Frequency range
Memory structure
read-write capability
Size Lifetime
Expenses
Range
Coupling typeMaterial
penetration
Source: Schumann, Melski; Grundlagen und betriebswirtschaftliche Anwendung von RFID, 2006.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Requirements and checklists – Definition of functions and requirements
Implementation of lean approaches
Identification of critical points
Flexibility & Speed
growth scenarios
Process design Spatial planning transparency
Optimization of material and information flows
standardization
Differentiation according to order volume
Defined organization but flexibility for complex special production
Mapping of insourcing/outsourcing
Reduction of paperwork
transparency
extension concept
land yield improvement
Consideration:
Related units
Legal requirements
environmental influences
Public image (access)
visitor concept
energy concept
Creation of ideal layouts
Separated for special products & standard products
Insourcing (use of EBIT advantages)
Cooperation in development projects
Preparation of CIP (yield per unit area, paths, reactive power))
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Requirements and checklists – Analysis of reference objects
Approach and objectives
Creation of an overview of the processes to be
considered
Recording of the technologies used
Checking which data and information is available
Definition of the focal points for the technical
conception
Assessment of the cost-benefit ratio to the pilotisation
proposal
Outcome
Project charter, clear and coordinated project
orientationProcess A Process B Process C
Objective
Clear standards Low stocks
High level of service
short cycle time
Cashflow
High productivity
Competitive advantages
Customer satisfaction Process
transparency
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Different viewing areas of the RFID systems
Internal application
Decisions are made within the company
Benefits arise in the company
Expenses and costs arise in the own company
Inter-company processes
Several companies are affected by the project
Added value must/should be created for all parties involved
or
a company has "power to assert itself" against others (cf. also internal company project, Improvement of own processes)
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Different viewing areas of the RFID systems
Internal application and use in inter-company processes
When used to improve internal processes, the company is self-sufficient in terms of implementation (objectives, type, scope, choice of technology, etc.) and the potential for improvement/savings (e.g. human capital) is recognizable and usable in its own company. Integration into existing IT systems is also usually possible with adequate effort.
The use in cross-company processes can only succeed with the close involvement and cooperation of the actors along the value chain. Benefits for the overall process and for the individual must be worked out jointly.
Improved utilization (capacity bundling of technology and infrastructure)
Increased productivity in the value chain and lower costs through more efficient processes, e.g. in order processing
Multiplier effect (simplified and unified information chains)
Cost reductions and/or cost reductions for customers
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Application fields in the automotive industry
Lo
gis
tics
Ap
pli
cati
on
sP
roce
sses
Product design and development
ProductionSales and
aftermarketRecycling
Tracing design data
Documentation
Traceability and control
Monitoring and adjustment
Maintenance and repair
Product progress
Vehicle identification
Kanban control loop
Spare parts and service
Distribution
Guarantee and warranty
Exchange and redemption
Material identification
Life Cycle Management
Information on disposal
Sequencing
Container management
Incoming and Outgoing goods
Sequencing
Supply Chain Security
Container management
Vehicle distribution
Customs clearance
Logistics for disposal
Third-Party-Logistics
Source: Schumann, Melski, Grundlagen und betriebswirtschaftliche Anwendung von RFID, 2006.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Identification and picking of material - collection and removal
RFID-Smartbox
RFID-strap
Control of material supply
RFID-TunnelgatesObject and
process history
Automatic acknowledgment of withdrawal processes
Control of picking processes
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Applications / Reference Examples Automotive.
