Industrie 4.0: IoT as a Game Changer in Future

ManufacturingProf. John Soldatos, PhD,

Athens Information Technology

(jsol@ait.gr; @jsoldatos)

2nd IoT Conference by Naftemporiki

December 8th, 2016

Drivers of Future Manufacturing

From capacity to capability

• ManufacturingFlexibility

• Respond to variablemarket demand andachieve high levels ofcustomer fulfillment

New production models

• Moving away from mass production

• From make-to-stock (MTS) to make-to-order (MTO), configure-to-order (CTO) and engineer-to-order (ETO) production

• Becoming more demand driven

• Mass Customization

Profitable proximity sourcing and production

• Modular products based on common platforms and configurable options

• Adopt hybrid production and sourcing strategies

• Produce modular platforms centrally, while leveraging suppliers, distributors, or retailers to tailor final products locally to better serve local customer demands

Workforce engagement

• People will remain at the center of the factory of the future

• People will provide the degree of flexibility and decision-making capabilities required to deal with increasing operational complexity

• Higher levels of collaboration

Fourth Industrial Revolution (Industrie 4.0) –Role of IoT & Cyber-Physical Systems (CPS)

11www.fiwareforindustry.eu

Source: Recommendations for implementing the strategic initiativeINDUSTRIE 4.0 by The Industry-Science Research Alliance &Sponsored by the German Federal Ministry of Education andResearch

IoT

Sensing of the physical world

Internet connectivity

Used in China and EU

CPSControl of combined

organizational and physical processes

Tight Human Machine

Interaction

Used in USA and EU (Industry 4.0)

IoT Interconnects factories and the manufacturing chain

Source: Cognizant.com

Connected Supply Chain (Across Factories)

Source: Cognizant.com

Case Study - Dell

• Employees are engaged with customers to help them find the best customized choice that fits their need.

• Orders translated to OptiPlexmanufacturing facility, which is able to build more than 20,000 custom-built products

• Orders arrive and are consolidated at the part level via real-time factory scheduling and inventory management

• Churns out a revised manufacturing schedule every two hours

• Enables communications (with time stamps) to suppliers to ensure that required materials are delivered to specific buildings, dock door and manufacturing lines

Flexible Decentrialized Factory Automation – EU’s H2020-723094-FAR-EDGE Project (Inside the Factory)

FAR-EDGE = Joint effort of global leaders in manufacturing and IoT towards adoption of virtualized Factory Automation

• Cloud and Edge Computing for Manufacturing

• Decentralization of control

• RAMI 4.0 & Industrial Internet standards

Expected Outcomes

• Reduced Time to deploy new automation concepts and technologies (e.g., 3D printers)

• Better Exploitation of Data

• Increase automation in factories

• Improve process agility

• Enable x-factory collaboration

• RAMI Compliant Implementation

Advisory Board Member

FAR-EDGE Aligns to RAMI4.0: Common Language for I4.0 (work-in-progress)

FAR-EDGE: Mass Customization & Reshoring

Process Agility(mass-customization)

X-Factory Collaboration(reshoring)

Case Study (in Greece): SENSAP’s INTEGRA™ Product

INTEGRA™ Industrial Traceability Kiosk – ITK

Controller

• Standalone automation module (i.e. sensor and actuator docking station and control unit)

• Used for product quality inspection, item-identification and code-verification, carton-box and pallet labeling,

• Monitors of material-consumption, machine-speed and machine-utilization.

INTEGRA™ IVS Vision System

• Robust, all-in-one camera controller,

• Plug-n-play, built-in automation functions, for demanding machine-vision applications

• Operation of multiple frame-grabbers at high-speed.

INTEGRA™ KL/KR/KM/KI-OPTION

• The KL/KR/KM/KI-OPTIONs are Spoilage Marking and Rejection modules for the ITK

• automatically track, mark or remove non-conforming cartons or printed sheets, without the need for machine stoppages.

• SENSAP’s patented spoilage monitoring algorithms guarantee accurate rejection.

Source: www.sensap.eu & www.sensap.ch