3D Printing - Robert Bosch GMBH PDF

Conference„ World Class Manufacturing“
17.03.2016 Ljubljana
Integration of Industrie 4.0 in the Bosch Production System

Dr. Thorsten Widmer
1 Intern | C/MPI | 05.10.2015

© Robert Bosch GmbH 2016. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Connected Industry- (Industrie 4.0)
Agenda
Influence of the connected world to production
Lean in a connected industry
Implementation of Industry 4.0 @ Bosch
Selected projects for Industry 4.0 @ Bosch
Conclusions
2 Intern | C/MPI | 05.10.2015

Agenda
Conclusions
3 Intern | C/MPI | 05.10.2015

4 Intern | C/MPI | 05.10.2015

Challenges and Opportunities
Volatile markets
German Industry
Individual customer German Industry 40 bn EUR/year
requirements 80% of additional
companies will investment
Shortened delivery have digital in industrial
times value streams 2 assets 2 Worldwide
Shortened product 50 billion
life cycles devices will
German Industry be connected
24/7 worldwide 30 bn EUR/year
German Industry
by 2020 1
service additional value
Ø 3,3 %/year growth
add by digital
Social behavior, in efficiency and
products &
new cooperation performance 2
services 2
Disruptive
business models
5 Intern | C/MPI | 05.10.2015
(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
Connected Industry (I 4.0): Definition
Fusion of the physical world of production with
the virtual world of information technology and
the internet.
Humans, machines, objects and systems are

connected via ICT and the internet and
communicate in a dynamic, real time optimized
and self-organised way.
In these intelligent production systems, all

instances of the added value chain from the
supplier over logistics to the customer are
connected across the company.
The industrial production can implement

individualized customer requests on the well-
known high-quality level, while reaching higher
flexibility and robustness as well as optimal
resource allocation.
6 Intern | C/MPI | 05.10.2015

Features of Connected Industry (I 4.0):
Fast integration
and flexible Open standards
configuration
Distributed People as Virtual real-time

intelligence key players representation
Digital
Secure value-
life-cycle
creation network
management
7 Intern | C/MPI | 05.10.2015

Influence in production
Volatilität
Volatility Konnektivität
Connectivity
Individualität
Individuality
Sensoren
Sensors
Dynamik
Dynamic Mass
Big Data
data
Production
Globalisierung
Globalization
Organisation
Organization
Menschen
People
8 Intern | C/MPI | 05.10.2015

Volatilität
Connectivity
Individualität
Individuality
Sensoren
Sensors
Dynamik
Dynamic Mass
Big Data
data
Production
Globalisierung
Globalization
Organisation
Organization
Menschen
People
9 Intern | C/MPI | 05.10.2015

Quantity and variants of industrial production
Number of units per product variant

1955
1980
Auto configurator
Globalization
VW-Käfer 1966
2000
1913
High
Complexity
“People can have the Model T in
any color – so long as it’s black” 1850
Henry Ford (1913)
Number of variants
Quelle: Koren, Y.: The global Manufacturing Revolution; zitiert aus: Bauernhansl, T.: Trend or Revolution – Integrated Industry – Industrie 4.0, Bosch Fertigungstagung 2013
10 Intern | C/MPI | 05.10.2015

Product life cycle
Users
5 [Bn.]
4
1 Mrd. in
3 1 bn. in 25 Jahren
8 Years
2
1 1 bn. in
130 Years
1800 1900 2000
The market penetration of new technologies is accelerating dramatically

11 Intern | C/MPI | 05.10.2015
Volatilität
Connectivity
Individualität
Individuality
Sensoren
Sensors
Dynamik
Dynamic Mass
Big Data
data
Production
Globalisierung
Globalization
Organisation
Organization
Menschen
People
12 Intern | C/MPI | 05.10.2015

Individualized products
Individualized products meet customer requirements

13 Intern | C/MPI | 05.10.2015
Individualized production technologies
 Rapid Prototyping / Tooling
 e.g. injection molding
(contour adapted cooling channels)
 Rapid Manufacturing
 Aerospace
turbine
(<10.000 pcs/year) blades
acetabulum dental technology

 Medical Industry
(<50.000 pcs/year)
hearing devices
There are a number of applications for individualized production technologies

