Professional Documents
Culture Documents
Industrie4.0 Smart Manufacturing For The Future en PDF
Industrie4.0 Smart Manufacturing For The Future en PDF
0
Smart Manufacturing
for the Future
Foreword One of 10 “Future Projects” identified by the German
government as part of its High-Tech Strategy 2020
Action Plan, the INDUSTRIE 4.0 project represents
a major opportunity for Germany to establish itself
as an integrated industry lead market and provider.
Photo: DMG MORI AG (cover), Germany Trade & Invest, acatech/D.Ausserhofer, Jim Rakete (left to right)
INDUSTRIE 4.0 is the German strategic initiative to The Internet of Things is finding its way into pro-
take up a pioneering role in industrial IT which is duction. Semantic machine-to-machine commu-
currently revolutionizing the manufacturing engi- nication revolutionizes factories by decentralized
neering sector. INDUSTRIE 4.0’s strategy will allow control. Embedded digital product memories guide
Germany to stay a globally competitive high-wage the flexible work piece flow through smart facto-
economy. Hence, cyber-physical systems (CPS) im- ries, so that low-volume, high-mix production is
prove resource productivity and efficiency and en- realized in a cost-efficient way. A new generation
able more flexible models of work organization. of industrial assistant systems using augmented
Companies that use CPS will have a clear advan- reality and multimodal interaction will help
tage when it comes to recruiting the best employ- factory workers to deal with the complexity of
ees, since they can offer a better work-life balance. cyber-physical production and enable new forms
Germany has the potential to develop its posi- of collaboration by digital social media. Since on-
tion as a leading supplier and to become the lead- demand production of highly individualized
ing market for INDUSTRIE 4.0 solutions - thereby products like cars or kitchens requires short logistic
strengthening the German economy, intensifying chains in the markets where they are used, pro-
international cooperation and creating new, internet- duction is guaranteed to remain the backbone of
based markets. Germany’s economic performance.
The second period of radical transformation – with Germany’s position as an embedded systems tech-
the advent of industrial production and the birth of nology leader gives birth to enabling cyber-physical
the factory at the start of the 20th century – was system (CPS) technologies which ingeniously
no less precipitous; ushering in as it did an age of marry the digital virtual world with the real world.
affordable consumer products for mass consump- Cyber-physical production systems (CPPS) made
tion. In the late 1960s the use of electronics and IT up of smart machines, logistics systems and pro-
in industrial processes opened the door to a new duction facilities allow peerless ICT-based inte-
age of optimized and automated production. gration for vertically integrated and networked
manufacturing.
Today we stand on the cusp of a fourth industrial
revolution; one which promises to marry the worlds One of 10 “Future Projects” identified by the German
of production and network connectivity in an “In- government as part of its High-Tech Strategy 2020
ternet of Things” which makes “INDUSTRIE 4.0” a Action Plan to pursue innovation objectives over
reality. “Smart production” becomes the norm in a a 10 to 15-year period, INDUSTRIE 4.0 represents a
world where intelligent ICT-based machines, sys- major opportunity for Germany to secure its tech-
tems and networks are capable of independently nological leadership role and establish itself as an
exchanging and responding to information to man- INDUSTRIE 4.0 lead market and provider.
age industrial production processes.
Germany has the ideal conditions to become a
The conditions which make the fourth industrial global leader in innovative, internet-based pro-
revolution or INDUSTRIE 4.0 possible are unique to duction technology and service provision. Tech-
Germany. It is no idle boast to claim that nowhere nological leadership and vision in the fields of
else in the world do the required conditions neces- manufacturing, automation and software-based
sary for the fourth industrial revolution exist. This embedded systems, as well as historically strong
brave new world of decentralized, autonomous industrial networks, lay the cornerstone for the
real-time production being pioneered in Germany long-term success of the INDUSTRIE 4.0 project.
has its basis in two things: Germany’s continued
role as one of the world’s most competitive and in-
novative manufacturing industry sectors; and the
country’s technological leadership in industrial pro-
duction research and development.
Photo: istockphoto/4x6
Content
5
INDUSTRIE 4.0 – What is it?
What is smart industry and what does “INDUS- INDUSTRIE 4.0 connects embedded system pro-
TRIE 4.0” mean exactly? Smart industry or “INDUS- duction technologies and smart production pro-
TRIE 4.0” refers to the technological evolution from cesses to pave the way to a new technological age
embedded systems to cyber-physical systems. which will radically transform industry and produc-
Put simply, INDUSTRIE 4.0 represents the coming tion value chains and business models (e.g. “smart
fourth industrial revolution on the way to an In- factory”).
ternet of Things, Data and Services. Decentralized
intelligence helps create intelligent object network- Technological Background: Embed-
ing and independent process management, with ded Systems and Networks
the interaction of the real and virtual worlds repre-
senting a crucial new aspect of the manufacturing Information and communication technologies (ICT)
and production process. INDUSTRIE 4.0 represents form the bedrock upon which tomorrow’s inno-
a paradigm shift from “centralized” to “decentral- vative solutions are built. Embedded systems and
ized” production – made possible by technological global networks – like the internet and the data
advances which constitute a reversal of conven- and services found there – are two major ICT mo-
tional production process logic. Simply put, this tors driving technological progress. Embedded
means that industrial production machinery no systems already play a central – if almost hidden –
longer simply “processes” the product, but that the role in all of our lives.
product communicates with the machinery to tell it
exactly what to do.
