IBM Perspektive auf und Erfahrungen mit Industrie 4.0

Matthias Dietel Renate FrankenMatthias.Dietel@de.ibm.com Renate.Franken@de.ibm.com

INTELLIGENT

INSTRUMENTED

=

+

+

Smarter Planet

INTERCONNECTED

Big Data & Analytics

End-to-End Integration

Internet of Things und M2M

Smarter Value Chain

From IBM Smarter Planet Strategy to Industrie 4.0

Collaboration

(embedded)Development

Mobile

Cloud

Security

Big Data & Analytics

End-to-EndIntegration

Internet of Things und M2M

INTELLIGENT

INTERCONNECTED

INSTRUMENTED

Watson

IndustrySolutions

Commerce

Industrie 4.0: IBM can provide technology and expertise

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Watson IoT offers a full set of capabilities that enables our clients to transform their business

IBM Watson IoT Platform

Design

Operate

Manufacture

Service

IBM Watson IoT Solutions

Packaged Applications

Transform with CognitiveDrive better results with cognitive capabilities to improve engagement and predictions

Analyze and PredictApply powerful analytics to drive actionable predictions and make better decisions

Visualize the patternsVisualize your data and distill useful information to see patterns of insight

Connect & SecureBring together the right data onto a versatile, scalable and secure platform

IBM Contributions to Industrie 4.0

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Plattform Industrie 4.0http://www.plattform-i40.de/

Analytics + Integration Layer

T Physical Device(the „Things“ of IoT)

P Presentation/Applications(KPIs, dashboard, mobile)

C Connectivity(connect the „Things“)

I Integration(transform data)

A Aggregation/Analytics(analyze data)

D Data(collect data/storage)

B Collaboration & Processes(Business)

Internet of Things –Connect the real world to business

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CI D

A

PBT Thing/Machine

C Connectivity

I Integration

D Data

A Analytics

P Presentation

B Business

TC

Internet of Things Industrie 4.0Vertical Integration

Enterprise IT

APB

C

Machines

C I D A

Production ITProduction IT

C I D A

Cyber Physical System

Production IT

Smarter Products

Smarter Production

Smarter Machines

IoT, Industrie 4.0 and Cyber Physical Systems

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MachinesMachines C

Machine Machine

Machines as a Service

Possible Business Models: ‘pay how you use’

T Thing/Machine

C Connectivity

I Integration

D Data

A Analytics

P Presentation

B Business

CI D

A

PB

TC

Internet of Things

Smarter Products

Industrie 4.0Vertical Integration

Enterprise IT

APB

C

Production ITProduction IT

C I D A

Smarter Production

MachinesMachines C

Produktionsstätten:Produktion IT, oft .Net/C#, individuell

MES

ProduktionAnlagen

Anlagen Steuerung

Anlagen Steuerung

ProduktionAnlagen

ProduktionAnlagen

Anlagen Steuerung

Anlagen Steuerung

ProduktionAnlagen

Zentrale IT: Zentrale Services wie E-Mail, Internet/Intranet, Datenbanken Auftragsverarbeitung (ERP/CRM, ...) Infrastruktur as a Service (Backup, Ausfallsicherheit, ...)

ITP

rod

uk

tio

n

Produktionsstätten:Produktion IT, oft .Net/C#, individuell

MES

ProduktionAnlagen

Anlagen Steuerung

Anlagen Steuerung

ProduktionAnlagen

ProduktionAnlagen

Anlagen Steuerung

Anlagen Steuerung

ProduktionAnlagen

Praxis today – how to get flexible?

