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Industry 4.0
The future of making things
Rik Vanhevel
23/11/2016
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23.11.16 2
The Airbus Future Factory
Building intelligent production systems
Designing the human centered workplace
Distributed manufacturing & the connected factory
How SIRRIS can help
© sirris | www.sirris.be | [email protected] |
Industry 4.0 The future of making things
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The Airbus Future Factory
4© sirris 2016 | www.sirris.be | [email protected] |
500 km wiring
60.000 brackets
120.000.000 holes
400.000 bolts
1000+ tightening tools
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The Airbus Future FactoryThe Airbus Shopfloor Challenge
5© sirris 2016 | www.sirris.be | [email protected] |
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6© sirris 2016 | www.sirris.be | [email protected] |
The Airbus Future FactoryCyber Physical Systems
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23.11.16 7
The Airbus Future Factory
Building intelligent production systems
Designing the human centered workplace
Distributed manufacturing & the connected factory
How SIRRIS can help
© sirris | www.sirris.be | [email protected] |
Industry 4.0 The future of making things
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23.11.16 8
4 themes
Connected, intelligent devices
Real and virtual world convergence
Horizontal integration
Vertical integration
© sirris | www.sirris.be | [email protected] |
Building intelligent production systemsCyber Physical systems (CPS)
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Cyber Physical SystemsConnected, intelligent devices
23.11.16 9© sirris | www.sirris.be | [email protected] |
Source : Kurzweil
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Cyber Physical SystemsConnected, intelligent devices
23.11.16 10© sirris | www.sirris.be | [email protected] |
Source : Kurzweil
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Cyber Physical SystemsConnected, intelligent devices
23.11.16 11© sirris | www.sirris.be | [email protected] |
Source : Kurzweil
Source : Yuri van Geest
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Cyber Physical SystemsConnected, intelligent devices
23.11.16 12
Have sensors and actuators (“physical”)
Perceive and interact with its environment
Linked with the internet (“cyber”)
Active Digital Product Memory
© sirris | www.sirris.be | [email protected] |
Source : SEW
Source : Fraunhofer IML
Source : Fraunhofer IML
Source : Fraunhofer IML
Source : Amazon Kiva
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Cyber Physical SystemsHorizontal integration
23.11.16 13
Plug and Produce
Modular, reconfigurable
Autonomous agents
Connecting products, machines, devices, people across the supply/value chain
© sirris | www.sirris.be | [email protected] |
Source : Fitman
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23.11.16 14© sirris | www.sirris.be | [email protected] |
Cyber Physical SystemsHorizontal integration
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Cyber Physical SystemVertical integration
23.11.16 15
Decentral control
Networked services
Service Oriented Control Architecture, event driven
Bringing ERP/PLM/MES down to the shopfloor
© sirris | www.sirris.be | [email protected] |
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Cyber Physical SystemsReal and virtual world converging
23.11.16 16© sirris | www.sirris.be | [email protected] |
Source : it’s OWL
Source : MiR
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23.11.16 17
“Digital twin” of the real world
Enabling end-to-end engineering of product and process
© sirris | www.sirris.be | [email protected] |
Cyber Physical SystemsReal and virtual world converging
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Building intelligent production systemsWhy we need Industry 4.0
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© sirris 2007 | www.sirris.be | [email protected] | 19
Building intelligent production systemsWhy we need Industry 4.0
Source : Koren
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Source : Koren
© sirris 2007 | www.sirris.be | [email protected] | 20
Building intelligent production systemsWhy we need Industry 4.0
Source :Adidas
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21© sirris 2016 | www.sirris.be | [email protected] |
Source : EC Workshop on “Innovation in Digital Manufacturing”
Building intelligent production systemsWhy we need Industry 4.0
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23.11.16 22© sirris | www.sirris.be | [email protected] |
Building intelligent production systemsWhen digital becomes human
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23.11.16 23
The Airbus Future Factory
Building intelligent production systems
Designing the human centered workplace