14 Intern | C/MPI | 05.10.2015
Individualized production technologies
 Rapid Prototyping / Tooling
 e.g. injection molding
(contour adapted cooling channels)
3D Metal Printing - Principle of SLM and EBM
3D printing allows fast and highly flexible adaptation to customer requirements

50 Bosch applications in various business units
15 Intern | C/MPI | 05.10.2015
Rapid Prototyping with 3D Printing
Traditional
3D 2D Required Prototype
Requirements … Prototype
Model Drawings Tools Delivered to
Gathering Machined
Created Created 2-5 days Customer
3 Days 1 Day 1 Day 2-5 Days 3-5 Days 1 Day
Total Delivery Time up to 13 days
3D Printed
3D Prototype Prototype
Requirements Model is printed Delivered to
Gathering Created overnight Customer
Metal 3D Printed (SLM)
3 Days 1 Day 0-1 Days 1 Day
(depending on print time)
High equipment allow flexibility and short lead
-
times
70%
Total Delivery Time < 3 days
improved market opportunities in volatile environment
16 Intern | C/MPI | 05.10.2015
Volatilität
Connectivity
Individualität
Individuality
Sensoren
Sensors
Dynamik
Dynamic Mass
Big Data
data
Production
Globalisierung
Globalization
Organisation
Organization
Menschen
People
17 Intern | C/MPI | 05.10.2015

Internet of Things - Development of a world network
1995 2005 2015 2020
of 5.7 bn.1
of 6.5 bn.1
0.8% connected2 of 7.3 bn.1
15.8% connected2 of 7.7 bn.1
0.5 bn. connected devices 44% connected2
12.5 bn. connected devices 60% connected2
0.1 connected devices/people 25 bn. connected devices
1.9 connected devices/people 50 bn. connected devices
3.3 connected devices/people
6.5 connected devices/people
World population People with access to the internet
18 Intern | C/MPI | 05.10.2015

(1) Source: United Nations Population Division (2) Source: Internet live stats, International Telecommunication Union (ITU) (3) Source: Cisco IBSG April 2011
Lead provider: Sensor applications in industrial environments
connected. . .
 building
 lines
 machinery
 Transport - and
storage containers
 Smart devices
, , , allow innovative
service models
19 Intern | C/MPI | 05.10.2015

Smart Plant
Business process
Business process
Business process
Object
Model Object
Model
Suppliers or Customer or
other Bosch other Bosch
plant OXOX plant
Machining
Object Assembly Object
Objects have their image (object model) in the cloud. Cross-linking

of objects is made possible. Created new potential for lean production.
20 Intern | C/MPI | 05.10.2015
Example: logistics batches and transparency
Trolley mit Dispatchliste Real time Dispatchliste

Machining
… …
Automatische Zuweisung von

Chargenzu Supermarkt
Regalen
In parts smart factories already exist. Automatic allocation of
batches to supermarkets or processes with high transparency.
21 Intern | C/MPI | 05.10.2015
Volatilität
Connectivity
Individualität
Individuality
Sensoren
Sensors
Dynamik
Dynamic Mass
Big Data
data
Production
Globalisierung
Globalization
Organisation
Organization
Menschen
People
22 Intern | C/MPI | 05.10.2015

Use of "Big Data" in production
Example of data
recording: RFID (Radio
Frequency Identification)
Problem
Supplier or Deviation from Customer or
other Bosch other Bosch
plants
target state plants
OXOX
Machining
Object Assembly
Problem
Data recording Data Mining Data evaluation Decision
23 Intern | C/MPI | 05.10.2015

Agenda
Conclusions
24 Intern | C/MPI | 05.10.2015

BPS is the framework of Industry 4.0
Bosch Produktions System
“We fascinate our customers and employees by delivering competitive products from an
agile and sustainably waste-free value stream.”
Industry 4.0
Fusion of the physical world of production with the virtual world of information technology and the internet.
Humans, machines, objects and systems are connected via ICT and the internet and communicate in a dynamic, real time optimized and
self-organised way.
Industry 4.0 defines a digital toolset, that supports the BPS-Vision of competitive
In these intelligent production systems, all instances of the added value chain from the supplier over logistics to the customer are
products from an agile and sustainably waste-free value stream!
connected across the company.
The industrial production can implement individualized customer requests on the well-known high-quality level, while reaching higher
flexibility and robustness as well as optimal resource allocation.
25 Intern | C/MPI | 05.10.2015

BPS principles in Industry 4.0
The BPS principles form the basis for action and cooperation among the various functions in the design of a sustainably waste-
free and agile order fulfillment process.
Pull principle We produce and supply only what the customer wants.
We avoid errors by means of preventive measures in order to deliver flawless products to the
Fault prevention
customer.
Process orientation We develop and optimize our processes holistically.
Flexibility We adapt our products and services quickly and effectively to current customer requirements.
Standardisation We standardize our processes and implement best-in-class solutions.