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IBM Integration Bus in the Manufacturing content

Remote Telemetry Unit

Remote Site (satellite link)

OPC Classic Server(including historian)

ManufacturingExecution Systems

OPC UA Server(including historian)

Plant StaffMobile Applications

Web ServicesHTTP / JSON

SCADA MQTTOPC DA OPC HAD OPC AE

OPC UAOPC B2MMLWeb

Services.NET

Corporate ApplicationsERP, Production Scheduling

DynamicsOracleSAP

AnalyticsDecision

Management

Portal Web Apps(internal)

Asset Management

Supply Chain Management

Product QualityManagement

IDOC, BAPIProprietary XML

Web ServicesIDOC, BAPI

SQL

Web ServicesProprietaryinterfaces

Web ServicesSOAP XML

ODBC JDBCSQL

Web ServicesSOAP, XML

Web ServicesHTTP, JMSFile, SQL

Manufacturing Landscape

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Produktionsstätte

Produktionsstätte

MES

ProduktionAnlagen

Anlagen Steuerung

Anlagen Steuerung

ProduktionAnlagen

Datendrehscheibe/ESBIBM Integration Bus Manufacutring Pack

Analytics/BIPredictive Maintenance

ProduktionAnlagen

MES

ProduktionAnlagen

Anlagen Steuerung

Anlagen Steuerung

ProduktionAnlagen

Manufacturing Integration Bus(IBM Integration Bus Manufacturing Pack )

Analytics/BIPredictive Maintenance

ProduktionAnlagen

Anlagen Steuerung

Anlagen Steuerung

ProduktionAnlagen

Manufacturing Integration Bus(IBM Integration Bus Manufacturing Pack)

ITP

rod

uk

tio

n

Zentrale IT: Zentrale Services wie E-Mail, Internet/Intranet, Datenbanken Auftragsverarbeitung (ERP/CRM, ...) Infrastruktur as a Service (Backup, Ausfallsicherheit, ...)

Manufacturing Service Bus – get flexible

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Ziele Erhöhung des Produktions-

volumens um 30 % (2010 - 2015) ohne die Möglichkeit räumlicher Ausdehnung → Gelände begrenzt durch Ort und Fluss/Berg

Modernisierung der Prozessautomatisierung

MES-Redesign auf Basis SAP NetWeaver

Warmwalzwerk und Adjustagen, Spezialist für kundenspezifische Stahl-Lösungen, bei denen auch kleine Losgrößen

wirtschaftlich gefertigt werden können

SAP Server

SAP

DB2Datenbank-

Server

SAP RFC JDBC, StoredProcedures

Weiterleitung für Benachrichtigung/ Weiterverarbeitung

Glühe

Schub-beize

Durchlauf-beize

Labor-PC

WaageDisomat

PLSVerpackungs-

linie

Dateiaustausch(FTP, SFTP, Verzeichnis)

Mess-geräte

Hoesch Hohenlimburg GmbHEin Unternehmen der ThyssenKrupp Steel Europe AG

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Sto

red

Pro

ce

du

res

TC

P/IP

(RF

C10

06

)

Business challenge: This auto company’s managers had an anecdotal understanding of which variables were tied to product-quality issues in the company’s cylinder-head production line, but not enough to change it. What they needed was a way to more precisely identify the complex patterns in machine settings, material temperatures and equipment maintenance activities that adversely affected product quality so that they could take preventive steps to minimize production-line waste.

The smarter solution: Each day, production-quality analysts run the more than 500 production-line variables they track through predictive models that tell them which specific parts of the line need to be adjusted to ensure that products remain within their tight tolerances. The solution also provides predictive insights on which production assets should be preventively maintained to avoid future problems.

By gaining a far deeper understanding of the many factors that affect production quality, proactive steps can be taken to maximize it.

Solution components IBM® SPSS® Modeler IBM SPSS Lab Services

> 50 % reduction in the time required to ramp up the process to target levels

100 % paybackachieved within two years

25 % increasein the overall productivity of the cylinder-head production line

http://www-935.ibm.com/services/multimedia/V500447K03616S21_reference_Daimler.pdf

Daimler in Germany uses predictive models to make the right production adjustments and meet tight tolerances

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2014: SAP - IBM Integration Bus – Siemens S7 - FanucRoboter/RFID/Farbsensor2015: IBM BPM – IBM Integration Bus – Siemens S7 - FanucRoboter/RFID/Farbsensor/Raspberry PI

2014: https://www.youtube.com/watch?v=RVzkUWweFGM2015: https://www.youtube.com/watch?v=AHQ_gVpob1M