Distributed manufacturing & the connected factory
How SIRRIS can help
© sirris | www.sirris.be | [email protected] |
Industry 4.0 The future of making things
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Designing the human centered workplaceAutomation of production is about taking people seriously
© sirris 2007 | www.sirris.be | [email protected] | 24
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© sirris | www.sirris.be | [email protected] |
Source : MTM-Institut
Designing the human centered workplaceThe lean, responsive, innovative workcell
Intelligent production systems
•reducing complexity, combining human intelligence with machine endurance and precision
•giving control to the worker,
•enabling autonomous work cells,
•combining lean thinking with low cost intelligent automation (LCIA),
•easy to learn, install, adapt, reconfigure
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© sirris | www.sirris.be | [email protected] |
Designing the human centered workplaceThe lean, responsive, innovative workcell
7Transparant
Factory
6OptimizedMaterial
Flow
2Safety
ByDesign
3Ergonomics
AndProductivity
1SinglePiece Flow
5Interactive
WorkInstructions
4Autonomation
Source : Bosch Rexroth
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23.11.16 27© sirris | www.sirris.be | [email protected] |
Designing the human centered workplaceSingle piece flow (Source : MTM institute)
Single operator
Enriching job content
Reducing cognitive workload
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23.11.16 28© sirris | www.sirris.be | [email protected] |
Designing the human centered workplaceSafety by design (Source : ABB, Kuka, UR)
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23.11.16 29© sirris | www.sirris.be | [email protected] |
Designing the human centered workplaceCognitive ergonomics and autonomation (Source : Arkite)
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30© sirris 2016 | www.sirris.be | [email protected] |
Designing the human centered workplaceCognitive ergonomics and autonomation (Source : Light Guide Systems)
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31© sirris 2016 | www.sirris.be | [email protected] |
Augmented reality quality check
Designing the human centered workplaceInteractive worker instructions (Source : Fraunhofer IFF)
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32© sirris 2016 | www.sirris.be | [email protected] |
Augmented reality work instruction
Designing the human centered workplaceInteractive worker instructions (Source : Viumore)
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23.11.16 33© sirris | www.sirris.be | [email protected] |
Designing the human centered workplaceEvery worker becoming a knowledge worker
Productive LeanResponsiveInnovative
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23.11.16 34
The Airbus Future Factory
Building intelligent production systems
Designing the human centered workplace
Distributed manufacturing & the connected factory
How SIRRIS can help
© sirris | www.sirris.be | [email protected] |
Industry 4.0 The future of making things
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The Connected FactoryThe power of being small… and connected
36© sirris 2016 | www.sirris.be | [email protected] |
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The Connected FactoryThe power of being small… and connected
37© sirris 2016 | www.sirris.be | [email protected] |
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The Connected FactoryThe power of being small… and connected
38© sirris 2016 | www.sirris.be | [email protected] |
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The Connected Factory3D printing services
39© sirris 2016 | www.sirris.be | [email protected] |
Source : i.Materialise
Source : i.Materialise
Source : i.Materialise
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The Connected FactoryElectrical design and assembly services
43© sirris 2016 | www.sirris.be | [email protected] |
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The Connected FactoryCommercial component purchasing services
45© sirris 2016 | www.sirris.be | [email protected] |
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The Connected FactoryThe internet of services
46© sirris 2016 | www.sirris.be | [email protected] |
Source : EC Workshop on “Innovation in Digital Manufacturing”
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47© sirris 2016 | www.sirris.be | [email protected] |
Industry 4.0 or how to eat an elephant
Van Hoecke
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Industry 4.0or how to eat an elephant
23.11.16 48
Van Hoecke, Factory of the Future 2016
© sirris | www.sirris.be | [email protected] |
Mass customisation
Flexible automisation
Flexible people
Single piece flow
72 hour delivery
40 sec tact-time (incl. setup)
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Industry 4.0or how to eat an elephant