Our procedures are self-explanatory and straightforward; deviations from the target situation are
Transparency
immediately apparent.
Continuous improvement We are developing continually and in a targeted way.
We know our tasks, competencies and responsibilities and carry them out actively and
Personal responsibility
independently.
26 Intern | C/MPI | 05.10.2015

Pull principle and Industry 4.0
We produce and supply only what the customer wants.
Bosch Production System Industry 4.0 potential

Operating the loop Operating the loop
• Mainly paper-based • Information transfer via
information transfer electronic Kanban without
Example
with manual Kanban e manual handling

handling • Automatic lot and sequen-
• Manual lot and se- ce formation
Machining Testing
quence formation Machining Testing
• “Continuous” recalculation
• Only occasional re- of loop
calculation of loop
Evaluation:
 Benefit:  Significant reduction of manual effort for control loop handling and calculation
 Improved stability of control loop due to higher data quality, “continuous” recalculation and elimination of human
errors
 Risk:  Reduced comprehension of system’s mode of operation compared to physical control loop
27 Intern | C/MPI | 05.10.2015

Transparency and Industry 4.0
Our procedures are self-explanatory and straightforward; deviations from the target situation are immediately apparent.
“Haptic transparency” “Digital transparency”

• Easy-to-understand control • Sensory real-time gathering of
SMT loops system status
Example
• Reduction of complexity MES

MES • “Big data” analysis
• Unambiguous material flow • Comprehensive data
• “Go to Gemba” as key preparation
element • Mastering complexity
Evaluation:
 Benefit:  Accurate real-time data available
 “Data history” for detailed analysis available
 Risk:  Data preparation is not comprehensive enough to support today’s shopfloor personnel in all aspects of CIP
 Even less “Go to Gemba” than today
28 Intern | C/MPI | 05.10.2015

Personal responsibility and Industry 4.0
We know our tasks, competencies and responsibilities and carry them out actively and independently.
Shopfloormanagement Shopfloormanagement
• Manual data collection • Automatic data collec-
• Manual data analysis tion
Example
• Discussion of impro- • Mainly automatic data

vement activities in analysis
teams • Discussion of improve-
ment activities in
teams
Evaluation:
 Benefit:  Relieve from time-consuming routine tasks
 Manual data collection
 Accelerated research for causes of errors
 Risk:  Strict IT-guidance causes resignation of employees
29 Intern | C/MPI | 05.10.2015

How does Industry 4.0 support BPS?
Industry 4.0 supports BPS mainly in two ways:
Enhancing transparency Relief from routine tasks

• Transparency is the essential prerequisite for • Reduction of routine tasks increases productivity and
continuous improvement (CIP) diminishes non-value-add
• Continuous improvement is our way to strive for • It is one possible approach towards the BPS vision
sustainably waste-free processes (BPS vision) Examples:
Electronic
Maintenance
Kanban
and operator
handling
support
(Levelling and
system
Consumption
(TPM)
Control)
Autonomous
Intelligent
milkrun robots
Supermarket
(cyclic
(Consumption
material
Control)
supply)
30 Intern | C/MPI | 05.10.2015

How does Industry 4.0 support BPS?
Industry 4.0 supports BPS mainly in two ways:
Enhancing transparency Relief from routine tasks

• Transparency is the essential prerequisite for • Reduction of routine tasks increases productivity and
continuous improvement (CIP) diminishes non-value-add
• Continuous improvement is our way to strive for • It is one possible approach towards the BPS vision
sustainably waste-free processes (BPS vision) Examples:
Electronic
Maintenance
Kanban
and operator
handling
support
(Levelling and
system
Consumption
(TPM)
Control)
Autonomous
Intelligent
milkrun robots
Supermarket
(cyclic
(Consumption
material
Control)
supply)
31 Intern | C/MPI | 05.10.2015

