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Connected Industry (Industrie 4.

0)

Industrie 4.0@Bosch 4.0@Bosch


Dr. Thorsten Widmer

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Connected Industry (Industrie 4.0)

Internet: driver of the connected world


Web 0 Web 1.0 Web 2.0 Web 3.0
Degree of connection

Internet of things and services


Connection of the digital with
the physical world

Connected business models

Connected
Business-services
people
Connected
companies Web-services

Connected
documents Java, XML

Browser, Webserver

1995 2000 2005 2020

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Connected Industry (Industrie 4.0)

Megatrend: connected people

Of 5.7 billion people … Of 6.5 billion people … Of 7.3 billion people …


… 0.7 % are connected. … 15 % are connected. … 75 % are connected.

1995 2005 2015

World population People with internet access

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Connected Industry (Industrie 4.0)

Internet of things and services

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Connected Industry (Industrie 4.0)

The world is changing – chances and challenges


Volatile markets
More than 50 billion
devices will be
Individual customer connected by 2020 1
requirements

Shortened delivery
times

Shortened product 40 bn EUR/year


80% of companies will
life cycles additional
have digital value
investment in industrial
streams 2
24/7 worldwide assets 2
service

Social behavior, 30 bn EUR/year 18%


new cooperation additional value add by growth
digital in efficiency
Disruptive products & services 2 and performance 2
business models

1) Source: Cisco IBSG April 2011, device per person


2) Source: PWC Study October 2014, Industry 4.0 – Chances and Opportunities of the 4th industrial revolution

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Connected Industry (Industrie 4.0)

Revolution or evolution? At least with disruptive potential!

Technology New
Trends Business Models
 Web based services
 OPC UA  Pay per use; pay per outcome
 Web-Services  Long Tail
 RFID  Multi Sided Platforms
 Vertical Integration  Freemium
 Open Busines Models
 Horizontal Integration  …
 Decentralized Systems
 Augmented Reality New
 Geture Control Dynamics
 3D-Printing  Market & Customer Behavior
 Sensoric  Social Networking
 “Generation Y”
 Miniaturization  Law of Moore
…  Shortened life cycles
 …

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Connected Industry (Industrie 4.0)

Our criteria for Connected Industry


Fast Open
integration standards
and flexible
configuration

People as Virtual
Distributed key players real-time
intelligence representation

Secure Digital
value-creation life-cycle
network management

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Connected Industry (Industrie 4.0)

I4.0 to support people – a prerequisite for success


Physical assistance
by amplify capability

Innovative forms of
learning
mobile, personalized, situative
 Extended space for decisions
and participation Networked working
 Opportunities for stress by multi-modal interaction
regulation human-machine and
 New challenges and human-human
opportunities for engineer´s and Maintenance and planning
skilled worker´s knowledge
assistance
Criterion for success : location-based,
I 4.0  „CIM 2.0“ context-adaptive
CIM: Computer Integrated Manufacturing

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Connected Industry (Industrie 4.0)

I 4.0 it’s straight on the way & Bosch is part of shaping future
2013 2014 2015
01 02 03 04 05 06 07 08 09 10 11 12 01 02 03 04 05 06 07 08 09 10 11 12 01 02 03 04 05 06 07 08 09 10 11 12

04.2013 03.2014 10.2014 04.2015


Final report & start Start Industrial Reorganisation Extension
Plattform I 4.0 Internet Consortium National IT-Gipfel Plattform I 4.0

05.2013 11.2013 01.2015


Bosch Dual Project Innovation Cluster
Strategy for I 4.0 I 4.0@Bosch Connected Industry @ Bosch
Bosch

04.2013 09.2013 11.2014 07.15


Hermes Award VDA Logistic Award I 4.0 Award Awarded place of ideas
Open Core Supply Chain Multi Productline Lean Production
Engineering Homburg 1 Homburg 2 I4.0@Blaichach

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Connected Industry (Industrie 4.0)

Bosch dual strategy Connected Industry (I 4.0)


Lead Provider Lead Operator
System manufacturer/Production resource view Product manufacturer/Product view

I 4.0 solution provider enabler technology or


with external business internal I 4.0 solution provider

Drive and Control Industrial Sensor


Technology Solutions

Bosch Software
Innovations Bosch Sensortec

Innovations-
Packaging Technology management Logistik

250+ Bosch plants world wide


Assembly Systems Machine Platforms
and Special Machinery
 Manufacturer of products
Bosch Connected
Data Mining, Big Data
 Machine operator
Devices & Solutions
 Plant operator
... Center of Competence
 Interface to customers/suppliers
RFID@BOSCH

Many practical pilot applications are


...
bundled within the Innovation Cluster CI

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Connected Industry (Industrie 4.0)

