industry 4.0 – it meets industry · individual customer requirements higher productivity high...

04/11/2016 | Wolfgang Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Dr.-Ing. habil. Wolfgang HornSenior Vice President TechnicalBosch Rexroth

Industry 4.0 – IT meets Industry

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04/11/2016 | Wolfgsng Horn | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.


Agenda

Conclusion and future outlook

Industry 4.0 @ Bosch

Value stream example for Industry 4.0

IT Products for Industry 4.0

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Important changes in recent years

CPU is available cheapand unlimited

Low priced

sensorsavailable

Data mining:Analyse big

data close toreal-time

Increase insoft-/hardware

usability

WorldwideGPS localization

is possible

Performance advantages bydecentralizednetworking

Internetis availableworldwide

Storageis availablecheap andunlimited

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Individual customerrequirements

Higher productivity

High flexibility•Minimize set-up time•Smart individual work piece in/out

Quality improvement

Real-time & preventive service

Low inventory

Lower dependence on labor

MarketRequirements

Manufacturers’Requirements

Volatile markets

Shortened delivery times

Shortened product lifecycles

24/7 worldwide service

Social behavior, newcooperation

Disruptive business models



Challenges Derived From the Market

Industry 4.0 would be an enabler to handle the challenges

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04/11/2016 | DC-IA/ENA DC-IA/PJ-I4.0-T | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Features of Industry 4.0

Distributedintelligence

Secure value-creation network

Digital life-cyclemanagement

People as key-players

Fast integrationand flexible

configuration

Openstandards

Virtual real-timerepresentation

Features of Industry 4.0

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Industry 4.0: Bosch Dual StrategyLead ProviderSystem manufacturer/ Production resource viewI 4.0 solution provider with external business

enabler technology or internal I 4.0 solution provider

Assembly Systems and Special Machinery

Industrial Sensor Solutions

Bosch ConnectedDevices & Solutions

Bosch Sensortec

Machine Platforms

RFID@BOSCH

Data Mining, Big Data

Bosch Software Innovations

Packaging Technology

Drive and Control Technology

Innovations-management Logistik

...

Lead OperatorProduct manufacturer/ Product view

250 Bosch plants world wide

Manufacturer of products Machine operator Plant operator Interface to customers/suppliers

Many practical pilot applications are bundled within the Innovation Cluster CI

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Agenda





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Industry 4.0 – IT meets Industry – Products

Product Overview

7.Eco

systemSolutions with

partners

1.I4.0

upgrade KitConnect existing Machines to the

I4.0 network

6.Open Core

EngineeringIT Programming

languages

2.IMS-A

Sensors & intelligenceintegrated

3.Smart

tighteningWireless

connection

4.Active Assit

Gudiance for workers

5.Active

CockpitInteractiveShop Floor

Communicationwith real time data,

paperless

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1. “i4.0 upgrade” Solution

Migration of existing

machines in a i4.0 network

Web based configuration Dashboard Devices Providers Logics

Standard Data Interfaces Gateway for different

communication protocols Device/Sensor Integration

with low engineering effort

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Features Power up without referencing

movement minimizes machine run-up time and prevents damages to the tool and work piece

Wear- and maintenance-free

Not sensitive to dirt and vibrations

Not sensitive to EMC interference

No magnetic components

No adjustment of the measuring system required

Very good protection against damage

No buffer battery

Compatible to common drive manufacturers



2. IMS-A: Integrated Measuring System – absolute

Highly precise position resolution

and top repeatability

High level of reliability and reduced down

times

Inductive measuring

principle without physical contact

Absolute System

Complete integration of

the measurement function in the linear guide

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3. Smart tighteningFeatures Wireless handheld tightening system

for industrial applications

Fully integrated process controller –no additional hardware required

Configurable display as real-time worker interface

Highly precise integrated torque and angle sensors for optimized process results

Integrated web-server

for connection of tablets and other mobile devices

Full connectivity

wireless communication of

process data / process control

information

Fully autonomous due to integrated process controller

Real time information of experts about

process anomalies based on statistics and expert rules

Failure reaction time drastically reduced

Down time reduced by 10%

Failure costs reduced by 10%

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4. Active Assist Industry 4.0 WorkplaceErgonomic &

interactive worker

guidance

Web-based, configurable

software

Worker identificationvia bluetooth tag.