Impacts of Industry 4.0 on transparency
Industry 4.0 does not naturally support transparency; rather it may enhance or diminish!
Enhancing transparency Diminishing transparency
Improved data quality due to sensory instead of Complexity rises to a degree incomprehensive
manual capturing to humans
High frequency, quasi continuous, data

System acts without knowledge of operator
gathering
Collected data is incomprehensive to CIP

Timely, quasi real-time, data provision
responsible
Recording of whole value stream ramp to ramp Industry 4.0 implemented in immature value
or supplier to customer stream (ambiguous, unstandardized, instable)
Paper-based shopfloor management shut down

Easy availability of data history
before Industry 4.0 reliably applied
…at low personnel effort To avoid theses effects we need to consider guidelines!
32 Intern | C/MPI | 05.10.2015
Agenda
Conclusions
33 Intern | C/MPI | 05.10.2015

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
04.13 03.14 10.14 04.15

Abschlußbericht & Start Industrial Reorganisation Erweiterung
External
Start Plattform I 4.0 Internet Consortium Nationaler IT-Gipfel Plattform I 4.0
05.13 11.13 01.15

Bosch Duale Project Innovation Cluster
Strategie I 4.0 I 4.0@Bosch Connected Industry @
Bosch
Bosch
04.13 09.13 11.14 07.15

Hermes Award VDA Logistic Award I 4.0 Award “Ort der Ideen” &
Open Core Supply Chain Multi Product Line Lean Production
Engineering Homburg 1 Homburg 2 I4.0@Blaichach
34 Intern | C/MPI | 05.10.2015

Dual strategy
Lead Provider Lead Operator
System manufacturer/ Product manufacturer/
Production resource view 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 Bosch Sensortec

Innovations
Innovationsmanagement 250+ Bosch plants world wide

Packaging Technology Logistik
Assembly Systems Machine Platforms  Manufacturer of products

and Special Machinery
 Machine operator
Bosch Connected Data Mining, Big Data  Plant operator
Devices & Solutions
 Interface to customers/suppliers
... Center of Competence
RFID@BOSCH
Experience out of more than 100+ pilot projects for
... connected industry
35 Intern | C/MPI | 05.10.2015

Plattform
I4.0 Customers
VDA
ZVEI
Suppliers
BITCOM Innovation Cluster

Connected Industry Universities
VDMA
Partners
IIC1
Publicly funded
DRC2 projects
…
36 Intern | C/MPI | 05.10.2015

ERP
„Pilot stream“
MES
Controls
RB
I 4.0 Innovation Level
Actuators
Pilot projects
development, part application phase

assembly testing usage
engineering tooling commissioning out
„Main stream“
new “I4.0-enabled” MAE1 and solutions
RB
existing MAE1 and solutions will be “I4.0-upgraded”
existing MAE1 and solutions
Starting Level Migration Level 1 Migration Level 2

Pilot applications I 4.0 Value Streams I4.0 IPNs2
2013 2014 2015 2016 2017 2018 2019 2020 …
37 Intern | C/MPI | 05.10.2015

Agenda
Conclusions
38 Intern | C/MPI | 05.10.2015

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.
39 Intern | C/MPI | 05.10.2015

Flows of Goods,
digitally recorded:
Due to automatic data
capture the supply Faster Work with
chain is virtually technical aids:
mapped and logistics Warehouse associates
are optimized. receive their orders
and operating
instructions directly on
displays.
RFID technology:
In pilot projects the
plant is already aware
of the condition of Smart glasses:
products and Technical aids like smart
containers via RFID glasses make work
technology. easier.
Initial tests are being
conducted in Bosch
plants.
40 Intern | C/MPI | 05.10.2015

Models at top speed:
A component is drafted
on the computer, sent
to the device, and Predictive quality:
produced there from a Close examination of
base material. questionable parts
based on millions of
Models at top speed: data points.
A component is
drafted on the
computer and send to
the 3D-printer.
Rapid prototyping:
3D- printers have a
place in the smart
production. One Data mining for
application at Bosch is quality:
prototype production. At the Anderson plant
in the U.S. “data
mining” already gets
used to improve
quality.
41 Intern | C/MPI | 05.10.2015

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.
Predictive “Nexo” Smart

Maintenance: Tightening:
A pilot is up and Screwdriver is able to
running At Bosch. measure and submit
Bosch Software the tightening torque
innovations offers this and screwing angle for
type of solution. quality prove.
42 Intern | C/MPI | 05.10.2015

