Fourth Industrial revolution - Cyber Physical Production Systems - Internet of Things and Factory of the Future

1. Keynote Address:
Industry
4.0:
the Internet of
Things
Smart Factories
From to
JAYESH C S PAI
MSME TOOL ROOM, KOLKATA

2. © DFKI GmbH
The German Future Project: Industry 4.0
 Industrial production is the backbone of Germany‘s economic
performance:
Germany is preparing the 4th industrial revolution based on the
Internet of Things, Cyber-physical Production Systems, and the
Internet of Services in Real industry.
Exponential growth of data

3. This is how we see our world

4. This is how we should see our world

5. From Industry 1.0 to Industry 4.0: Towards
the 4th Industrial Revolution
First
Mechanical
Loom
1784
mechanical production
water and steam
End of
18th
Centu
t
DegreeofComplexity
1. Industrial Revolution
facilities powered by
Industry 1.0

6. From Industry 1.0 to Industry 4.0: Towards
the 4th Industrial Revolution
First
Mechanical
Loom
1784
Industry 1.0water and steam
End of
18th
Centu
Start of
20th
Centu
t
DegreeofComplexity
2. Industrial Revolution
mass production based on
the division
of labour powered by
electrical
energy1. Industrial Revolution
through introduction of
mechanical production facilities
powered by

7. From Industry 1.0 to Industry 4.0: Towards
the 4th Industrial Revolution
Industry 3.0of production
First
Mechanical
Loom
1784
Industry 1.0water and steam
Start of
70s
End of
18th
Centu
Start of
20th
Centu
t
DegreeofComplexity
3. Industrial Revolution
electronics and IT and heavy-
duty industrial robots for a
further automization
2. Industrial Revolution
through introduction of mass
production based on the division
of labour powered by
electrical
energy
Industry 2.0
1. Industrial Revolution
through introduction of
mechanical production facilities
powered by

8. From Industry 1.0 to Industry 4.0: Towards
the 4th Industrial Revolution
001010100
100101010
Industry 3.0of production
First
Mechanical
Loom
1784
Industry 1.0water and steam
Start of
70ies
End of
18th
Centu
Start of
20th
Centu
today t
DegreeofComplexity
010001101
010010101
4. Industrial Revolution
based on Cyber-Physical
Production Systems
Industry
4.03. Industrial Revolution
through Introduction of
electronics and IT for a further
automization
2. Industrial Revolution
through introduction of mass
production based on the division
of labour powered by
electrical
energy
Industry 2.0
1. Industrial Revolution
through introduction of
mechanical production facilities
powered by

9. The Industrial Revolution

10. Industrial Revolution Hearths
• The iron industry was first to
increase production through
extensive use of (James)
Watt’s steam engine, plus
other inventions.
• The textile industry followed.
• From these two pioneering
industries, new industrial
techniques diffused during the
nineteenth century.
Fig. 11-1: The Industrial Revolution originated in areas of northern England. Factories often
clustered near coalfields.

14. SELLING PRICE
-
COST PRICE
=
PROFIT

17. Towards Intelligent Environments based on
the Internet of Things and Services
4) Embedded Computers Smart Factory
1) Central Computer 90% of all3) Smart Phone
computers are
embedded
2) PC, Notebook Smart Card
1 Computer
1 User
Many Users
Many Computers, 1 User
20201960 20001941 1980
5) Intelligent
Environments
4) Embedded Computers
Smart
1) Central Computer 3) Smart
Phone
2) PC, Notebook Smart Card
1 Computer

18. Vision: Internet der Dinge
Intelligente Umgebungen
z.B. Smart City
Future Project Industry 4.0
500 M€ for 3 Years
National Program:
250 M€ Funding of
Ministry for Research and
Ministry for Economics
Evolution from
Embedded Systems
to Cyber-Physical
Systems
Cyber-Physical SystemsEmbedded Systems
Intelligent Environments/Smart Spaces
Digital City
Cyber-
Physical
Systems
Smart
Factory,
Smart Grid
Networked
Embedded
Systems
Intelligent Street
Crossing
Embedded
Systems
Internet of Things

19. Iron Man Suit

20. Talos in Greek mythology

21. Liquid Armor
It is liquid under low or normal pressure and solid under high
pressure. This liquid is made with polyethylene glycol and the
solid part is made of nano-particles of silica. This liquid is soaked
into all the layers of a Kevlar vest.

24. Industry 4.0: Smart, Green, and Urban Production
Smart Production
High-precision, superior
quality production of high-
mix, low volume smart
products
Urban Production
Green Production
clean, resource-efficient,
and sustainable
Smart Factories in the city
close to the employees‘
homes

55. What is Smart Manufacturing?

56. A future vision
…the integration of data…
Smart Manufacturing is:
…with process expertise…
…to enable “evidence based” management…
…of manufacturing.