6
More than 98 percent of all processors produced Germany – Embedded Systems
worldwide are deployed in regulator, control, and Leader
monitor functions in devices for all facets of daily
life. For instance, they are there in everything from Germany is an international leader in embedded
vehicle ABS and ESP systems, smart phone commu- systems and also enjoys a leading position in se-
nication and information services and ordinary do- curity solutions and business enterprise software.
mestic household devices to industrial production Germany also boasts an enviable engineering repu-
plant systems. Embedded systems are the intelli- tation in matters system solutions-related and can
gent central control units at work in most modern call upon considerable semantic technologies and
technological products and devices. They typical- embedded systems know-how.
ly operate as information-processing systems “em-
bedded” within an “enclosing” product for a set Germany’s embedded system market currently
range of device-specific applications. These “con- generates around EUR 20 billion annually, a figure
nect” with the outside world using sensors and which is forecast to rise to more than EUR 40 billion
actuators; allowing embedded systems to be in- by 2020. The applications sector alone generates
creasingly interconnected with each other and annual turnover in the region of EUR 4 billion, with
the online world. an estimated value added factor of approximately
EUR 15 billion. As such, Germany’s embedded sys-
tems market is the third biggest in the world be-
From Industry 1.0 to INDUSTRIE 4.0
hind the USA and Japan.
The interplay between high performance software- Cyper-Physical Systems and the Inter-
based embedded systems and dedicated user in-
net of Things, Data and Services
terfaces which are integrated into digital networks
creates a completely new world of system func- The “The Evolution of Embedded Systems into the
tionality. Modern mobile telephones are perhaps Internet of Things, Data and Services” illustration
the most obvious example of this, offering as they depicts the vision of a global “Internet of Things,
do a complete bundle of applications and services Data and Services” through the evolutionary
which completely outstrip the device’s original development of embedded system as a result of
telephony function. Cyber-physical systems also their being networked over the internet. Closed
represent a paradigm break from existing business embedded systems (e.g. airbags) represent the
and market models, as revolutionary new starting point. Recommendations for the next step
applications, service providers and value chains to locally networked embedded systems were
become possible. already made in the National Roadmap Embed-
ded Systems 2009. acatech’s “Agenda CPS” study
Industry sectors including the automotive indus- extended the spectrum to global networking (one
try, the energy economy and, not least, produc- example being the intelligent networked road
tion technology (“INDUSTRIE 4.0”) for example, will junction that makes use of traffic jam informa-
in turn be transformed by these new value chain tion). Cyber-physical systems represent the next
models. Global megatrends of globalization, urban- stage on the road to the creation of smart cities
ization, demographic change and energy transfor- through the creation of an Internet of Things,
mation are the transformative forces driving the Data and Services.
technological impulse to identify solutions for a
world in flux. In the future, cyber-physical systems
will make contributions to human security, efficien-
cy, comfort and health in ways not previously
imaginable. In doing so, they will play a central part
in addressing the fundamental challenges posed by
demographic change, scarcity of natural resources,
sustainable mobility, and energy change.
8
What does INDUSTRIE 4.0 mean for However, because both traditional ERP and MES
the software sector – ERP or MES? functionalities remain indispensable to production
INDUSTRIE 4.0 has sparked a debate within the management, it remains unlikely that one software
German software industry as to whether enter- system will replace the other.
prise resource planning (ERP) or manufacturing ex-
ecution systems (MES) will establish themselves as A more likely scenario is the increasing convergence
the dominant software system force in production of the two systems, with the line dividing corpo-
environments. Some industry voices believe that rate IT and production IT becoming blurred. This
ERP software will be directly linked to process con- scenario matches the essence of interdisciplinary
trol systems (PCS) at the production level, thereby integration and the different stages of the product
eliminating the need for ERP software. Conversely, cycle foreseen in INDUSTRIE 4.0 (e.g. idea, develop-
a significant contingent considers MES software to ment, production, service, and phasing out). Soft-
be excellently situated for the implementation of ware systems utilized in INDUSTRIE 4.0 will also
INDUSTRIE 4.0. have to address new challenges including, for ex-
ample, data correlations, as a result of ever more
In reality, the answer is not as clear cut, as INDUS- semantic networks and learning applications and
TRIE 4.0 will also cause significant transformation the need to manage ever larger and more complex
in the field of production management software. amounts of data.
ICT as Innovation Motor for all Fields of Demand – Relevance of the Internet of the Future
Source: Germany Trade & Invest 2013 (based on “IKT als Innovationsmotor für alle Bedarfsfelder – die Relevanz des Internets der Zukunft” in
“Bericht der Promotorengruppe Kommunikation – Im Fokus: das Zukunftsprojekt Industrie 4.0, Handlungsempfehlungen zur Umsetzung”,
Forschungsunion 2012)
9
The Smart Factory – The Future High levels of automation come as standard in
of Automated Manufacturing the smart factory: this being made possible by a
flexible network of cyber-physical system-based
The merging of the virtual and the physical worlds production systems which, to a large extent, au-
through cyber-physical systems and the resulting tomatically oversee production processes. Flexible
fusion of technical processes and business process- production systems which are able to respond in
es are leading the way to a new industrial age best almost real-time conditions allow in-house produc-
defined by the INDUSTRIE 4.0 project’s “smart tion processes to be radically optimized. Produc-
factory” concept. tion advantages are not limited solely to one-off
production conditions, but can also be optimized
The deployment of cyber-physical systems in pro- according to a global network of adaptive and
duction systems gives birth to the “smart factory.” self-organizing production units belonging to more
Smart factory products, resources and processes than one operator.
are characterized by cyber-physical systems; pro-
viding significant real-time quality, time, resource,
and cost advantages in comparison with classic
production systems. The smart factory is designed
according to sustainable and service-oriented busi-
ness practices. These insist upon adaptability, flexi-
bility, self-adaptability and learning characteristics,
fault tolerance, and risk management.
10
This represents a production revolution in terms of ·· Optimized individual customer product manu-
both innovation and cost and time savings and the facturing via intelligent compilation of ideal pro-
creation of a “bottom-up” production value crea- duction system which factors account product
tion model whose networking capacity creates new properties, costs, logistics, security, reliability,
and more market opportunities. Smart factory pro- time, and sustainability considerations;
duction brings with it numerous advantages over ·· Resource efficient production;
conventional manufacture and production.