The Innovation Cluster Connected Industry


Plattform
I4.0
Customers
VDA

ZVEI Bosch- Steering


Divisions Committee Suppliers

Innovation
BITKOM Cluster
Connected Universities
Industry

VDMA
Corporate Employee Partners
Functions Representatives

IIC1
Publicly funded
DRC2 projects

(1) Industrial Internet Consortium (2) Development Research Center China

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Lead
Connected Industry (Industrie 4.0) Operator

Implementation roadmap for Bosch plants


Starting Level Migration Level 1 Migration Level 2
(bottom up) (bottom up, top down) (top down, bottom up)
Pilot applications Pilot I 4.0 Value Stream Pilot IPN I 4.0
I 4.0 innovation level

RB „pilot
stream“

Pilot projects

new machinery/equipment and solutions

existing machinery/equipment and solutions modernized


RB „main
stream“ today existing machinery/equipment and solutions

2013

Systematic roll out for holistic approach driven by strategically focused pilots
IPN = International production network
the systematic and fast I 4.0 transfer and roll out to be ensured by Project I 4.0 @ Bosch

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Connected Industry (Industrie 4.0)
I 4.0 feature: distributed intelligence
Example: autonomous rollers
• Parts transport from the
supermarket to the production line
• Autonomous navigation of the rollers
on the shop floor
• Collecting, processing and
communicating data
• Independent work of logistics tasks
through swarm

Example: flexible
manufacturing modules with
own controls
• Module knows its technical skills
and autonomously organizes its
work steps in the process
• Module detects different parts
and processes them

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Connected Industry (Industrie 4.0)
I 4.0 feature: open standards

Compatible equipment, machinery, components and services


• Easy integration of machines and components from different manufacturers
• Harmonized interfaces: e.g. of semantics, protocols, connectors
• Platform-independent and universal interfaces

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Connected Industry (Industrie 4.0)
I 4.0 feature: people as key players
People play the decisive role
in the connected plant
• Decisions based on contextual
digital information
• Mastering complexity through new
ways of visualization and
operation

New ways of learning


• Individual integration of the
employee in the work process
• Assistance functions and ability
amplifier for people
• Health and well-being through
adaptive workplace ergonomics

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Connected Industry (Industrie 4.0)
I 4.0 feature: fast integration and flexible configuration
Value-added network based
on comprehensive
broadband infrastructure
• Guaranteed latency, reliability
and quality
• Ad hoc connection of people,
processes and machines

Flexible integration and (re)


configuration of machines
• Quick setup of process modules
for new tasks
• Modules are strung together ad
hoc to form a large-scale
production line
• "Plug and Produce" - modules can
be interchanged quickly

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Connected Industry (Industrie 4.0)
I 4.0 feature: secure value-creation network
Secure cross-company value-
creation networks
• Secure infrastructure for people,
processes, and data
• Protection of the means of
production and the company’s IT
systems from attacks and
disturbances (data security)

• Unique tamper-proof digital


identity for each intelligent
component, machine, and
product
• Tight and secure collaboration
between people and machines
(safety)

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Lead
Connected Industry (Industrie 4.0) Operator

Bosch with numerous examples straight on the way

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Lead
Connected Industry (Industrie 4.0) Operator

Bosch with numerous examples straight on the way


Round or angular?:
Robots share the Components tell
load: machines how they
Handling of dangerous, need to be shaped. The
strenuous, or system then adjusts
monotonous tasks so itself accordingly.
associates don`t have
to.

Bosch Rexroth in
The APAS Family: Homburg:
The mobile production A manufacturing
assistants of the APAS system with batch size
family already work of one already is in
hand in hand with their place producing many
human colleagues. products on one line.

APAS: Automated production assistant

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Lead Lead
Connected Industry (Industrie 4.0) Provider Operator

Pilot value stream HoP2 – step one was successful


Use Case
Assembly of hydraulic valves for mobile
applications in HoP2

I 4.0 Approach
 Unique product identification by RFID, flexible
work sequence
 Exchangeable autonomous stations,
user-specific work place configuration
 Line-/product status via „active Cockpit“
ERP

Results
 Stock reduction ~ 50 %
 Output increase ~ 20 %, no setup time
 Savings up to 0,5 Mio. EUR (year / line)

Adaptive assembly line to control high product variance

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Lead
Connected Industry (Industrie 4.0) Operator

Bosch with numerous examples straight on the way


Faster Work with
Flows of Goods, technical aids:
digitally recorded: Warehouse associates
Due to automatic data receive their orders
capture the supply and operating
chain is virtually instructions directly on
mapped and logistics displays.
are optimized.

Smart glasses:
RFID technology: Technical aids like
In pilot projects the smart glasses make
plant is already aware work easier.
of the condition of Initial tests are being
products and conducted in Bosch
containers via RFID plants.
technology.