container tracking
component tracking
toll application
Areas of application for RFID solutions in the automotive industry include:
Track + trace of components (e.g., condition documentation)
Track + trace of vehicles
Track + trace of returnable transport items
RFID-based production / assembly control
Most of the applications are so far "only" closed-loop-applications
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Application - Applications/reference examples Automotive
Tracking + Tracing of RTIs is an important field of application in the field of logistics:
Testing of the usability of RFID tagged load carriers by OEMs (technical feasibility)
Standardization of data identifiers for RTIs (ISO standardization)
Development of new generations of KLTs with integrated RFID accompanied by VDA
Over 100 million KLTs in circulation
New small load carriers generation as of 2017
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Avoid media disruption
Supplier Automotive manufacturer Customer
Design and describe components with RFID tags
Packing and shipping Transport
Incoming goods Batch-based storage
Installation of vehicle with components
Check production condition
Delivery to the customer
Mastering the complexity of changing components
Early consideration of RFID in the design phase
Parallel testing of the detection capability of RFID tags in test mode
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Consider sources of interference
When integrating suppliers into the RFID application, various possible sources of interference are typical:
Selection and position of transponders Support elementary
Information on procurement, sources of supply and integration of RFID in the company Support possible
Internal coordination and control effort for the introduction of RFID at the supplier Limited support possible
Data structures and IT connection Use of established norms and standards elementary / Support for IT connection important
Suppliers should be involved in test applications as early as possible in order to identify and leverage potential benefits for the supplier!
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Dependence on material classification
Supplier Automotive manufacturer Customer
Design and describe components with RFID
tags
Packing and shipping Transport
Incoming goods Batch-based storage
Installation of vehicle with components
Check production condition
Delivery to the customer
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Production planning
Sales order processing
Technical order processing
Dispositive logistics control loop
Procurement loop
Internal operational logistics loop
Guidance and control systems
Material flow accompanying information
Distribution
© Fraunhofer IFF
Transponder type Surface material Note
Smart label (paper) plastic, fabrics, glass (uncoated) direct sticking of labels. not suitable for metal etc.
Flag tag (paper) plastic, fabrics, glass, carbon, metal smart-label. Distance to the surface material is created by bending. also suitable for metal or similar.
Hard tag (plastic) plastic, glass (coated), carbon, metal the distance to the surface is ensured by the construction design
Embedded transponder plastic, fabrics, glass transponder is integrated into the rfid object
Embedded RFID with slot antenna metal transponder is integrated into the object. object surface material serves as antenna
Identification technologies as an enabler for Industrie 4.0RFID System Design - Selection of components and RFID transponders
© Fraunhofer IFF
Mounting method Advantage Disadvantage
Gluing Quick and inexpensive installation
Adhesive bond must meet component requirements (temperature, weather, service life, etc.)
Hanging More flexible use. Multiple use possible
Can only be used for temporary assignment of transponders to objects
Riveting Particularly suitable for sheet metal, light metals
Special material required; probability of corrosion
Screwing Permanent connection. Use of standard tools
Drilling required; probability of corrosion
Magnetic fixation More flexible use. Multiple use possible
Magnetic surface required. Can only be used for temporary assignment of transponders to objects
Identification technologies as an enabler for Industrie 4.0RFID System Design - Selection of components and RFID transponders
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - IT infrastructure of an RFID system
BPM – Business process management
Transponder, reader/writer, printer, sensors
RFID software
EAI – Enterprise Application Integration
ERP
Enterprise Resource Planing
MES
Manufacturing Execution System
SCM
Supply Chain Management
Prepared data
Raw data
Control data
Configuration data
Process
Backend
Middleware
Edgeware
Hardware
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Main topics - decision tree
RFID in the company
Field of application
Functional concept
Instrumental solution design
Pilot system
Productivesystem
Strategic RFID Process Decisions
Make or Buy
(Information) technical decisions
Must-Haves & Nice2Haves
Process Redesign vs. Optimization
Transfer?
Decision about field of application
Supplier selection for hardware
Overall concept
Customization?
Roll-out scope
Extension?