·· Tailored adjustments to the human workforce
These include: so that the machine adapts to the human
work cycle.
·· CPS-optimized production processes: smart fac-
tory “units” are able to determine and identify
their field(s) of activity, configuration options and
production conditions as well as communicate in-
dependently and wirelessly with other units;
Smart Factory 1
M2M-Communication
Application Platform
for Machines
Cyber-Physical Production
Systems (CPPS)
Launched in August 2006, the “High-Tech Strategy” The objectives set out in the High-Tech Strategy
represents the first national concept to bring key were continued and extended within the frame-
innovation and technology stakeholders together work of the “High-Tech Strategy 2020” launched
in a common purpose of advancing new technologies. in July 2010. Building on the initial successes of the
High-Tech Strategy, this successor initiative intends
The initiative combines the resources of all gov- to create lead markets, further intensify partner-
ernment ministries, setting billions of euros aside ship between science and industry, and continue to
annually for the development of cutting-edge improve the general conditions for innovation. The
technologies (R&D projects can also count on gen- High-Tech Strategy 2020 exists to establish Germany
erous financial support in the form of R&D grants). as a lead provider of science and technology-based
solutions in the fields of:
·· Climate/Energy
·· Health/Nutrition
·· Mobility
·· Security
·· Communication
12
High-Tech Strategy 2020 Agenda CPS
Action Plan
The objective of the Agenda CPS project led by the German
The German government passed the High-Tech National Academy of Science and Engineering (acatech) on be-
Strategy Action Plan in March 2012 for the further half of the Federal Ministry of Education and Research (BMBF)
implementation of the High-Tech Strategy. The is to establish an integrated CPS research agenda that allows
Action Plan identifies 10 “Future Projects” – includ- Germany to shape this technological revolution as a lead mar-
ing INDUSTRIE 4.0 – which are considered as being ket and provider in competition with other industrial and
critical to addressing and realizing current innova- technological players.
tion policy objectives as the focus of research and
innovation activity. Within these lighthouse pro- Agenda CPS has identified four major fields of application
jects, specific innovation objectives will be pursued up to the year 2025. These are “Energy” (cyber-physical
over a 10 to 15 year time frame. The INDUSTRIE 4.0 systems for the smart grid); “Mobility” (cyber-physical
project has been allocated funding of up to EUR 200 systems for networked mobility); “Health” (cyber-physical
million within the High-Tech Strategy 2020 Action systems for telemedicine and remote diagnosis); and, of
Plan. The coalition agreement for the 18th legisla- course, “Industry” (cyber-physical systems for industry and
tive period signed by the newly constituted automated production).
CDU-CSU-SPD coalition government of December 14,
2013, identifies the INDUSTRIE 4.0 future project as
an important measure in consolidating Germany’s ICT 2020: Research for Innovations –
technological leadership in the mechanical engi- IT Systems for INDUSTRIE 4.0
neering sector. The coalition government plans to
push ahead with the digitalization of tradition- Innovative ICT research (including IT systems for INDUSTRIE 4.0)
al industry with expansion into the area of “Smart is provided by the Federal Ministry of Education and Re-
Services” foreseen, as well as the strengthening of search (BMBF) in its “ICT 2020 – Research for Innovations”
projects and activities in the “Green IT” sector. program within the framework of the High-Tech Strategy
2020 and the federal government’s “Digital Germany 2015”
ICT strategy. Particular ICT research focus is concentrated in
Germany – Lead Market for the area of ICT in complex systems (e.g. embedded systems),
Cyber-Physical Systems 2020 new business processes and production methods as well as
the Internet of Things and Services. Research activities con-
As part of the country’s INDUSTRIE 4.0 project, ducted in the area of IT systems for cyber-physical systems,
Germany aims to be the lead provider of cyber- the Internet of Things and Services, and INDUSTRIE 4.0 are
physical systems by 2020. In marked contrast to all eligible for funding.
many other industrialized nations, Germany has
maintained a stable manufacturing labor force Software systems and knowledge processing research
while integrating new technological developments funding is divided into three specific categories:
into industrial products and processes at an early
stage. A bridge between the real and virtual ·· Embedded systems focusing in particular on software-
worlds is being created with the digital refining of intensive embedded systems with links to electronics,
everything from production facilities and industri- communication technology and microsystems technology;
al products to everyday products with integrated ·· Simulated reality for grid applications and infrastructure,
storage and communication capabilities, radio sen- virtual/augmented reality and ambient intelligence,
sors and intelligent software systems. Boundaries simulation, information logistics and software
between the real and virtual worlds are collapsing development for high-performance computing;
to create an Internet of Things. Germany’s superi-
or embedded system and cyber-physical systems ·· Human/machine interaction with language and media
know-how represents a major opportunity for in- technologies, bioanalogous information processing,
dustry in Germany to help shape the fourth indus- service robotics and usability.
trial revolution (INDUSTRIE 4.0).
The three category research areas are complemented by the
cross-sectional technologies of software engineering, relia-
bility and security due to their specific focus on the strate-
gic priorities of software-intensive embedded systems, grid
applications and infrastructure as well as virtual/augmented
reality. Applicant projects should be business-oriented and in-
clude cooperation with either university or non-university re-
search institutions. Calls for applications are published on a
case-by-case basis.
