24/10/2013
Thomas Runkler, Siemens Corporate Technology Session:The role of Cyber-Physical Systems (CPS) for manufacturing
Cyber-Physical Systems in manufacturing and production workshop Brussels 30th October
Workshop organised by Platte Consult SPRL/PGmbH
Cyber Physical Systems for Manufacturing and Production
1
The pace of change in manufacturing has never been faster
Growing importance of manufacturing industries in all economies
1
Increase efficiency
• Energy- and resourceefficiency are decisive cost factors
2
Reduce time to market
• Merger of real and virtual production • Interlinking automation and drive technology with industry software
3
Enhance flexibility
• Increasing importance of industrial IT and industry software
We are well prepared to make our customers more competitive
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October 2013
Corporate Technology
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1
Energy- and resource-efficiency are decisive cost factors
Energy is often the single biggest cost factor in energy-intensive industries
57%
47%
36%
29%
27%
Aluminum
Cement
Steel
Paper
Basic chemicals
In Europe, industry accounts for about 25% of end energy usage
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October 2013
Corporate Technology
Energy prices for industry expected to rise some 70% by 2030
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2
Reduced time-to-market through simulation of product development and production process
Product development process with physical prototypes vs. virtual prototypes
296.0
2002
2008
Product data in terabytes (TB) 1)
Physical (real) function prototype
Physical (real) product prototype
Physical (real) production prototype
Virtual (digital) function simulation prototype
Virtual (digital) product simulation prototype
Production check
Physical (real) mass production prototype
Production check
-40%
28.0 1.8 2002
2005
2008
1) Considered Data types: Image Data, ASIC, CAD, PDM, Animation Data Page 4
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Corporate Technology
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3
Enhanced flexibility through use of industrial IT and industry software
Complete Ford F-150 program Trim Line
6
6
Cab
3
18
Drive
2
36
Box
4
144
Engines
3
432
Transmission
3
1,296
Rear Axle Ratio
7
9,072
Wheel
9
81,648
Tires
8
653,184
Seats
18
11,757,312
Power Seats
2
23,514,624
Radios
5
117,573,120
Running Boards
4
470,292,480
Rear Window
3
1,410,877,440
12
16,930,529,280
3
50,791,587,840
12,870
653,687,735,500,800
Colors Trim Colors 16 Individual Options
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Corporate Technology
• Thousands of marketable combinations • Millions of buildable combinations • Trillions of theoretically possible combinations
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Cyber-physical systems (CPS) enable the future of manufacturing
Communication everywhere and every time • Future infrastructure will support the access to information everywhere and every time without any specific installation / parameterization needs Production and products will be intelligent • Production resources will be autonomic and will connect to each other (M2M) • Products know their own production systems
Digital and real world will merge • Each real object will have a digital shadow, which reflects the characteristics of the real object
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Corporate Technology
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Data Analytics: The era of data just begins Innovation waves lifting Business Intelligence / Data Analytics Big data analytics Data Mining
Today
Data warehousing Digital data
~1990 ~1980
~ 1960
• Data cubes • Digital data collection • Relational databases • First databases • Financial data Documentation
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October 2013
Enterprise mgmt.
Corporate Technology
• • • • •
Statistics Artificial intelligence Machine learning Knowledge discovery Unstructured data Process optimization
• Stream processing (Complex Event processing) • Autonomous systems • Collective intelligence • Massively distributed analytics • NoSQL databases • Heterogeneous data and knowledge • Petabytes of data Real-time decision support and control
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End-to-end engineering across entire value chain
Historically grown IT systems with complex interfaces
Seamless integrated tool chain Product and production always harmonized on each other
Services Production Production engineering Production planning Product design
• Enhanced quality • Enhanced customer satisfaction • Reduced operation costs
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Corporate Technology
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Research to realize the vision of Industrie 4.0 covers 3 levels: Strategy, processes, system Level strategy Horizontal integration across value networks • New business models • Eco-systems Defines goals
Implements
Set rules
Enables
Level processes End-to-end engineering across entire value chain • Integration of product and production lifecycle: From design to production to service and loop-back
Level system Vertical integration and networked production systems • Flexible reconfigurable and adaptable production systems based on cyber-physical systems
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October 2013
Corporate Technology
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Many regional initiatives making progress to innovate manufacturing – Industrie 4.0 just one of them
Focus: German initiative driven by BMBF, BMWI, associations (e.g. acatech), companies (e.g. Telekom, SAP, Bosch).
• Horizontal integration across value networks • End-to-end engineering across entire value chain • Vertical integration and networked production systems
Topics: e.g. Horizontal integration, IoT1, CPS2
US government initiative and funding. Communities involving universities (e.g. MIT, CMU), companies (e.g. General Electric, Honeywell, IBM) Topics: IT breakthroughs, new materials
defines goals
implements
set rules
enables
Non profit org. founded in 2012. Members: associations (e.g. MESA), manufacturers (e.g. General Motors), suppliers (e.g. Rockwell, Honeywell) Topics: e.g. community platforms for virtual plant enterprise
National program driven by Chinese Ministry of Science & Technology, released 03/2012 Topics: Industrial robotics, digital plant, Industry IoT1
Source: Siemens / Arbeitskreis Industrie 4.0 1) Internet of Things Page 10
October 2013
2) Cyber-physical systems Corporate Technology
Siemens participates Unrestricted © Siemens AG 2013. All rights reserved
Many regional initiatives making progress to innovate manufacturing – Industrie 4.0 just one of them
Focus: German initiative driven by BMBF, BMWI, associations (e.g. acatech), companies (e.g. Telekom, SAP, Bosch).