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Main topics - decision tree
Project initiation RFID strategyRepresentative
field of applicationMake or Buy RFID macro
processProject release
Project planning ResponsibilitiesTeam & Partner
Must-Haves & Nice2Haves
Time, Budget & Project Plan
Analysis & Diagnosis
Type & scope ofanalyses
Feasibility & cost check
Conception RFID micro-processRFID Technology &
Data Model Security concept
Overall concept
Solution design & feasibility
RFID Hardware & Software
Technology partner
Piloting & endurance test Test application Scope
Testing forintroduction
Rollout Responsibility in series operation
Utilisation depth
Utilisation Check for transfer
Bu
dg
et
Co
ntr
ollin
g
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design – Project organization
Top-level management
Coordinator / Project Manager
Change Manager
Team „Acceptance ofchange“
Communication
Traning / Organization
RFID Manager
Team „RFID-Hardware & Environment“
Technology provider / Experts
RFID engineers
Process Manager
Team “Process”
Logistics
SC-Operations
Application Manager
Team “IT Interface”
EPC/PML Manager
Information technologies
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Involved units in the RFID process
Overall coordination and standardization
RFID-Management
RFID Technology / Engineering
Communication
Training Organization
Planning
Logistics planning
Maintenance planning
Information
Technologies (IT)
Factory control
Operation
Factory planning
Technical Service (TS)
IT Operations
Factory control
(embedded in coreprocess)
© Fraunhofer IFF
Specific detailed knowledge of physics, technology, IT, processes, standards and
security
Knowledge and abilities for operation & application up to
instruction level
RFID basic knowledge of technology
Source: [https://www.eecc.info/schulungen.html#]
Identification technologies as an enabler for Industrie 4.0RFID System Design – Qualification requirements
© Fraunhofer IFF
External influences (e.g., new corporate strategy)
Identification technologies as an enabler for Industrie 4.0RFID System Design – Avoiding errors
© Fraunhofer IFF
Hard coded
Read Only transponder
Programmable
Write Once Read Many Transponder
Read/Write Transponder
Identification technologies as an enabler for Industrie 4.0RFID System Design - Transponder types per after programmability criteria
Electronic data carrier
Hard coded
by supplier
passive
by user
Programmable
Partly programmable
active passive
semi-active
Full programmable
[
Source: Lolling, 2300
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design – Environment interactions
Electromagnetic interaction between antenna and environment
The antenna must be dimensioned so that it functions optimally in the environment (encapsulation + object material)
No capsulation Capsulation Capsulation and applied
1) 2) 3)
Object
Source: ://www.identpro.de/fileadmin/pdf/Deutsch/1103_IdentPro_RTP_table_D.pdf.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design – Things to know about weakness points
Influencing the functional characteristics by environmental conditions
Shielding e.g. through water, metalConsequences: lower read ranges or read failures
Functionality must be maintained
Even passive transponders have a kind of "internal battery",e.g. Capacitors must be addressed (charged) at intervals
High density of transponders
Possibly. Interference and read errors (for example, "master days")
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - Memory of RFID transponders
Memory
64 Bit
512 Bit
32 kByte
…
Source: Schumann, Melski, Grundlagen und betriebswirtschaftliche Anwendung von RFID, 2006.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - RFID Hardware Overview
When selecting RFID readers, be aware of:
Application environment / installation options for the detection point (reader / antenna / cable / shielding, if necessary)
Number of transponders to be recorded (single - burst)
Near field or far field application (RF output power - note max EIRP 2 Watts)
Number of antenna ports, if applicable, remote antenna multiplexer / integrated antenna
IT integration - control of the reader (for example via LLRP, PLC)
Availability of power supply
Dimensions / size / robust housing / handling
Long-term availability of the hardware:
Impinj, Kathrein, SICK, Intermec, Deister, Siemens, etc.
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - RFID Hardware Overview
When selecting the antennas you should be aware of :
Frequency range: UHF (ETSI, FCC)
Circular or linear
Dipole or patch emission characteristic
Opening angle - antenna gain - dimensions
Near field - far field application (RF output power - note max EIRP 2 watts)
Robust housing / Handling / Mounting options / Ordinary brackets
Long-term availability:
MTI, metratec, Impinj, Kathrein, flexiray,Time-7, SICK, Intermec, Huber + Suhner
Selection of suitable antenna cables (consideration of cable loss, bending radius, resistance)
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - RFID Hardware Overview
For mobile readers there should be a focus on the questions of good connectivity and if necessary compatibility with other processes and Auto-ID structures
Frequency range: UHF (ETSI, FCC)
Type of antenna - circular or linear
Combination of devices with other Auto-ID technologies (e.g., 2D barcode imager + 2D codes; GPS)
Usable output power (achievable read range / readability)
Connectivity (WLAN, Bluetooth, GPRS etc.)