Photo: Fotolia/Berlinpictures 13
Autonomics for INDUSTRIE 4.0 This will allow the complexity of increasing compe-
tition to be controlled, but also lead to a sustain-
The AUTONOMIK für INDUSTRIE 4.0 – Produktion, able and significant increase in productivity and
Produkte, Dienste im multidimensionalen Internet flexibility of manufacturing companies through the
der Zukunft (”AUTONOMICS for INDUSTRIE 4.0 – development and introduction of cyber-physical
Production, Products, Services in the Multidimen- production systems (CPPS). The resulting CPPS
sional Internet of the Future“) technology program technologies will allow Germany to increase its
contributes to the implementation of the goals set competitiveness as an international production lo-
out in the High-Tech Strategy 2020. cation as a result of improved productivity and
flexibility, while simultaneously allowing CPPS to
Priority areas include developing the next evo- be introduced to the market as marketable prod-
lutionary steps for machines, service robots and ucts, thereby establishing the country as a lead
other systems able to deal with complex tasks CPPS provider.
autonomously as the transition from ICT-based
control mechanisms to autonomously acting com- CyPros follows three separate goal stages:
ponents and systems ushers in a new age in which
efficiency, cost effectiveness, and quality increase ·· Development of a reference architecture and a
in new and flexible production infrastructures. representative spectrum of cyber-physical system
modules for production and logistics systems;
The technological development of the Internet
·· Provision of universal practices, support tools
of Things has already been covered in the Federal
and platforms for the introduction of cyber-
Ministry for Economic Affairs and Energy (BMWi)
physical production systems;
next generation media (new technologies and
ubiquitous computing) and AUTONOMIK (autono- ·· Technical and methodological basis for the com-
mous, simulation-based systems for small and mercial operation of cyber-physical production
medium-sized enterprises) precursor projects which systems and their implementation in the real pro-
provided significant impulse to new products, ser- duction environment of a showcase factory.
vices and business models in different application
scenarios. Important developments in the field of
semantic technologies applicable in the Internet of RES-COM
Applications and Services were also established in
the BMWi THESEUS R&D funding project. The Launched in June 2011 and funded by the Federal
successor AUTONOMICS for INDUSTRIE 4.0 project Ministry of Education and Research, the RES-COM
has made EUR 40 million in funding available to project addresses automatized conservation of re-
companies and research institutions in order to sources through highly interconnected and inte-
advance intelligent interacting between ICT and grated sensor-actuator systems in an INDUSTRIE 4.0
industrial production in the areas of future- context. Prototype scenarios for context-activated
oriented production systems and production logic; resource efficiency are being implemented. RES-COM
future-oriented premium products (including adopts a completely new type of core technology
service robots); and future-oriented, knowledge- based on active digital product memory and soft-
intensive electronic services. ware service agents with embedded sensors and
actuators. The project is overseen by the German
Research Center for Artificial Intelligence (DFKI) in
CyProS (Cyber-Physical Production partnership with partners including SAP, Siemens,
Systems) IS Predict, and 7x4 Pharma.
16
THE ACATECH PERSPECTIVE
What role does your organization play What advantages does INDUSTRIE 4.0 have
in Germany’s INDUSTRIE 4.0 project? for small and medium-sized companies?
acatech – the National Academy of Science and Germany’s global market leaders include numer-
Engineering – supports policy-makers and society ous “hidden champions” who provide specialized
by providing qualified technical evaluations and solutions – 22 of Germany’s top 100 small and
forward-looking recommendations. In 2010, acatech medium-sized enterprises (SMEs) are machinery
initiated a research project on cyber-physical and plant manufacturers, with three of them
systems – the technical core of INDUSTRIE 4.0. featuring in the world’s top ten. INDUSTRIE 4.0 will
Initial implementation recommendations were also result in new ways of creating value and novel
formulated by the INDUSTRIE 4.0 Working Group business models. In particular, it will provide start-
between January and October 2012 under the ups and small businesses with the opportunity to
coordination of acatech. develop and provide downstream services.
Photo:
Photo: istock/PeopleImages
iStock/PeopleImages 17
THE DFKI PERSPECTIVE
German Research Center for Artificial ship (ppp) is nationally and internationally consid-
Intelligence – DFKI ered a blueprint for corporate structure in the field
of top-level research.
The German Research Center for Artificial
Intelligence (DFKI) was founded in 1988 and has DFKI is actively involved in numerous organizations
research facilities in Kaiserslautern, Saarbrücken, representing and continuously advancing Germany
Bremen and a project office in Berlin. In the field as an excellent location for cutting-edge research
of innovative commercial software technology and technology. Far beyond the country’s borders
using artificial intelligence, DFKI is the leading DFKI enjoys an excellent reputation for its academ-
research center in Germany. ic training of young scientists. At present, 413 high-
ly qualified researchers and 272 graduate students
Based on application-oriented basic research DFKI from more than 60 countries are contributing to
develops product functions, prototypes and pa- more than 232 DFKI research projects. Over the years,
tentable solutions in the field of information and more than 60 staff members have been appointed
communication technology. Research and develop- professors at universities in Germany and abroad.
ment projects are conducted in fourteen research
departments and research groups, ten competence DFKI is on the forefront of INDUSTRIE 4.0 research.
centers and five living labs. Funding is received from The SmartFactory Living Lab performs operation
government agencies like the European Union, and testing of the latest technologies in process
the Federal Ministry of Education and Research engineering and piece goods under industrial con-
(BMBF), the Federal Ministry for Economic Affairs ditions. The project ”RES-COM“ examines the vi-
and Energy (BMWi), the German Federal States and sion of an automatized conservation of resources
the German Research Foundation (DFG) as well as through highly interconnected and integrated
from cooperation with industrial partners. sensor-actuator systems.
Apart from the state governments of Rheinland- “SmartF-IT” is looking at cyber-physical IT systems
Pfalz, Saarland and Bremen, numerous renowned to master complexness of a new generation of
German and international high-tech companies are multi-adaptive factories due to the intensive use
represented on the DFKI supervisory board. The of high-networked sensors and actuators, over-
DFKI model of a non-profit public-private partner- coming traditional production hierarchies of central
control towards decentralized self-organization.
Both projects are funded by the BMBF establishing
Germany as one of the leading pioneers in the field
of the Internet of Things.
