© 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

1

5

2

3

7 6

4

8

1

9

2

3

4

5

6

7

8

9

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

1

2

3

4

5

6

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

e

Go

od

Qu

alit

y

… …

Sto

rag

e m

ed

ium

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

min

47

5 S

tk.

Se

tup

tim

e

Cycle

tim

e

Ava

ilib

ility

Dow

ntim

e

Go

od

Qu

alit

y

… …

© 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 4090-621sebastian.haeberer@iff.fraunhofer.de

© Fraunhofer IFF