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Lead
Connected Industry (Industrie 4.0) Operator

Transparent Supply Chain


Use Case
 Logistic enhancements in the entire value chain
(common rail: injector, rail; pump), enabled by
RFID
I 4.0 Approach
 Explicit identification of products as enabler of
the internet of things
 Product memory e.g. quality data
 Decentralized self monitoring (Kanban, …)
 Automatic order processing throughout the entire
value chain

Result / Targets
 Reduction of internal transport ~ 10%
 Stock reduction ~ 30%
 Efficiency increase in processes ~ 10%

Real time transparency increases process efficiency

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Lead Lead
Connected Industry (Industrie 4.0) Provider Operator

Shopfloor Suite
Use Case
Comprehensive solution package
“Shopfloor Service Suite" with Active
Cockpit and Shopfloor Management Cycle

I 4.0 Approach
 Role specific information is mobile available
 Digital support for PDCA, f. e. KPIs
 Management of deviations, shift book
 Connection of shopfloor, SAP and office

Result / Targets
 Current status in real time available
 Higher transparency of production data

Role specific & customized information in real time and for communication support

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Lead
Connected Industry (Industrie 4.0) Operator

Bosch with numerous examples straight on the way


Models at top speed:
A component is drafted Predictive quality:
on the computer, sent Close examination of
to the device, and questionable parts
produced there from a based on millions of
base material. data points.

Models at top speed:


A component is
drafted on the
computer and send to
the 3D-printer.

Rapid prototyping:
3D- printers have a Data mining for
place in the smart quality:
production. One At the Anderson plant
application at Bosch is in the U.S. “data
prototype production. mining” already gets
used to improve
quality.

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Lead
Connected Industry (Industrie 4.0) Operator

Bosch with numerous examples straight on the way


Data from Tools
Facilities predict Tools are networked
problems: and send important
Smart lines analyze data to server for
data and report quality proof.
problems directly to the
service department.

“Nexo” Smart
Predictive Tightening:
Maintenance: Screwdriver is able to
A pilot is up and measure and submit
running At Bosch. the tightening torque
Bosch Software and screwing angle for
innovations offers this quality prove.
type of solution.

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Connected Industry (Industrie 4.0)
Lead Operator – Pilot: Energy management (NuP1)
Use Case
 Network charge discount through peak
reduction management

I 4.0 Approach
 Peak reduction due to dynamic
management of bulk consumers
 Sensors are checking the energy
consumption and bulk consumers get
shut down if possible during peaks
 Load cold storage at night (discharge of chillers
at daytime, use of cheap energy)

Result / Targets
 Grading of peaks in consumption
 Reduction of energy consumption

Evenly energy consumption 24/7/12

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Lead Lead
Connected Industry (Industrie 4.0) Provider Operator

NEXO – Smart Tightening


NEXO – Tightening System
Use Case
Cordless, tightening system for
safety / functional relevant
 Intelligent use of tightening process data of all
applications. Fully integrated tools in a production environment
process controller. Wireless
communication capabilities.

I 4.0 Approach
Source Make Deliver
 Communication between tightening system and
(Data Provisioning) (Service Production) (Service Delivery) data base; automated data analysis; configured
Rexroth Tightening
Systems (Devices)
Private Cloud
 Big Data handling
Process Quality
Manager for
visualization (cockpit view)
 User Management
 Alerting algorithms
Tightening Systems
 Cockpit
 Real time information of experts about process
anomalies based on statistics and expert rules
Connectivity

 Statistical algorithms  Alerting


 Web-based UI  Drill down
 Statistics

Result / Targets
 Reduction downtime ~ 10 %
 Reduction failure cost ~ 10%
 Reaction time in case of failure occurrence

Intelligent devices as enabler for intelligent process data analytics

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Lead Lead
Connected Industry (Industrie 4.0) Provider Operator

Enabler Connected Industry – some examples …


Software Solutions: e. g.
Manufacturing Execution:
Bosch IoT Suite
e.g. OpCon MES

Assmbly Technologies:
Sensor Solutions:
e.g. Smart
e.g. MEMS
Workstation

Human & Machine: e.g. Automation: e.g. cabinet


APAS free drive technology

Multi-Ethernet

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Connected Industry (Industrie 4.0)

Our People are our key players for Connected Industry

Tasks Organization

People as
key players Leadership
Safety &
Workplace Enabling
Collaboration Security
Change

Qualification Communication

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Connected Industry @ Bosch (I 4.0)

Chance & challenge: from individual actor to orchestra


We are just at the very
Customer
beginning with many
Service
steps to go… Users &
Operators Suppliers

System
I 4.0 techno-
integrators
logies Research &
Science

potential
technological efficiency

I 4.0
current
situation
state-of-the art  Alignment activities to common interests

potential
 Explorative approach & implementation speed
status quo
 Long term viable IT architecture
status quo
techno-  Synergies & standards
logies
 Trust & security

R&D effort  Legal framework

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Connected Industry (Industrie 4.0)

Thank you for your attention!

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