→
www.dfki.de
www.facebook.com/DFKI.GmbH
www.smartf-it-projekt.de
www.res-com-projekt.de
18
How does the INDUSTRIE 4.0 project What advantages does INDUSTRIE 4.0 have
contribute to the attractiveness of Germany for small and medium-sized companies?
as a location? What impact will INDUSTRIE 4.0 INDUSTRIE 4.0 will be of paramount importance to
have beyond Germany? small and medium-sized enterprises (SMEs). Flexi-
The Internet of Things is finding its way into pro- ble value chains will transcend departmental, busi-
duction and revolutionizing existing manufactur- ness and company boundaries. As a result, SMEs
ing logic through high-resolution networking and can become temporary production networks with
extreme flexibility in the value chain. German me- precisely calculated value added contributions.
chanical engineering and plant manufacturers, who Continuous networking of course presents a chal-
are international leaders, will profit from INDUS- lenge for security technology, but INDUSTRIE 4.0
TRIE 4.0 as providers, as of course will the IT sector allows client series and personalized products to be
which is tasked with making production and busi- produced at unit costs previously only possible in
ness processes in real-time capable enterprise soft- mass production.
ware solutions. On the INDUSTRIE 4.0 user side we
primarily see auto manufacturers and suppliers as How can international companies profit
well as manufacturers of agricultural equipment, from INDUSTRIE 4.0?
the packaging industry, and companies from the INDUSTRIE 4.0 is an industrial not a political rev-
logistics sector. There will be no stand-alone solu- olution. That is to say, there will be no single de-
tions in the globally networked economy, but in- fining event that takes place, but rather a period of
stead opportunities for global business innovation – dynamic development. New resource-efficiency
with Germany preparing the path ahead. optimization processes make environmentally
friendly and urban production at acceptable costs
What role does your organization play possible in the near future – not only in Germany
in Germany’s INDUSTRIE 4.0 project? but across the world. INDUSTRIE 4.0 will there-
The DFKI has already worked on the initial concepts fore make a significant contribution to the biggest
for INDUSTRIE 4.0 as part of the Industry-Science problems facing society; be it climate change, ener-
Research Alliance advisory group. The partners gy transformation or mega-city management.
work with policy makers on an equal footing in or-
der to design and practically implement joint pro-
ject of real societal importance. For several years
the DFKI has, together with leading plant manu-
facturers, been operating the world’s first so-called
“smart factory” as a living lab which serves as a ref-
erence architecture for INDUSTRIE 4.0.
Photo: DFKI 19
THE FRAUNHOFER PERSPECTIVE
→
www.fraunhofer.de
20
What role does your organization play in What impact will INDUSTRIE 4.0 have
Germany’s INDUSTRIE 4.0 project? beyond Germany?
The Fraunhofer IAO* has been helping shape the INDUSTRIE 4.0 is not an issue that is limited just to
INDUSTRIE 4.0 project since as early as 2011 as Germany. There are similar approaches being car-
part of activities carried out by the Industry- ried out across the world which are being promot-
Science Research Alliance. Since 2012 we have ed under the names of “Internet of Things” and
been working with industry partners in the area of “Industrial Internet” for example. As well as man-
highly flexible, self-organized capacity manage- ufacturing, these highlight many more everyday
ment as part of the publicly funded “KapaflexCy” and routine fields of application for networked
(www.kapaflexcy.de/) INDUSTRIE 4.0 lead systems. However, the full potential of INDUSTRIE 4.0
project. The current Produktionsarbeit der Zukunft – can only be fully exploited through the global net-
INDUSTRIE 4.0 (“Production of the Future – working of production resources and the use of
INDUSTRIE 4.0”) pilot study lays the foundations globally functioning applications. The identifica-
for the Innovationsnetzwerk Produktionsarbeit 4.0 tion and introduction of uniform standards is espe-
(“Innovation Network Production 4.0”) in which cially important in this respect.
Fraunhofer IAO is developing new applications and
business models for INDUSTRIE 4.0 with industry How can international companies profit
and trade association partners. from INDUSTRIE 4.0?
Global sourcing and distributed processes are al-
How does the INDUSTRIE 4.0 project contribute ways associated with considerable coordination
to the attractiveness of Germany as a location? and management time and effort. INDUSTRIE 4.0
With its innovative and leading mechanical engi- allows information to cover long distances in close
neering, automotive and electrical industries, to real time. International companies will there-
Germany is a country with deep industrial roots fore be able to quickly react to client requirements
that is already a world leader in embedded systems in globally distributed production systems as well
(the technological basis for INDUSTRIE 4.0). This as provide their customers with a current picture of
provides the German manufacturing sector with production progress at all times.
the opportunity of following a dual strategy for
the future. On the one hand, Germany can continue What significance does INDUSTRIE 4.0 have for
to build on its competitive position as a production the future employment market? What impact
country thanks to innovative factory concepts and will it have on the education and training of
INDUSTRIE 4.0 applications. On the other hand, the workforce?
Germany can become the global technology suppli- The operation of a factory according to the INDUS-
er for INDUSTRIE 4.0 factories. TRIE 4.0 principle requires workers with the rele-
vant production and IT know-how. For the future it
What advantages does INDUSTRIE 4.0 have is important to create certified training courses in
for small and medium-sized companies? order to take interdisciplinarity to a new and highly
The German manufacturing environment is char- innovative level. By means of just-in-time learning
acterized by a large number of small and medium- and just-in-time training, workers can be equipped
sized enterprises (SMEs). These SMEs often produce for dealing with short-term, unplanned ad-hoc
highly innovative products for the rest of the work activities with changing content on the job,
world. New market segments will open up for thereby becoming qualified to solve problems as
these companies domestically and internationally they are dealing with them.
with INDUSTRIE 4.0. Moreover, SMEs in particular
* The Fraunhofer IAO is a member institution of the Fraunhofer-
stand to benefit from the standardized networking
Gesellschaft. Fraunhofer IAO activities include applied research
of their own production resources as many still and development in the fields of engineering, IT, economics, and
social sciences.
work with proprietary systems. This will allow
SMEs to drastically reduce production management
efforts and respond in significantly faster fashion
to market requirements.