Robust housing / handling
Long-term availability:
NordicID, Motorola, Workabout, ...
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID System Design - RFID Hardware Overview
For the selection of the suitable transponder on should keep in mind the following points:
Application environment - OnMetal - NonMetal - Liquids - physical loads (impact load, temperature load, ...)
Label / FlagTag / HardTag / OnMetalTag / ...
Reading distance (near field - far field)
Possibility of attachment
glue / screw / rivet / ...
Optimized frequency range - local (ETSI / FCC) or worldwide?
Requirements for storage capacity EPC memory bank, user memory, etc.
Chipmaker Impinj, NXP, Alien, ...
Transponder manufacturer Smartrac, Alien, Confidex, ...
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Integration of digitization into the classic PDCA improvement work
Possibilities of digitization ...
Mobile information availability without waiting and search times
Reduced information complexity / decision support
Capture and use of product and process data
Lean ideal
0 errors
100% added value
Single piece flow (in sequence on customer demand)
Appreciation for employees
support …
Ist-Zustand
Projekt
project
project
Classic lean, for example:
Autonomous maintenance
Shopfloor Management
Poka Yoke
Lean 4.0, for example:
Predication residual life
Digital shop floor management
Order-specific standard work documents
P D
CA
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Basics of digitization value stream analysis - concept of the method
Further development of the method
Proven and known approach
Allows neutral discussion on current production processes
Create understanding of the system
Structure of the used IT systems & storage media
Transparency about collected data streams
Revealing digital waste
Starting point for further improvement measures
Digital value stream design
Digital Kaizen
Digital opportunities (also business model)
Concept of the method
Benefits of digitization value stream analysis
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Basics of digitization value stream analysis - basic rules for creation
Classical value stream analysis
Detailed analysis of process information & information flows
Analysis of data usage
Collection of information logistics waste
Derivation and Prioritization of Kaizen Activities
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Draw in swimlanes of storage media
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Basics of digitization value stream analysis - The 8 steps of classical value stream analysis
Determine customer
requirements
Draw process steps
Collect process data
Improve stocks
External material and information
flow
Internal material and information
flow
Cycle times and cycles
Kaizen flashes
Fact-based overview of the status quo of production
Showing waste
Mark he biggest problems
Starting point for further improvement measures
Value stream design
Kaizen
Benefits of Value Stream Analysis & Typical Findings
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Basics of digitization value stream analysis - Draw in swimlanes of storage media
1. Survey of all project participants for known and used storage media
ERP
MES
MS EXCEL
Paper (documentation / orders)
Kanban
Employee (remembering information)
Etc.
2. Tracing the storage media on the left side of the template
3. Drawing the use of the data
ActionGrinding
1
Shifts: 3
Interval
Recording type
Actual Value
Sto
rag
e m
ed
ium
Use
Employee
paper
Cards-Kanban
ERP
Excel
Process control
Shopfloormgmt.
…
…
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Basics of digitization value stream analysis - Detailed analysis of process information & information flows
ActionGrinding
1
Shifts: 3
Interval s h h d d
Recording type m t a m m
Actual Value
15
min
54
s
80
%
27
min
47
5 S
tk.
Se
tup
tim
e
Cycle
tim
e
Ava
ilib
ility
Dow
ntim
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Go
od
Qu
alit
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… …
Sto
rag
e m
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Use
Employee
paper
Cards-Kanban
ERP
Excel
Process control
Shopfloormgmt.
