© 2015 IBM Corporation 1
© 2015 IBM Corporation 1
Industrie 4.0
Von der Vision zur Realisierung
GSE Jahrestagung Hamburg 12 Mai 2015
Updated Version 7-May-2015
© 2015 IBM Corporation 2
The 2013 Vision Industrie 4.0
Industrie 4.0 is a customer led growth initiative
Convergence of
– Internet of People ,Internet of Things, Internet of Services
Available technology for vertical and horizontal communication
and cooperation in realtime between all participants.
ROI Expectations
– plus F2 Productivity
– minus F2 Resources.
Innovation
– Intelligent machines enable individualized products
– Value chains around individualized products = Lot size
1 for the price of a mass produced item
Real–time communication & collaboration between all
participants
– enables new value chains and
– new integrator less business models
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© 2015 IBM Corporation 3
© 2015 IBM Corporation 3
Industrie 4.0 Driver: Exponential Growth Of IT Capabilities (F2 in 18 m)
1961: Apollo Control System (*)
– 4100 Integrated Circuits
– 1 K Byte Cache
– 12 K Byte ROM
– 1 Mhz clock
Connected to Houston Control
2014: Mid Class Car (**)
– 25plus embedded IT-Systems connected via bus
– 20 x Power of PC (quote: Winterkorn, CEO VW, Cebit 2014)
– Generates more than 3.6 GB system data per hour 1 MB/s
– 100 Mio ICs, 1MB cache , > 1 GHz clock – for each CPU!
Connected to the Internet, other cars & road side services
Price 400 K USD IT-HW Price 35K Euro incl Car + Car2Everything Communication
Source: AUTOSAR
(*) Source: Wikipedia (**) Source: AUTOSAR
© 2015 IBM Corporation 4
© 2015 IBM Corporation 4
20th century: the mass era
21st century: era of the “new individual”(*)
(*) “… a new awareness that I call psychological self-determination…”
Shoshana Zuboff, Charles Edward Wilson Professor of Business Administration, Harvard Business School
Industrie 4.0 Motivation: Customers Expect Uniqueness
© 2015 IBM Corporation 5
© 2015 IBM Corporation 5
Industrie 4.0 ROI: Modernize existing machinery in a sheet metal plant
Project Goals - Vertical integration of plant automation and
sensors with IT/ ERP System (in team with SAP)
- Horizontal IT based íntegration of existing machinery (in team with Siemens)
- Productivity increase plus F 1.x
- Resource input decrease minus F 1.x
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© 2015 IBM Corporation 6 6
Serielle
Schnittstelle
Dateien (FTP, SFTP,
Verzeichnis) TCP/IP
PLS Ver-
packungs-
line
Waage
Disomat
Mess-
geräte
Durchlauf
-beize
Schub-
beize
Koppel-PC
Labor Glühe
Stored Procedures
DB Verbindung
PC für Waage
S7-Adapter
MQ
optional: Weiterleitung
für Benachrichtigung /
Weiterverarbeitung
Stored
Procedures
JDBC/ODBC
Daten-bank
Server
RFC (BAPI,
ALE)
ERP Server
ESB: Sichere und stabile Interoperabilität 0100101 0010101 0101001
01010101 01010101 111010101
0101010 1010101 1010101
0010100 1000010 1101010
0101010 1010101 1010100
0001101 1110101 0100010
10101010 1010101 1010101
Modernisation of sheet metal plant - IBM SOA ESB as backbone
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+ Analytics +
Optimization
© 2015 IBM Corporation 7 7
Industrie 4.0 Innovation: New Flexible Value Chains enabling “lot size 1”
The consumer interacts directly with shop floor – bypassing retail
– Enabler: Any lot size possible / unique personalized products
– Chances:
• Customer demand can be more precisely fulfilled. Cost saving & better ROI
• Additional differentiators, new offerings and enhanced extended customer relationship
– Examples: Fashion, Toys, e-engines, Furniture, Cars.
Friedrich Vollmar
Design
Production
Retail
Consumer
Design
Production Communication
Customer
Pay direct
© 2015 IBM Corporation 8
1. Engineering & Software development Leading Edge Automotive System and Software Development for Robert Bosch GmbH
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Continuous Engineering
Develop smarter products
MarketAnalytics
SystemVerification
SystemTest
SystemRequirements
SystemDesign
Deploymentto Mfg.
CustomerRequirements
Operations and Maintenance
Implementation
Agile SoftwareEngineering
ElectricalDesign
MechanicalDesign
Process & Data Mgmt.