→
www.its-owl.com
22
What role does your organization play in What impact will INDUSTRIE 4.0 have
Germany’s INDUSTRIE 4.0 project? beyond Germany?
Mr. Roman Dumitrescu, chief executive it’s OWL: It has certainly not gone unnoticed by other coun-
The it’s OWL (Intelligent Technical Systems Ost- tries that Germany has fared comparably well
WestfalenLippe) leading-edge cluster is currently despite the financial and economic crises of re-
the largest INDUSTRIE 4.0 project. Our intelligent cent times. The reason for this is that we are still a
technical systems provide a strong boost to strong production location. For instance, even the
Germany’s competitiveness as a production lo- European Institute for Innovation and Technology
cation and pave the way to the fourth industrial (EIT) will invite tenders for a Knowledge and
revolution. INDUSTRIE 4.0 solutions are being de- Innovation Community (KIC) in the area of “Val-
veloped in 45 different projects with a budget of ue Added in Production” in 2016. I don’t think this
around EUR 100 million. We see our strengths as would have been the case without Germany’s
being in industrial automation, human-machine INDUSTRIE 4.0 initiative.
cooperation and the realization of so-called ‘self-x
capabilities’ like, for example, self-optimizing How can international companies profit
production systems. from INDUSTRIE 4.0?
Quite simply: by buying our solutions. Because here
How does the INDUSTRIE 4.0 project contribute they can access all of the components for future-
to the attractiveness of Germany as a location? proof production. International companies can of
The project clearly strengthens machine engineer- course also profit from these innovations. We should
ing as well as the electronics industry; industries not forget that Germany has invested enormously
which are thankfully still very strongly represented in research and development for this success.
in Germany. In recent times these industry sectors That is the only reason why we now stand on the
have been dismissed as “old economy,” with coun- threshold of a fourth industrial revolution.
tries like Great Britain fully focusing on the service
sector – something we now know to be a mistake. I
believe that with INDUSTRIE 4.0 we have a unique
opportunity to combine and play off our strengths
to become not only the lead provider for produc-
tion in the future but also to remain an important
production location.
24
What role does your organization play in be more intertwined than ever before as a result of
Germany’s INDUSTRIE 4.0 project? INDUSTRIE 4.0. The change process of INDUSTRIE 4.0
Together, three leading industry associations are and the transformation it represents can be ar-
pushing the INDUSTRIE 4.0 theme forward. BITKOM, ranged with new opportunities. Examples already
VDMA and ZVEI founded the Plattform INDUSTRIE 4.0 exist where INDUSTRIE 4.0 provides real added val-
partnership which started operations in April of ue to daily operations as well as strategic orienta-
this year. The Plattform is based in Frankfurt am tion for agile business behavior.
Main with a joint information portal and “virtual
office” set up online. Plattform INDUSTRIE 4.0 will What impact will INDUSTRIE 4.0 have
continue the work of the Federal Government’s beyond Germany?
“Future Project INDUSTRIE 4.0” within the frame- It is important to defend and expand the tradi-
work of the High-Tech Strategy. The main objective tional core of German industry and its excellent in-
is the development and expansion of knowledge ternational position with the advent of internet
and understanding as well as the distribution of technologies. As an export nation, machines and
research results and their practical application in plants are not only sold, maintained and operated
INDUSTRIE 4.0. The Plattform is intended as the worldwide, but also produced in branch factories
central point of contact for all matters INDUSTRIE 4.0 and by licensees. The concepts at play in INDUS-
related and, as such, will actively involve and/or TRIE 4.0 do not observe national borders. The par-
participate with all relevant actors. adigm shift in industrial production and intelligent
products creates the opportunity to increase pro-
How does the INDUSTRIE 4.0 project contribute ductivity, flexibility and quality in many different
to the attractiveness of Germany as a location? economic regions.
The INDUSTRIE 4.0 project builds bridges between
manufacturing companies, providers, science, and How can international companies profit
politics. Cross-industry exchange of ideas and in- from INDUSTRIE 4.0?
formation help accelerate knowledge transfer for Further improvements in the implementation of in-
innovation in Germany. From the point of view of dustrial processes in manufacturing, engineering,
the three industry associations, INDUSTRIE 4.0 is of supply chain and life cycle management insist on
tremendous importance to the competitiveness of new ideas, algorithms, technologies, reference
German industry. The term stands for networked – architectures, standards, and business models.
often with the internet over and beyond company Germany has the ideal conditions to fulfill these
borders – and connected industrial production. As a tasks in order to play an internationally leading role
location we are strong in the development and ap- in INDUSTRIE 4.0. Numerous standards, like the
plication of production, automation, and embed- internet protocol, will be used internationally by
ded software-intensive IT and have longstanding foreign companies, thus allowing a swift entry for
and established industrial networks. the Internet of Things and the Internet of Services
into industrial production in Germany too.
What advantages does INDUSTRIE 4.0 have for
small and medium-sized companies?
From an overall economic perspective, SMEs in par-
ticular account for a significant share of employ-
ment and value creation in Germany and, as such,
are of central importance to the economic struc-
ture. INDUSTRIE 4.0 is also of relevance to small
and medium-sized enterprises: the next industrial
revolution will be characterized by networking and
the internet. Value chains become value networks.
ICT, automation and production technologies will
Photo: Fotolia/industrieblick 25
THE SMARTFACTORY KL PERSPECTIVE
28
What role does your organization play in What impact will INDUSTRIE 4.0 have
Germany’s INDUSTRIE 4.0 project? beyond Germany?
Bosch finds itself in a dual role on the way to net- The ideas behind INDUSTRIE 4.0 will change ex-
worked and integrated industry (“INDUSTRIE 4.0”). isting value chains – even across national borders.