Adaption of language, qualification level and

ergonomics.

MES/ERP integration,

Connection to Active cockpit

Reducedfailure costs

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5. Active Cockpit



Technical data Browser-based

software (App/Widget)

Communication to various back end systems

Mobile and stationary end devices

Intuitive user interface

Functional data management

Ergonomic & interactive

worker guidance

Information & communication

platform for shop floor

management

30% efficiency increase in

preparation of information and decision making

Creating Visualization & consistency of relevant pro-duction data

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6. Smart Control „IndraControl XM“ ► Automation apps► Multi-language enabled

− IEC 61131-3 (PLC, Motion)− G-Code (CNC)− Java (IoT)− Lua (Open Source)− C/C++/C# (Real-time)

► Operating via Smart Devices− iOS, Android, Windows

► Enabled for simulation andmodel-based engineering− LabView, Matlab, Simulink,

Modelica (CATIA, SolidWorks)► IT/IoT/Cloud communication

(OPC UA, WebSockets, MQTT, JSON / REST, MES protocols)

► Safety on board► Energy Management► Data Analytics

Smart Controlcombines

PLC Automation with

IoT solutions

* Bosch IoT Cloud, Oracle, SalesForce, Microsoft Azure etc.

Multi-Ethernet

ConnectedReal-Time Fieldbus, OPC UA, Web & IoT, Cloud Connection*

Real-time enabled for

C/C++

SmartDevices & Web HMI

based

PLC

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“In building the Connected World of the future, we believe no singlecompany will be able to do this alone.

We believe in Open Platforms, in Open Standards, in Open Source and in Strategic Alliances.”

7. Eco-System & Partner

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Agenda





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04/11/2016 | DC-IA/ENA DC-IA/PJ-I4.0-T | © Bosch Rexroth AG 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Indu

stry

4.0

Inno

vatio

n le

vel

2013 2014 2015 2016 2017 2018 2019 2020

1) Pilot projects

2) Value streams

3) International ProductionNetwork

Implementation roadmap

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Industry 4.0 – IT meets Industry – Value stream example

Industry 4.0 Award

Homburg Plant multi-product line

Small batch

change over

stock6

~4 million yuan savings each year for the product line

productfamiliesTailored

Over 2000different products

Zero

-30%Productivity

High variance

+10%

Case I : Homburg Plant

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Suzhou Plant line苏州工生产线

20% direct productivity improvement

10% indirect productivity improvement

40% on-line inventory reduction @ SMT project

Suzhou Plant line

Case II: Suzhou Plant

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Case III: QCMT – Robot gearboxes production

Connected- Workers- Machines- Automation- Products

Autonomous workstationsHorizontal networking

Self guiding product

Deviation and malfunction management

Quality controlLaser sensors & camera system

User Identification & Adaption

Smart connection

Tablets & ActiveCockpit

Heating systemData controlled

Process control“Pick to light”

Complete Bosch Rexroth Automation System CNC and Motion Controls and PLC (line control) Smart Tightening Tools Nexo Multi-Touch HMI & Smart Devices Rexroth Active Cockpit MES Bosch OpCon

Productivity

x 10

ROI

2.5 yearsFlexibility

100%

High Product Variance

7 types, 35 variants

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Industry 4.0 – IT meets Industry – Industry 4.0 in Education

Case IV: The Rexroth Drive & Control Academy

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Universities:Combining automation and IT capabilitiesStart active with i4.0 know howResearch and development and partner for industryProviding additional skill development

Vocational Institutes:Integrate first i4.0 features / presentation in your mechatronic courses Start with first i4.0 courses or projectsPossibly provide additional skill development courses



Conclusion

Production lines Multi product line

Homburg Plant Suzhou Plant Customer QCMT

ProductsI4.0 upgrade KitSmart Control XMTightening NexoOpen Core InterfaceActiveCockpitActive AssitIMS-A

Industry 4.0always

starts with production!

Thanks for your

Attention

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industry 4.0 – it meets industry · individual customer requirements higher productivity high...

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