IBM Continuous Engineering Solutionfor Systems and Software Engineering
Open Lifecycle Integration
Quality Requirements
Architecture, Design and Development
Systems and SoftwareEngineering
Change/ Configuration Management
Best Practices and Services
Bosch example:
Car Instrument Cluster Demo
Increase re-use of software
Automate dashboards
Get real-time project status information
Full data traceability and query capabilities
Continuously plan, design,
implement and build the product
software in an iterative, taylored and
ASPICE compliant process
Connect and manage all data across
the development lifecycle
+
IBM Rational
Collaborative
Lifecycle Management
© 2015 IBM Corporation 9
2. Production & Integration Shopfloor Integration based on Industrie 4.0 principles and standard SOA software 2015
HMI / Worker assistance (assembly instructions,
„pick-by-light“, digital reflection)
Plug&Play, flexible uniform shopfloor
(re-)-configuration
Illustration of material
handling and withdrawal,
pull rope, screwdriver
Real-time data capture and machine parameter control
+
9
IBM BPM with real-
time machine SCADA
visualization
IBM Integr. Bus
Manufact. Pack + S7
Adapter, MQTT &
WSRR
© 2015 IBM Corporation 10
Straigth from Software to Product New value chains around 3 D printing
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Erstes Triebwerk aus 3D-Drucker •
• AERO Telegraph Donnerstag, 26. Februar 2015 - 17:22 Laura
Frommberg
http://www.aerotelegraph.com/erstes-triebwerk-3d-druck-universitaet-
australien
Ein Jahr lang haben die Forscher der australischen Monash University
gemeinsam mit der Deakin University und der Commonwealth Scientific
and Industrial Research Organisation am Projekt gearbeitet. Jetzt
präsentieren sie das Ergebnis - und beeindrucken eine ganze Branche.
Sie haben das erste Triebwerk entwickelt, dass komplett aus einem 3D-
Drucker stammt - und das zweite gleich auch noch.
Angefangen hat alles, als der Triebwerkhersteller Safran
Ihnen zwei ältere Flugmotoren zur Verfügung stellte.
Mit ihnen kann man etwa einen Falcon-20-Jet antreiben.
Diese haben die Forscher nun nachgedruckt.
Mit dem Ergebnis sind sie mehr als zufrieden. Offenbar nicht nur sie:
Auch Airbus und Boeing zeigen bereits Interesse an der Technologie.
Tests in den kommenden Jahren
Forschern gelingt weltweit erster 3D-Druck eines
vollfunktionsfähigen Flugzeugtriebwerks
Von: Michael Kammler in Technik 26. Februar 2015 um
12:07 0
DMG MORI hat eine neue Maschine entwickelt, die
unter anderem auch in der Werkstatt von Iron Man ein
Plätzchen finden dürfte. Zudem ist es Forschern unter
der Leitung von Prof. Xinhua Wu gelungen, weltweit das
erste Flugzeugtriebwerk mit einem 3D-Drucker zu
drucken.
© 2015 IBM Corporation 11
© 2015 IBM Corporation 11
What is missing? The IoT assessment of Gartner (*)
Gartner Hype Cycle for Internet of Things July 2014
Concerns / Issues
– Who owns the data ?
– Customer relationship
• With whom does the customer actually
want the relationship?
– Standards. Missing or too many diverse
or even conflicting
– IoT security lags behind IoT technology
• Things interfere with public safety
– Integrate Legacy Artifacts
– Get IT and OT to cooperate
(OT = operation technology)
We are here
(*) Source: Gartner, July 2014
© 2015 IBM Corporation 12
© 2015 IBM Corporation 12
The 5 Dimensions of Industrie 4.0
Industrie 4.0 demands cross-branches, cross-company, public-private teamwork
Moving forward in all 5 dimensions will make Industrie 4.0 become reality
User Acceptance Usability
ROI
Demand
Legacy Integration Different lifecycles
of IT and Things
Standardization of communication and cooperation -
Protocols, ConnectionPlatform,
Semantics
Legal Framework Security + Safety
Secure, trusted solid Infrastructur
Ownership of data + liabilities
Governance + legal approvement
IT / IoT Technology
Enables new opportunities for innovation
and industrial capabilities
© 2015 IBM Corporation 13
Public Private Partnership to Enable Industrie 4.0 secure integrator-less value chains
Politics starting to take action
– Digitale Agenda in Germany
– Digital Europe
Modify Legal Framework to enable usage of New Technologies
– Example autonomous driving. Technology is nearly there, the legal framework is missing
Legal Framework for digital business and new value chains.
– M2M Machines act in business context - / ordering, contracting /
Shared Infrastructure (digital marketplace / shared dataspace ) incl. legal framework
– Infrastructure to enable secure integrator - less value chains
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© 2015 IBM Corporation 14
The central service platform of Industrie 4.0
Connects all participants
Assures trusted identity and
secure communication
Filter fraud and verifies
transactions. Acts as digital
market place.