The company itself deploys technologies and soft- Value chains in which companies and business pro-
ware in order to network its own manufacturing base. cesses are horizontally integrated will emerge. This
On top of this, the company also develops solu- means that business processes – including their
tions in this area. Bosch Rexroth provides numerous engineering – will be consistently designed across
solutions for the Factory 4.0. Bosch Packaging Tech- the whole value chain. Production systems are con-
nology is already building intelligent equipment ceived in networks – from the supplier to the cus-
for intelligent factories in the pharmaceuticals and tomer. These highly dynamic business networks
foodstuff industries. A software suite developed provide potential for innovation and new business
by Bosch Software Innovations also optimizes the models. The same also applies to better data gen-
complete equipment maintenance process. eration and evaluation.
How does the INDUSTRIE 4.0 project contribute How can international companies profit
to the attractiveness of Germany as a location? from INDUSTRIE 4.0?
The advent of Web 3.0, i.e. the Internet of Things Digitalization and networking help to optimize the
and Services, in industrial production provides value chains: customers are no longer obliged to
Germany with enormous opportunities in two ways. choose from a fixed product spectrum set by the
On the one hand, German companies will devel- manufacturer, but instead are able to individually
op, sell and export technologies and products for combine single functions and components. The range
networked industry. On the other hand, the use of of variety will become profitable for companies. This
these technologies will improve the efficiency, and can consequently increase the size of the market
therefore competitiveness, of German industry. and turnover. At the same time, customer satisfac-
tion increases as the internal operative costs sink as
What advantages does INDUSTRIE 4.0 have for a result of increased value chain digitalization.
small and medium-sized companies?
German companies are – notwithstanding the in-
creasing competition from Asia – leaders in plant
and mechanical engineering. German companies
also have considerable know-how and a competent
workforce in the fields of IT, embedded systems
and automation technology. The framework for a
concentrated implementation of networked pro-
duction has been established with the creation of
the BITKOM, VDMA, and ZVEI-funded “Plattform
INDUSTRIE 4.0.” German companies must actively
shape the way to networked production and not
lose sight of what is required.
Photo: Bosch 29
THE FESTO PERSPECTIVE
What role does your organization play INDUSTRIE 4.0 activities. Continuous and open
in Germany’s INDUSTRIE 4.0 project? standard architectures are also clearly more advan-
Festo contributed to the recommendations made tageous for small and medium-sized enterprises
by the Industry-Science Research Alliance. Within (SMEs) than closed concepts from major concerns
this context, a “Resilient Factory” application case – that shape the market themselves. It is therefore
with systems that are tolerant to disruptions – was worthwhile for SMEs to force non-proprietary solu-
introduced. These activities have subsequently tions within an INDUSTRIE 4.0 context.
been transferred to the Plattform INDUSTRIE 4.0 in
which Festo is also very much actively involved. What impact will INDUSTRIE 4.0
have beyond Germany?
How does the INDUSTRIE 4.0 project contribute Activities are being closely followed, for example,
to the attractiveness of Germany as a location? in Great Britain and the USA. Horizontal network-
From a European perspective it is important to en- ing in value chain networks is not limited to just
sure that production in high-wage countries, of one company or country. Successful concepts which
which Germany is one, remains competitive in the are developed will also be accepted internationally.
long term. INDUSTRIE 4.0 activities will contribute
to achieving this. The perspective merging of man- How can international companies profit
ufacturing technology with IT can be carried out in from INDUSTRIE 4.0?
especially efficient manner in Germany in particu- As already alluded to in the answer to the previ-
lar, as public funds are also in operation. This spe- ous question, economic concepts are not applied
cial situation allows the attractiveness of Germany nationally. International companies will be able to
to be significantly increased with INDUSTRIE 4.0. benefit just as much where technological and com-
mercial advantages arise from the implementation
What advantages does INDUSTRIE 4.0 have of INDUSTRIE 4.0 concepts.
for small and medium-sized companies?
The creation of commonly defined standards
with widespread effect is an important part of
Photo:
Photo: Festo
Festo AG
AG &
& Co.
Co. KG
KG 31
THE SAP PERSPECTIVE
SAP AG
Simpler
Improve adaptability, consumability,
and flexibility
32
What role does your organization play in What impact will INDUSTRIE 4.0 have
Germany’s INDUSTRIE 4.0 project? beyond Germany?
SAP has been engaged in several public research Manufacturers all over the world face increased
projects and initiatives in the context of INDUS- cost pressure and market volatility. Product life
TRIE 4.0 and contributed to the recommendation cycles are getting shorter and products are be-
paper issued by acatech – the National Academy of coming more complex and customized. Manufac-
Science and Engineering. SAP provides technolo- turers must find ways to balance customization
gies and solutions that help companies to embrace with mass production. Production will increasing-
the upcoming changes in the manufacturing indus- ly be local to meet rapid changes in demand. Many
tries. SAP follows a holistic approach called “Idea to countries are aware of this trend and launched
Performance” enabling companies to develop new programs similar to INDUSTRIE 4.0. In addition,
business models and a roadmap for implementing INDUSTRIE 4.0 addresses some of today’s biggest
INDUSTRIE 4.0 scenarios. challenges such as resource and energy efficiency.
How does the INDUSTRIE 4.0 project contribute How can international companies profit
to the attractiveness of Germany as a location? from INDUSTRIE 4.0?
For highly industrialized countries like Germany, INDUSTRIE 4.0 is a global topic, encompassing
INDUSTRIE 4.0 is a great opportunity to keep manu- fast-growing markets like China or India as well
facturing jobs in the country and secure long-term as traditional manufacturing countries such as
growth and innovative strength. German manufac- Germany, US, Korea, or Japan. Wherever they are
turers are often highly specialized global leaders based, companies can use INDUSTRIE 4.0 scenari-
in their field. With INDUSTRIE 4.0, they can further os to prepare for upcoming changes and lead this
enhance their competitive advantage by becoming new industrial revolution. With SAP’s holistic
more efficient and responsive to market changes “Idea to Performance” approach, our customers
and introducing new service offerings based on a can position themselves and start implementing
wealth of data from smart products and machines. INDUSTRIE 4.0 scenarios to work smarter, faster,
and simpler.