…
…
4. Determine which information is captured in the process
5. Connecting the key figures with the respective storage medium (possibly supplementing Swimlanes). Identify connection through a node
6. Uncertained key figures are identified by empty fields
7. Detailed description of the individual key figures by:
Sampling interval
Capture type
Measurement value
Delivery frequency
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Basics of digitization value stream analysis - Collection of information logistics waste
Action
Sto
rag
e m
ed
ium
Use
Employee
paper
Cards-Kanban
ERP
Excel
Process control
Shopfloormgmt.
…
…
8. Connect the captured KPIs with dashed lines to the usage systems (if the KPIs are used there)
Grinding
1
Shifts: 3
Interval s h h d d
Recording type m t a m m
Actual Value
15
min
54
s
80
%
27
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47
5 S
tk.
Se
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tim
e
Cycle
tim
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Ava
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ility
Dow
ntim
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Go
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Qu
alit
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… …
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Value stream design – typical questions
Can media breaks be reduced?How can complete and
consistent information be guaranteed?
Can imminent events (production stop) be
recognized at an early stage?
Can the cost of information provisioning, processing and
storage be reduced?
Can the information also be made decentralized?
How can the future increase in the volume of information be
handled?
Is the full potential of the IT systems already being used?
How can the transparency regarding important
information be increased?
How / where can paper-based processes be digitized?
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Digital nameplate »Memory-Motor«
Provide fast and comprehensive information about one object and it’s history data on-site
Clear and unique identification of a motor ( replacement part IDs, piracy protection)
Complete and up-to-date configuration data
Production data
Quality assurance record
History data, including all maintenance activities
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Intelligent rack
Passive HF / UHF RFID system
Automated monitoring of material input and output without the need of manual booking activities
Enables to perform digital inventory tracking
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID sorter conveyor belt
Passive RFID based system
Products find identify the correct exit by themselfes
Desired target:
self-organization of complex logistics tasks with decentral information storage and processing
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Fraunhofer IFF-Smart-Box
Protection from unauthorized access
Access control via RFID
Registration of transfer of risk
Constant inventory tracking performed by integrated RFID reader
GSM / GPS based monitoring module for localization and datatransmission
Local display
Self-sufficient energy supply
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Filling level of logistics areas
Usage of depth imaging sensors for movement tracking
Filling level tracking of buffer areas
Forklift information system
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Filling level of logistics areas (VIDEO)
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Holistic RFID usage in industrial laundry facilities
Passive UHF-RFID system for application in flat laundry related processes
Automated inventory management and dispatching
Laundry facilitycustomer
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Sensor equipped tool drawer
Easy to use solution for performing completeness checks of the tool set
Optical comparison of target tool allocation and current tool allocation
Line sensor is attached to the drawer and activated automatically bay closing or opening the drawer
Possibility of retrofitting the to existing solutions is given
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0RFID checking process via »ELISA« tool
Identification of inspection obligated inventory, load handling attachment, ladders, racks, hydraulic pumps
Automated supply and paperless documentation of the necessary inspection data
Daily updated information on current status of the inspections
Halves the effort and costs for recurring inspection tasks
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0Conclusions and Outlook Complexity for the implementation of RFID systems
RFID
Electromagnetic Field disturbances
Comprehensive technologies
Costs for transponders
Different use cases
Missing Standards
Integration of Suppliers
Security
© Fraunhofer IFF
Identification technologies as an enabler for Industrie 4.0General recommendations for implementation of Industrie 4.0 measures
Don’t follow the classic calculus for return on investments – Industrie 4.0 affects the entire company
Implement a sustainable transformation and change management – Involve all employees
Constantly question you own business model by e.g. using the business model canvas or the 55 pattern
Build up you own IT competence for programming customized applications
Follow the rules of user interface design to provide good service to your employees
© Fraunhofer IFF
The Fraunhofer Institute for Factory Operation and Automation IFF Let us research your application together!
Fraunhofer Institute for Factory Operation and Automation IFF
Sandtorstraße 2239106 Magdeburg
www.iff.fraunhofer.de
© Fraunhofer IFF
Sebastian HäbererM.Sc.
Business UnitLogistics and Factory Systems
Telephone +49 391 [email protected]
© Fraunhofer IFF