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Towards Positive Impact Factories
IoT as an enabler
Prof. Dr.-Ing. Christoph Herrmann | Sustainable Manufacturing in IoT Era | 11.03.2017
Technische Universität Braunschweig
 Founded 1745
 ca. 19,500 students
 3,750 university staff
 1,800 scientists
 223 professors
 120 institutes
 65 degree programs
 10 central service units
 6 departments
8%
7%
6%
Anteil am BIP
5%
4%
3%
2%
1%
0%
[Eurostat 2002] R&D-Density in
European regions (share of
GDP).
The region of Braunschweig
(7,1%) is ahead of North Finland
(4,2%) and East England (3,9%).
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 2
www.tu-braunschweig.de
Agenda
1
4
Digitalization
2
From Bad to Positive Impacts
3
Building Blocks for “The Positive Impact Factory”
ICT and IoT enabling the Positive Impact Factory
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 3
Industry 4.0 | The Fourth Industrial Revolution
Degree of complexity
First Industrial
Revolution
Second Industrial
Revolution
Third Industrial
Revolution
Fourth Industrial
Revolution
based on the
introduction of
mechanical
production
equipment driven
by water and steam
power
based on mass
production achieved
by the division of
labor concept and the
use of electrical
energy
based on the use of
electronics and IT
to further automate
production
based on the use of
cyber-physical
systems
First conveyor belt,
Cincinnati
slaughterhouse, 1870
First programmable
logic controller (PLC)
Modicon 084, 1969
First mechanical
loom, 1784
Late 18th
century
Beginning
20th century
1970s
Today
[DFKI 2011]
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 4
Digitalization | Cyber Physical Production Systems
Cyber Physical Production System
Smart Products
Physical
Cyber
Digital Twin
(Factory,
Machine,
Process,
Learning…)
Smart Data/
Machine
Learning
Industral assistance systems
Multi-modal
input
analysis
Multi-modal
presenstation
of results
Learn-/
Productionmode
[Microsoft BING 2016]
Collaboration & Interaction
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 5
[DFKI 2012, acatech 2013]
Digitalization | Cyber Physical Production Systems
Automation Pyramid
Automation Diabolo
ERP
ERP
Enterprise
MES
SCADA
MES
Plant
Shop Floor
Information Model
SPS
Real-time
critical
I/O signals
Control
Automation
Field
Production Process
•
•
„Traditional“ information model from
automation technology
Data is exchanged between systems on
the different layers via gateways
•
•
•
[VDI/VDE 2013, Vogel-Heuser 2014, Trends+Innovation 2015]
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 6
Information model as connection to MES
Layers from automation technology are
dissolved
Data exchange in vertical and horizontal
direction
Digitalization | Cyber Physical Production Systems
Automation Diabolo
Cyber-Physical Systems (CPS)
ERP
MES
Information Model
Automation
Production Process
•
•
•
Information model as connection to MES
Layers from automation technology are
dissolved
Data exchange in vertical and horizontal
direction
•
•
•
•
Real-time critical control near the processes
and distributed
Utilization of decentralized services requires
new human-machine-interfaces (HMI)
New layers above the ERP are added
Different OEM and users are integrated
[VDI/VDE 2013, Vogel-Heuser 2014, Trends+Innovation 2015]
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 7
Agenda
1
4
Digitalization
2
From Bad to Positive Impacts
3
Building Blocks for “The Positive Impact Factory”
ICT and IoT enabling the Positive Impact Factory
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 8
From Bad to Positive Impacts |
The current thinking about Factories
Bad Factory
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 9
From Bad to Positive Impacts |
The current thinking about Factories
1
6
10
3
2
4
7
11
5
9
8
12
13
Image Sources: 1. static.panoramio.com; 2. maverickbiofuels.com; 3. captainkimo.com; 4. IWF; 5. beobachter.ch; 6. english.cri.cn; 7. ctvnews.ca; 8. cdn.ientry.com; 9. daviscos.com;
10. paritynews.com ; 11. robots.com; 12. i.huffpost.com; 13. 73192314.weebly.com; 14. czech.homestead.com
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 10
14
From Bad to Positive Impacts |
Efficiency and Effectivity
How to reach positive impacts?
Factory Impacts
Technology s-curve concept acc. to Foster (1986)
positive
limit of effectiveness
technology
potential
Effort
neutral
technology
potential
limit of efficiency
today
today
negative
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 11
From Bad to Positive Impacts |
Examples of Fields of Action
From bad to positive impacts – examples:
Energy & Resource Demand
Bad Impacts
-
Positive Impacts
+
Particle Emissions
Bad Impacts
-
Positive Impacts
+
Working Conditions
Bad Impacts
-
Positive Impacts
+
Image Sources: static.panoramio.com; oag.ca.gov, captainkimo.com; solar-fabrik.de, paritynews.com; onlinecareertips.com
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 12
Agenda
1
4
Digitalization
2
From Bad to Positive Impacts
3
Building Blocks for “The Positive Impact Factory”
ICT and IoT enabling the Positive Impact Factory
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 13
Enabling “The Positive Impact Factory” |
Building Blocks
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 14
Agenda
1
4
Digitalization
2
From Bad to Positive Impacts
3
Building Blocks for “The Positive Impact Factory”
ICT and IoT enabling the Positive Impact Factory
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 15
Enabling “The Positive Impact Factory” |
Energy Transperency in Production
Energy Transperency in Production




Identification of non-value-creating
energy demand
Effective analysis and evaluation of
energy demand data
Decision support on the shop floor
Process best practices to reduce
cost and process times while
maintaining quality
[IWF – mit uns digital, 2017]
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 16
Enabling “The Positive Impact Factory” |
Power Autonomous Sensor Systems
Power Autonomous Sensor Systems




Miniaturised power autonomous sensor systems
No intereference with the production system
Monitoring of machine data, energy demand, environmental data
Human-machine-interaction supporting energy management and
maintenance
[ESIMA, 2016]
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 17
Enabling “The Positive Impact Factory” |
Matrix production concept
Self-Organising Matrix Production Concept






Agent based simulation for system
planning and control
Highly flexible - synergetic use of
the matrix production systems by
different products
Cycle time independent
Large cycle time spreads possible
System stability by redundancy
Products and production processes
are connected and can take
actions
[IWF]
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 18
Enabling “The Positive Impact Factory” |
Energy flexibility
Energy Flexibility in Production Systems




Align electricity demand of a factory to supply
All planning stages considered in holistic approach
Goal: Real-time manufacturing control through modular system design
tool with energy and material flow dynamics
Multi-indicator evaluation
[Beier et al. 2017]
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 19
Enabling “The Positive Impact Factory” |
Industrial Symbiosis
Energy Flexibility in Production Systems




Industrial symbiosis describes the utilization of output flows (waste) as
resource input to other companies
Market place system needs to dynamically connect all resource flows
and decentral data input
For the realization of the simulation data input from a high number of
physically distributed entities and decentralized computing is required
Transport means
and companies
are modelled as
autonomous
agents
Elaborated from Low (2015)
11.03.2017 | Prof. Dr.-Ing. Christoph Herrmann | Positive Impact Factory | Slide 20
Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen
Towards Positive Impact Factories
IoT as an enabler
Prof. Dr.-Ing. Christoph Herrmann | Sustainable Manufacturing in IoT Era | 11.03.2017