What advantages does INDUSTRIE 4.0 have for
small and medium-sized companies?
With INDUSTRIE 4.0, supply chains will evolve into
highly adaptive networks. Small and midsize com-
panies will play an important role in such value-
add networks. By integrating INDUSTRIE 4.0 con-
cepts and technologies, they can provide individ-
ualized products and services and will be highly
adaptive to demand changes. Sensors flexibly pro-
vide machine data that is captured and analyzed
while the manufacturer is producing, delivering,
assembling, and operating machines. Pro-active
services for example trigger machine data anomalies.
Photo:
Photo: SAP
SAP AG
AG 33
THE TRUMPF PERSPECTIVE
TRUMPF GmbH & Co. KG In 2012/13 the company – which has approximately
9,900 employees – achieved sales of EUR 2.34 bil-
TRUMPF is a leading global technology company lion. With more than 60 subsidiaries and branches,
with machine tools, laser technology, electronics the TRUMPF Group is represented in almost all the
and medical technology as its business fields. Prod- countries of Europe, North and South America, and
ucts manufactured with the company’s technolo- Asia. It has production facilities in Germany, China,
gy can be found in almost every sector of industry. France, Great Britain, Japan, Mexico, Austria, Po-
TRUMPF is the world technological and market land, Switzerland, the Czech Republic and the USA.
leader for machine tools used in flexible sheet metal
processing, and also for industrial lasers. →
www.trumpf.com
What role does your organization play ing foreseen in INDUSTRIE 4.0 allows all production
in Germany’s INDUSTRIE 4.0 project? processes to be transparent and easily influenced.
TRUMPF has been a member of the federal gov- INDUSTRIE 4.0 provides the companies with the
ernment initiated INDUSTRIE 4.0 Working Group flexibility which allows them to remain interna-
since 2011 and has already provided a decisive con- tionally competitive.
tribution to the definition of the “smart factory.” As
well as this, TRUMPF is also active in the Plattform In your opinion what impact will INDUSTRIE 4.0
→
INDUSTRIE 4.0 management board and steering have beyond Germany?
group set up by the VDMA, BITKOM and ZVEI in- The “Global Facility“ is one of the five elements of
dustry associations. Alongside projects like CyProS – the Smart Factory. Production systems are already
in which 20 partners are conducting research into often internationally networked – with INDUSTRIE 4.0
the implementation of cyber-physical production this networking will continue to increase. More-
systems – TRUMPF is also working to create over, the new technological opportunities are not
solutions for more productive and efficient pro- only available in Germany. The advantages that the
duction processes. Internet of Things for example brings to manufac-
turing won’t go unnoticed in other countries. The
How does the INDUSTRIE 4.0 project contribute different elements of INDUSTRIE 4.0 will therefore
to the attractiveness of Germany as a location? also affect production in other countries.
The INDUSTRIE 4.0 vision is one of networked sys-
tems in which no capacity bottlenecks or available How can international companies profit
resources remain undetected. They are transpar- from INDUSTRIE 4.0?
ent, can react to variations flexibly and allow hu- Just as is the case for German companies, interna-
mans to intervene as intelligent decision makers tional companies will be able to more efficiently
according to the situation. These systems will allow shape their own production according to the prin-
individual products to be produced in an efficient ciples of INDUSTRIE 4.0. For this they can call upon
and swift manner normally associated with mass the services of German machine builders who have
production. The INDUSTRIE 4.0 project creates the long been occupied with the opportunities made
conditions for the implementation of such produc- possible by networking. TRUMPF provides its cus-
tion networks in Germany. tomers, whether domestic or international, with
state-of-the-art technology. The company has al-
What advantages does INDUSTRIE 4.0 have ready been deploying the first elements of INDUS-
for small and medium-sized companies? TRIE 4.0 in its machine tools and lasers for years.
Small and medium-sized companies in particular
must react quickly to changes – for example short-
term customer orders. The networked manufactur-
Photo: WITTENSTEIN AG 37
GERMANY TRADE & INVEST
Support services
38
Imprint
Publisher
Germany Trade and Invest
Germany Trade & Invest would like to
Gesellschaft für Außenwirtschaft
thank the following organizations and
und Standortmarketing mbH
companies for their invaluable support in
Friedrichstraße 60
making this publication:
10117 Berlin
Germany ·· acatech – National Academy of Science
and Engineering
T +49 (0)30 200 099-555 ·· DMG MORI AG
F +49 (0)30 200 099-999
·· German Research Center for Artificial
invest@gtai.com
Intelligence – DFKI
www.gtai.com
·· Fraunhofer-Gesellschaft
Executive Board ·· it’s OWL Clustermanagement GmbH
Dr. Benno Bunse, Chairman/CEO ·· Plattform INDUSTRIE 4.0
Dr. Jürgen Friedrich, CEO
·· SmartFactory KL
Layout
Germany Trade & Invest
Print
inpuncto:asmuth druck +
medien gmbh, Köln
Notes
All rights reserved©Germany Trade & Invest,
July 2014.
Reproduction, in whole or in part, only permissible
with express prior authorization.
All data provided is based on the most current
information available at the time of publication.
Germany Trade & Invest accepts no liability for
the actuality, accuracy, or completeness of the
information provided.
Order Number
20750
39
About Us
Germany Trade & Invest is the economic development agency of the
Federal Republic of Germany. The company helps create and secure
extra employment opportunities, strengthening Germany as a busi-
ness location. With more than 50 offices in Germany and abroad and
its network of partners throughout the world, Germany Trade & Invest
supports German companies setting up in foreign markets, promotes
Germany as a business location and assists foreign companies setting
up in Germany.