IBM und PA Solutions Showcase Industrie 4.0 CeBIT und Hannover Messe

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Data Historian

Integration Layer

1 2

3Real-time Dashboard Predictive Analytics

Smarter Factory:Transparenz und Visualisierung in Echtzeit

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Industry 4.0 Pilot Fast Prototype

First Implemented Use Cases

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I4.0/IoT Enabling @ John Deere Mannheim

Use Case 1/3:

Digital Build PaperUse Case 2/3:

Worker AssistanceUse Case 3/3:

Sense & Act

Demonstration Use Case 2, Worker Assistance System

SMP Pilot Functional Architecture

Integration Layer

Workflow(HMI for

Worker & Planer)

ShopfloorData Model (contents)

Other systems (SAP, databases, etc.)

CPS(intelligent gateway)

Rules (relation-

ships)

uses

usesbased on

integrates

integrates

accesses

integrates

accesses

Smart Manufacturing Platform

Machines / Equipment

TellMeWhatsHappening@theLine in the Three-Layers SMP Architecture

RFID Antenna

Camera

Worker Assistance System

TellMeWhatsUp @theLine

1. Potential problem alert2. Image Recognition

3. Watson Dialog

Demonstration Watson Maintenance Advisor

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Industrial Security

Vertical Integration in

Production

Analysis of Production

Data

Collection ofProduction

Data

Real-time analysis Analysis of production parameter Predict failure patterns (predictive maintenance)

Maximize OEE: Availability Scrap rate Optimized production speed

Space-saving and performant data collection Consolidated data at factory level and beyond

Bidirectional communication between machines, shopfloor and IT-systems Gain data out of your machineChange parameter within your machine

Modularity and Flexibility

Secured network transition from Office-IT to Shopfloor-IT Industrial security from machine, to shopfloor, IT floor, even Internet Detective and forensic analysis of anomalies

Turning Data into Insights. Insights into Actions.

Transparency of your company gold.

Connectivity as enabler for data collection.

Close your Security gap. Connected Devices = Target of Hackers.

What would it be like if you could take advantage of...

IBM Industrie 4.0 StarterPack – Tech Core Team

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For Vertical Integration

Efficient Collection of historical data

Predictive Analytics

Security Intelligence in one solution

StarterPack 4.0 = Proved Software

Including Self-Study for fast start in your own project

Early- Bird - Promotion

The first 20 StarterPack User receive a discovery workshop worth 5.000 € for free

IBM Industrie 4.0 StarterPack as fast and pragmatic approach for your first Industrie 4.0 Experiment

IBM Integration Bus

IBM Informix TS

IBM SPSS Modeler

IBM Qradar SIEM

Integration of dozens standard- , application-specific-, andshopfloor -protocols such as OPC, OPC UA, OSIsoft PI, MQTTBased on Service-orientated Architecture (SOA)

SQL-based Data Historian: for efficient storage of time seriesSaving of disk storage (60 %)Higher performance (60K/s time series values)

Intelligent algorithms and mathematical models used in playmodeProductivity improvement (e.g., 25 %)Scalable towards Big Data

Centralized Security Intelligence, protection against advancedthreats, network flow capture and analysis, sophisticatedcorrelation of events, flows, assets, topologies, vulnerabilities,forensic

IBM Industrie 4.0 StarterPack – Tech Core Team

Ziel des Workshops:

Lernen Sie selbst anhand von praktischen Übungen, wie einfach Sie die Daten in der

Produktion in Ihre bestehende IT integrieren können oder auch neuen Anwendungen oder

Geschäftsmodellen zur Verfügung stellen.

Agenda:

Industrie 4.0 und IBM Lösungen

Einführung MQTT als Protokoll für das Internet der Dinge

Praktische Übung mit MQTT

Einführung IBM Integration Bus Manufacturing Pack

Praktische Übung für den ersten Umgang mit dem IBM Integration Bus und

DB Integration

Praktische Übung für das Verarbeiten von Maschinendaten über MQTT oder OPC UA

Optionale praktische Übung: Lernen aus den Maschinendaten/predictive Analytics mit

SPSS Modeler

Industrie 4.0 – SeminarIntegration mit IBM Integration Bus Manufacturing Pack - Termin Januar/Februar 2017 -

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