57. Internet der Dienste
© DFKI GmbH
The Internet of Things and Services as a
Basis for the Smart Factories in the Industry 4.0
Products
Plattform
Internet of Things
Smart
App
Smart
Material
App
Plattform
Semantic PLM-, SCM-,
CRM-, QMS- and
ERP-Services Smart
Fact
ory
App Plattform
Cyber-Physical
Production System
Internet of Services

58. Pipelines of Smart Factories for Industry 4.0
based on Secure Networks of Clouds
…
Machine 1
Secure Cloud
Networks
Smart
Products
Smart
Materials
Smart Factory 2…N
Smart Factory 1
M2M-
Comunication
Smart … Smart
Machine N
Application Plattform
for Machines
Cyber-Physical
Production Systems
CPPS

59. Raising the Level of Abstraction
If Smart Manufacturing is such a
smart idea why aren’t companies
already doing it?

60. What is
Smart Manufacturing?
Business (Collaboration, Broader Metrics
Real-time Decisions)
Technology
(Horizontal & Vertical
Pervasive)
Workforce
(Innovation &
Broad-Based)
Organizational
Mindset

61. 21st Century Smart Manufacturing
Data
Analyze
Model
Apply
• Demand-dynamic economics keyed
on the intelligence of the ‘customer’
• Coordinated enterprise responses
throughout the entire
manufacturing supply chain
• Predictive, preventive
• Integrated computational materials
engineering
• Performance-oriented enterprise,
minimizing energy and material
usage and maximizing
environmental sustainability,
health and safety and economic
competitiveness
Dramatically intensified application of
manufacturing intelligence using advanced
data analytics, modeling and simulation to
produce a fundamental transformation to
transition/new product-based economics,
flexible factories and demand-driven supply
chain service enterprises

62. SMLC Priority: Situational Awareness performance tools across the enterprise to manage dynamic
production, use, and storage of essential resources (energy, water, air)
Supply Chain
Distribution Center
Customer
Business
Systems, ERP
an interconnected world…
voice, data, mobile, etc.
Smart Grid
Smart Factory
Modern, smart factories will be interconnected
with supply chain, distribution and business systems

63. SMLC Priority: Production and Demand-Dynamic Supply Chain Efficiency - At Scale Virtual Supply Chain Planning, Computational
Materials Engineering and Product Tracking & Traceability Tools
Manufacturing Plant
Supply Chain
Customer
Distributor
Farming
Mining
SMLC Priority:
New Productivity/Efficiency Metrics – Change from output/input
productivity measures to customization, flexibility,
responsiveness, energy performance and reuse
• Customers “pushing” demands
• Flexible production of smaller
volumes of custom products
• Less vertically integrated
• More information driven
and automated

64. Smart Manufacturing is the Application of a Manufacturing Industry Internet
Supply Chain
Distribution Center
Customer
Business
Systems, ERP
Smart Grid
Smart Factory
New Degrees of freedom for
Performance, efficiency and productivity
Anticipate, plan,
manage risk
across
suppliers
Merging actionable
business &
Operations
information
New forms
equipment
benchmarking
Tracking &
traceability
New real-time global
performance
metrics

65. Old Traditional Factory
• More jobs: labor-intensive
• Lower output and productivity
• Lower quality products
• Lower paying unskilled jobs
• Higher risk working conditions
• Higher environmental impact
• Higher production costs
• Rigid, high-volume production
• Longer time-to-market
• Socially optimized (Six Sigma)
New Smart Manufacturing Plant
• Less jobs: automation-intensive
• Higher output and productivity
• Higher quality products
• Higher paying skilled jobs
• Safer working environment
• Less waste, resource use
• Lower production costs
• More flexible customization
• Faster time-to-market
• IT-optimized (models, simulation)
Attributes of a Smarter Manufacturing Sector

66. 21st Century Manufacturing Ecosystem
Much Greater 3x to 15x+ Economic Multiplier -
Smart Manufacturing: The Essential Nucleus For SME’s & The Service Economy
100% automated
Intel Chip FAB –
Some engineers and
technicians
Smart Factory
Innovation and
specialties
25% automated
75% labor
Small Businesses
Components and
other suppliers
50% automated,
50% labor
Medium-size
Manufacturers
Financial, IT Services,
Consulting, etc.
100% labor
Services & Support
Community colleges and
Universities, healthy
knowledge workers,
public-private
partnerships
Education, Health Care and
Government
As Factories Get Smarter, More Jobs Surround Them