• Domestic manufacturing capabilities in critical national security industries • Reduction of time to develop and deployment of advanced materials • Next-generation robotics and innovative energyefficient manufacturing processes
Topics: e.g. Horizontal integration, IoT1, CPS2
US government initiative and funding. Communities involving universities (e.g. MIT, CMU), companies (e.g. General Electric, Honeywell, IBM) Topics: IT breakthroughs, new materials
Non profit org. founded in 2012. Members: associations (e.g. MESA), manufacturers (e.g. General Motors), suppliers (e.g. Rockwell, Honeywell) Topics: e.g. community platforms for virtual plant enterprise
National program driven by Chinese Ministry of Science & Technology, released 03/2012 Topics: Industrial robotics, digital plant, Industry IoT1
Source: www.manufacturing.gov 1) Internet of Things Page 11
October 2013
2) Cyber-physical systems Corporate Technology
Siemens participates Unrestricted © Siemens AG 2013. All rights reserved
Many regional initiatives making progress to innovate manufacturing – Industrie 4.0 just one of them
Focus: German initiative driven by BMBF, BMWI, associations (e.g. acatech), companies (e.g. Telekom, SAP, Bosch).
• Manufacturing intelligence on existing installed base using data analytics, modeling and simulation • Smart manufacturing platform and test beds (community source) to lower costs: e.g., platform initiated to pool industrial data
Topics: e.g. Horizontal integration, IoT1, CPS2
US government initiative and funding. Communities involving universities (e.g. MIT, CMU), companies (e.g. General Electric, Honeywell, IBM) Topics: IT breakthroughs, new materials
Non profit org. founded in 2012. Members: associations (e.g. MESA), manufacturers (e.g. General Motors), suppliers (e.g. Rockwell, Honeywell) Topics: e.g. community platforms for virtual plant enterprise
National program driven by Chinese Ministry of Science & Technology, released 03/2012 Topics: Industrial robotics, digital plant, Industry IoT1
Source: https://smartmanufacturingcoalition.org/ 1) Internet of Things Page 12
October 2013
2) Cyber-physical systems Corporate Technology
Siemens participates Unrestricted © Siemens AG 2013. All rights reserved
Many regional initiatives making progress to innovate manufacturing – Industrie 4.0 just one of them
Focus: German initiative driven by BMBF, BMWI, associations (e.g. acatech), companies (e.g. Telekom, SAP, Bosch).
• Intelligent manufacturing as well as measurement and control systems • Industrial automation instruments, control systems and industrial robots • 2015 target for basic “Internet of Things“ structure
Topics: e.g. Horizontal integration, IoT1, CPS2
US government initiative and funding. Communities involving universities (e.g. MIT, CMU), companies (e.g. General Electric, Honeywell, IBM) Topics: IT breakthroughs, new materials
Non profit org. founded in 2012. Members: associations (e.g. MESA), manufacturers (e.g. General Motors), suppliers (e.g. Rockwell, Honeywell) Topics: e.g. community platforms for virtual plant enterprise
National program driven by Chinese Ministry of Science & Technology, released 03/2012 Topics: Industrial robotics, digital plant, Industry IoT1
Source: Netscribe, “Internet of Things Market in China 2012“ 1) Internet of Things Page 13
October 2013
2) Cyber-physical systems Corporate Technology
Siemens participates Unrestricted © Siemens AG 2013. All rights reserved
Manufacturing will have an enormous impact on global economy, trade and employment Facts and figures about manufacturing Manufacturing share of global GDP: 16 percent Germany: 19 percent (2010) Advanced economy manufacturing jobs in 2010: 45 million Share of service jobs in manufacturing: 30 55 percent Number of global manufacturing groups where China leads: 3 where US leads: 2 …. Source: McKinsey Global Institute/McKinsey Operations Practice November 2012 Manufacturing the future: The next era of global growth and innovation Page 14
October 2013
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Large developing countries are moving up in global manufacturing Top 15 manufacturers globally • Manufacturing output continues to grow by about 2.7 percent annually in advanced economies and 7.4 percent in large developing countries (between 2000 and 2007) • Economies as China, India, and Indonesia (2000: 20th, 2010: 13th) haven risen into the top ranks of global manufacturing – and in the world’s 15 largest economies Ranking by share of manufacturing gross value added
1980
1990
2000
Manufacturing share of GDP in percent
Average 17
2010
Source: McKinsey Global Institute, IHS Global Insight, United Nations Statistics Division, BEA Page 15
October 2013
Corporate Technology
Unrestricted © Siemens AG 2013. All rights reserved
Thomas Runkler, Siemens Corporate Technology
Thank you!
Unrestricted © Siemens AG 2013. All rights reserved