23.11.16 49
Biobakkerij De Trog, Factory of the Future 2016
© sirris | www.sirris.be | [email protected] |
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Industry 4.0 or how to eat an elephant
23.11.16 50
The Airbus Future Factory
Building intelligent production systems
Designing the human centered workplace
Distributed manufacturing & the connected factory
How SIRRIS can help eating the elephant
© sirris | www.sirris.be | [email protected] |
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How Sirris can helpTowards some practical themes
23.11.16 51© sirris | www.sirris.be | [email protected] |
MasterplanInnovation
Belgiancompanies
Impact of digitising
manufacturing 6 themes tostart withdigitising
manufacturing
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Digitising manufacturing6 themes to start with digitising manufacturing
1. Managing increased complexity
2. Enabling fast response
3. Supporting operators in their tasks
4. Enabling first time right production
5. Making the shop floor transparent
6. Creating a manufacturing network
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Digitising manufacturing1. Managing increased complexity
Bron: Sirris
Product development process aligned forshift towards custom made products
• Modular/platform design
• Supporting SW tools:
CAD/CAM/PDM/PLM…
• Product visualization techniques
• Advanced engineering tools
Production process aligned for shift towards small batch sizes
• Flexible automation
• Planning and execution
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Digitising manufacturing2. Enabling fast response (QRM)
Bron: Sirris
Lead time reduction in front office (fast customer response)
• Self steering teams
• Supporting SW tools: ERP/CRM/APS/FCS
• Predict lead time at the moment of the customer request
Lead time reduction in production
• Self-organizing methods (QRM/lean/POLCA/…)
• Fast changeover tools
• Low level work preparation
• Appification of production
• Simulating adaptive production systems
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Digitising manufacturing 3. Supporting operators in their tasks
Bron: Sirris
Bron: Sirris
Increase flexibility of operators
• Cross training of operators
• Involvement of operators
Free up more operator time for Q-control & process improvement work
• Reduce cognitive & physical operator
load
• Collaboration human/robots
• Digital operator support
• Capture/monitor operator behaviour
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Digitising manufacturing4. Enabling first time right production
In line optimized/automated quality control
• Production process monitoring (sensors, embedded devices, …)
• Technologies for optimized/automated quality control (vision, 3D measuring, ...)
• Production data analysis: root cause analysis
Adaptive production systems
• Real-time production monitoring
• Real-time production data analysis
• Adaptive technologies
Predictive production systems
• Analyse historical production data and develop predictive production model
• Simulate production systems (predict and anticipate problems)
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Digitising manufacturing5.Making the shop floor transparent
Bron: Sirris
Bron: Sirris
Create bridges between production modules
• Making machines CPS
• M2M communication
Monitor and visualize production
• Tracking/tracing
• Provide visual data-driven insights into the
production process
Intelligently use production data
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Digitising manufacturing 6. Creating a manufacturing network
Linking different production units
• Open communication and API standards
• Cyber security
• Cloud technology
• Uniform policy on data management and sharing between
different sites
Creation of co-development platforms
• Open System Architectures
• Digital partner platforms (suppliers, customers, competitors, …)
• Digitised industrial eco-systems
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The Connected FactoryDigitised industrial eco-systems
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The Connected FactoryDigitised industrial eco-systems
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61© sirris 2016 | www.sirris.be | [email protected] |
The Connected FactoryDigitised industrial eco-systems
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Machinebouw en productiebedrijven
The Industrie 4.0 machine
The ultimate factory
VR en AR in M&M sector
Slimme productie & assemblage
Slimme productie aansturing
Nieuwe business-modellen
M&M Competence Center W.VL. Machinebouw & Mechatronica
Bron: HomagBron: LVD
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How Sirris can helpFrom demonstration to implementation
23.11.16 63© sirris | www.sirris.be | [email protected] |
Imagine what we could do together.
Looking forward to your ideas and suggestions.
Thank you !