71. Products with Integrated Dynamic Digital Storage,
Sensing, and Wireless Communication
⇒The product as an information
container
Capabilities
I was
produced on
30 April 2010
and shipped
on 3 May 2010
– The product carries information
across the complete supply chain
and its lifecycle. Grasp at
the middle
⇒The product as an agent
–
The product
affects ist
environment
2 mins open
Please close!
⇒The product as an observer
–
The product
monitors itself
and

72. Service-oriented planning of plant systems
Hardware-independent planning of plant systems
ERP Enterprise
Resource Planning
MES
Manufacturing
Execution System
Field Layer
Service Library
Sensor-Service Valve-Service Pump-Service Control-Service Communication-Service
Industry 4.0: All-IP Factories, no chaos of field buses, Internet-
based Factory Networking based on IoS and IoT
Abstract Service
hardware-independent
Device Control
hardware-dependent

73. The SmartFactory Shop Floor: Wireless,
RFID-, Sensor- and Service-based Architecture
continuous flow process discrete handling process
bottling, handling, labeling, QC, packaging…
Live Webcam: http://www.smartfactory.de/webcam.de.html
discrete handling proce
bottling, handling, labeling, QC, p
continuous flow proce
colored soap production

74. Data Mining and Knowledge
Smart Factories
Manufacturing stores more data than any
other industrial sector.
Close to two exabytes of new production
data were stored in 2010 from multiple
sources:
Discovery in
•
•
instrumented production machinery
supply chain management systems
• product life-cycle systems
New ICT Coordination Action of EU:
BIG: Big Data
Public Private
Forum

75. Industrielle
Assistenz-
systeme
Human-Centered CPS-based Assistance
Systems for the Smart Factory
Physical
Assistance by
Exoskeletons
Mobile,
Personalized,
Situation-
Adaptive,
Tutoring Systems
Context-adaptive
Assistance for
Fault Diagnosis
AR/VR/DR-
Assistance in
Complex Work
Processes
Multimodal
Human-Machine
Interaction
Location-based
Maintenance and
Planning
Assistance

76. App Stores for the Smart Factory: Downloading
Tailored User Interfaces for User Groups:
Supervisors…Elderly, Trainees, Disabled,

77. Location-based Industrial Assistance Systems in Smart
Factories for Resource Efficiency Improvements

78. Industrial Environment
Advanced Industrial Assistant Systems Based
on Augmented Reality Technologies
Industrial Worker
with Google Glasses
Mobile, Interactive and
Situation-Aware
Tutoring
Tools

79. Augmented Reality Systems Supporting Maintenance Staff

80. Industry 4.0: Robots are no Longer Locked in
Safety Work Cells but Cooperate with Human Workers
Today
Tomorrow
A new generation of light-weight, flexible robots collaborate with
humans in the smart factory

81. DFKI’s Fembot AILA: Using the Semantic Product
Grasping and Smart ProductMemory for
Assembly
Adaptive
Stereo Cameras in the Head and a 3D
Camera on the Torso for Approaching
an Object
Reading
from the
Size, Weight and Lifting Points
Product Memory with an
antenna in the left hand – the Robot
gets instructions from the product
beingproduced in the CPPS

82. W3C Standards as a Basis for the Project of
the Future Industry 4.0
Product Memory
Standardization
EMMA:
Multimodal
Industrial
Assistance
Systems
Industry 4.0
Smart Factory
OMM:
Semantic
USDL:
Semantic Services
in Cyber-Physical
Production Systems

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The Software-defined Car: Customizing
a Car Environment
Android Market
through Apps
App Store
Intelligent
User
Interface
Apps
Motor
Managem
ent
Apps
Driver
Assistan
ce
Apps
Green
Driving
Apps
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84. © DFKI GmbH
BMW Apps: Integrating the Most Recent
Web Services Into the Car Environment
Source: BMW

85. Conclusions
1. High-precision, superior quality production of high-mix, low volume
smart products are the future of Europe’s successful export-
oriented economies like Germany.
2. 80% of the innovations in manufacturing are based on ICT. They will
lead to Smart Factories, Green and Urban Production.
3. The fourth Industrial Revolution will be based on cyber-physical systems,
the Internet of Things and the Internet of Services. It will generate
enormous BIG data streams that can be harvested and analyzed for
resource-efficient and ultra-high quality production.
4. CPS-based industrial assistant systems are needed to support, help
train the next generation of workers in smart factories.
and
5. Augmented and dual reality systems allow individualized workflows and
fast learning of new production processes.

86. Tha
nk
yo
u
ve
ry
mu
ch
fo
r
yo
ur
attenti
on.
THANK YOU METALLIX &
JADAVPUR UNI