Lead Provider: APAS family – Changeable Automation
APAS family – your partner on the path of the production of tomorrow.
flexibel
 Simple and fast application in different production environments
mobil
 agile production island
collaborativ
 direct and safe collaboration between man and machine without the
need of additional guards
vernetzt
 exchange of workflows between APAS family systems
 Ethernet connection ensures efficient remote maintenance
Flexible automation for the smart factory of the future

43 Intern | C/MPI | 05.10.2015
Example - Multi Product Line
Use Case X User X Provider
Assembly of hydraulic valves for mobile applications
I 4.0 Approach
 Precise product identification via RFID, Work instruction
synchronization, individual assembly steps
 Flexible autonomous work stations, virtual user-specific work
space configuration
 Line/product status via „Active Cockpit“
Result
 Inventory reduction ~50 %
 Output increase ~20 %, no setup time
 Savings up to 0,5 Mio EUR (year/line)
Adaptive assembly line to increase flexibility with

product variance
44 Intern | C/MPI | 05.10.2015
Agenda
Conclusions
45 Intern | C/MPI | 05.10.2015

Conclusions
People remain in a connected factory

in a central role
- Lean production also forms in a connected factory the

framework for a waste-free production.
- I4.0 solutions support lean production through improved
transparency and avoidance of routine work
We are pursuing a dual strategy as a leading

supplier and lead provider for rapid
development of mature I 4.0 solutions
46 Intern | C/MPI | 05.10.2015

Connected Industrie- (Industrie 4.0)
Thank you!
47 Intern | C/MPI | 05.10.2015


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Conference„ World Class Manufacturing“

Integration of Industrie 4.0 in the Bosch Production System

1 Intern | C/MPI | 05.10.2015

Lean in a connected industry

Implementation of Industry 4.0 @ Bosch

Selected projects for Industry 4.0 @ Bosch

2 Intern | C/MPI | 05.10.2015

Lean in a connected industry

Implementation of Industry 4.0 @ Bosch

Selected projects for Industry 4.0 @ Bosch

3 Intern | C/MPI | 05.10.2015

4 Intern | C/MPI | 05.10.2015

Humans, machines, objects and systems are

In these intelligent production systems, all

The industrial production can implement

6 Intern | C/MPI | 05.10.2015

Distributed People as Virtual real-time

7 Intern | C/MPI | 05.10.2015

8 Intern | C/MPI | 05.10.2015

9 Intern | C/MPI | 05.10.2015

Number of units per product variant

10 Intern | C/MPI | 05.10.2015

1800 1900 2000

The market penetration of new technologies is accelerating dramatically

12 Intern | C/MPI | 05.10.2015

Individualized products meet customer requirements

acetabulum dental technology

There are a number of applications for individualized production technologies

3D Metal Printing - Principle of SLM and EBM

3D printing allows fast and highly flexible adaptation to customer requirements

3 Days 1 Day 1 Day 2-5 Days 3-5 Days 1 Day

Total Delivery Time up to 13 days

17 Intern | C/MPI | 05.10.2015

1995 2005 2015 2020

World population People with access to the internet

18 Intern | C/MPI | 05.10.2015

19 Intern | C/MPI | 05.10.2015

Objects have their image (object model) in the cloud. Cross-linking

Trolley mit Dispatchliste Real time Dispatchliste

Automatische Zuweisung von

22 Intern | C/MPI | 05.10.2015

Data recording Data Mining Data evaluation Decision

23 Intern | C/MPI | 05.10.2015

Lean in a connected industry

Implementation of Industry 4.0 @ Bosch

Selected projects for Industry 4.0 @ Bosch

24 Intern | C/MPI | 05.10.2015

25 Intern | C/MPI | 05.10.2015

Standardisation We standardize our processes and implement best-in-class solutions.

26 Intern | C/MPI | 05.10.2015

Bosch Production System Industry 4.0 potential

with manual Kanban e manual handling

27 Intern | C/MPI | 05.10.2015

Bosch Production System Industry 4.0 potential

“Haptic transparency” “Digital transparency”

• Reduction of complexity MES

28 Intern | C/MPI | 05.10.2015

Bosch Production System Industry 4.0 potential

• Discussion of impro- • Mainly automatic data

29 Intern | C/MPI | 05.10.2015

Enhancing transparency Relief from routine tasks

30 Intern | C/MPI | 05.10.2015

Enhancing transparency Relief from routine tasks