Must be democratic –
monopole will not be broadly
accepted
E.g. SWIFT / Cooporative /
Open Standards
© 2015 IBM Corporation 15
Plattform Industrie 4.0 Defined Reference Architecture Industrie 4.0
New Challenges
All Layers connected with / connected World/
Products stay connected after leaving plant
Facts
Industrie 4.0 needs real-time processes
Industrie 4.0 needs 100% security
Strong growth of computing power & communication
– In production & engineering
– Products
– Aftersales
– New business models with connected
products
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© 2015 IBM Corporation 16 16
Plattform Industrie 4.0 Defined Reference Architecture: Industrie 4.0 Component
Internal
Control(s) S 1 A x
Internal
communication
Application A Industrie 4.0
Component Internet
Control
subsystem(s)
SOA Administration shell Defines services provided and requested by this component
ESB as Service
Repository
• Protected kernel
• Service offerings at interface,
based on Standards
• Life cycle independence
= prepared for future
integration of
legacy systems
Industrie 4.0 Component =
Any kind of intelligent /Thing/
© 2015 IBM Corporation 18
IBM Confidential | Do Not Distribute © 2014 IBM Corporation 18
Minister Siegnar Gabriel , Germany on Hannover Fair April 2015
Forcast Industrie 4.0 in Germany
• Invest Industry in Industrie 4.0 2016-2020 30 B Euro p.a
• Based on 1.6 T Euro BIP Germany from industrial sector
– + 3.5 % Growth = 48 B Euro p.a
– - 3.5 % Cost = 48 B Euro p.a
– EU estimated 4-5 Times German invest and ROI
EU view
– Growth + Re-Industrialization with Industrie 4.0
– Lot size enables EU to compete in markets with higher scale of economics (China, NA ) on level playing field
– Industrie 4.0 will come anyway. Be early, be first ==> Same invest , better ROI
– Unified legal framework for Digital Europe as base for Industrie 4.0.
Germany is anchor point for 44 % of all industrial value chains.
Market Industrie 4.0
© 2015 IBM Corporation 19
© 2015 IBM Corporation 19
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IT Technology : Two alternative Architectures for Industrie 4.0 + technology of both alternatives available from IBM and demonstrated on HMI + different business value chains . Any interconnected hybrid possible
IOT Cloud Commercial Apps
Shared data Technical Apps
Analytics
s A M C
Value
S M C
SOA
ESB
SOA SOA
Integration Peer to peer
Value
Integration thru Cloud Service
Friedrich Vollmar
Commercial Apps Shared Data
Analytics
© 2015 IBM Corporation 20
Plattform Industrie 4.0 defined Reference Architecture Industrie 4.0 . Who will manage the Overall Corporate - IT and - Network ??
New Challenges
All Layers connected with / connected World/
Products stay connected after leaving plant
Facts
Computepower Car = 20 X Thinkpad
Computepower Plant = xx classic IT
Industrie 4.0 needs 100% security
Strong growth of computepower + communication
– In Production + Engineering
– Products
– Aftersales
– New business models with connected
products
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Interconnected Product
Basis for new value chains
Engineering + Plant
From island
to
Interconnected
© 2015 IBM Corporation 21 21
Software will connect everything Software will bring different industries into functional overlaps and competition
Friedrich Vollmar
Software
Entertainment-
electronic
Automotive
Retail
Telecommunication
Machine Builder
Chemie/ Pharma
Financial-
Services
Electronic
IT - Industry
IT-Services
Agriculture
Chance
Alliances
Risk
© 2015 IBM Corporation 22 22
/ Software ist .... das neue Rad der Industrie/
Dr. Elmar Degenhart CEO Continental ( FAZ 06-03-15)
/ Nowadays, a small team of talented programmer
can change the world /
Marissa Mayer CEO Yahoo 2013
( as response to the question how to revitalize Yahoo )
/ Make sure it is Your team ……….. /
Fritz Vollmar IBM HMI 2015
Friedrich Vollmar
© 2015 IBM Corporation 23
© 2015 IBM Corporation 23
. Industrie 4.0 Represents Massive Opportunities Let’s get it done together !!! Packen wir es an !!!
Thank you for your attention
Legal Framework
Security + Safety Right of Ownweship + Liabilities
Governance + certification + approval
Reliable, secure network
IT Technology
Enables innovations and
new value chains
User Acceptance
Value
ROI
Legacy Connection
Standards For communication, cooperation,
services
© 2015 IBM Corporation 24
– Growth + Re-Industrialization based on Industrie 4.0
– Lot size 1
• Fits to the diverse local markets in EU and individualized demands of EU customer
• Enables EU to compete in markets with higher scale of economics (China, NA ) on level playing field
• First industries in successfull implementation process ( f.e Automotive)
– Industrie 4.0 will come anyway. Be early, be first ==> Same invest , better ROI
– Proven legal framework to be extended to digital world ( Digital Europe, Digital Marketplace ...etc )
– Expected WW growing demand for individualized products can position Europe in a leadership position
==> Industrie 4.0 has the potential
- to leave Europe lagging behind
+ to transform Europe into a leading economy + society of the 21 century.
Chances & opportunities for Europe in Industrie 4.0
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