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 [email protected] 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
Mac
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to m
achi
ne
Pred
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e m
anuf
actu
ring
syst
em
SCA
DA Big data
Popular keywords
IoT
M2M Cyber Physical Systems
PLC
Picture source: http://www.uberb2b.com
"loo
m"
"con
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t"
"PLC
aut
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ion"
"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