Securing the future of German manufacturing industry
Recommendations for implementing the strategic initiative INDUSTRIE 4.0
Final report of the Industrie 4.0 Working Group
April 2013
Imprint
Authors Contact details / Marketing
Communication Promoters Group of the Industry-Science Office of the Industry-Science Research Alliance
Research Alliance: beim Stifterverband für die Deutsche
Prof. Dr. Henning Kagermann Wissenschaft Ulrike Findeklee, M.A.
National Academy of Science and Engineering [email protected] (Spokesperson of the Promoters Group) Prof. forschungsunion.de Dr. Wolfgang Wahlster
Secretariat of the Platform Industrie 4.0 German Research Center for Artificial Intelligence Dr. Johannes Helbig Lyoner Straße 9 60528 Deutsche Post AG Frankfurt/Main kontakt@plattform- acatech – National Academy of Science and Engineering i40.de plattform-i40.de
Editorial staff
Ariane Hellinger, M.A.
Veronika Stumpf, M.A.
With the assistance of: Christian Kobsda, B.A. acatech – National Academy of Science and Engineering Publication date: April 2013
Copy editing
Linda Treugut, M.A. acatech – National Academy of Science and Engineering
English translation
Joaquín Blasco
Dr. Helen Galloway
Layout and typesetting
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Contents Contents
Executive summary ...... 04
Working group members | Authors | Technical experts ...... 08 1 Introduction ...... 12
2 The vision: Industrie 4.0 as part of a smart, networked world ...... 18
2.1 Shaping the vision of Industrie 4.0 ...... 19
2.2 What will the future look like under Industrie 4.0? ...... 20
2.3 Novel business opportunities and models ...... 22
2.4 New social infrastructures in the workplace ...... 23
2.5 Novel service-based, real-time enabled CPS platforms ...... 24
2.6 The road to Industrie 4.0 ...... 25
Example application 1 Reducing the energy consumed by a vehicle body assembly line while it is not in use ...... 27
3 The dual strategy: becoming a leading market and supplier ...... 28
3.1 Leading supplier strategy ...... 29
3.2 Leading market strategy ...... 29
3.3 The dual strategy and its key features ...... 30
Example application 2 End-to-end system engineering across the entire value chain ...... 33
4 Research requirements ...... 34
5 Priority areas for action ...... 38
5.1 Standardisation and open standards for a reference architecture ...... 39 5.2 Managing complex systems ...... 42 5.3 Delivering a comprehensive broadband infrastructure for industry ...... 45
5.4 Safety and security as critical factors for the success of Industrie 4.0 ...... 46
5.5 Work organisation and work design in the digital industrial age ...... 52 5.6 Training and continuing professional development for Industrie 4.0 ...... 55 5.7 Regulatory framework ...... 58
5.8 Resource efficiency ...... 62
Example application 3 Supporting custom manufacturing: an example of how an individual customer’s requirements can be met ...... 64
2 Industrie 4.0
C
ontents Example application 4 Telepresence ...... 65
6 How does Germany compare with the rest of the world? ...... 66
Example application 5 Sudden change of supplier during production due to a crisis beyond the manufacturer’s control ...... 73
7 Outlook ...... 74
Background: The strategic initiative Industrie 4...... 76
Industrie 4.0 3
Executive summary
mmary
su Executive
Executive summary
Germany has one of the most competitive manufac- enable and require end-to-end engineering across turing industries in the world and is a global leader in the entire value chain. the manufacturing equipment sector. This is in no small measure due to Germany’s specialisation in re- Industrie 4.0 holds huge potential. Smart factories allow search, development and production of innovative individual customer requirements to be met and mean manufacturing technologies and the management of that even one-off items can be manufactured profitably. In complex industrial processes. Germany’s strong ma- Industrie 4.0, dynamic business and engineering chinery and plant manufacturing industry, its globally processes enable last-minute changes to production and significant level of IT competences and its know-how deliver the ability to respond flexibly to disruptions and in embedded systems and automation engineering failures on behalf of suppliers, for example. End-to-end mean that it is extremely well placed to develop its transparency is provided over the manufacturing process, position as a leader in the manufacturing engineering facilitating optimised decision-making. In-dustrie 4.0 will industry. Germany is thus uniquely positioned to tap also result in new ways of creating val-ue and novel into the potential of a new type of industrialisation: business models. In particular, it will pro-vide start-ups Industrie 4.0. and small businesses with the opportunity to develop and provide downstream services. The first three industrial revolutions came about as a result of mechanisation, electricity and IT. Now, the in- In addition, Industrie 4.0 will address and solve some troduction of the Internet of Things and Services into of the challenges facing the world today such as the manufacturing environment is ushering in a fourth resource and energy efficiency, urban production and industrial revolution. In the future, businesses will es- demographic change. Industrie 4.0 enables continu- tablish global networks that incorporate their machin- ous resource productivity and efficiency gains to be ery, warehousing systems and production facilities in delivered across the entire value network. It allows the shape of Cyber-Physical Systems (CPS). In the work to be organised in a way that takes demograph-ic manufacturing environment, these Cyber-Physical change and social factors into account. Smart as- Systems comprise smart machines, storage systems sistance systems release workers from having to per- and production facilities capable of autonomously ex- form routine tasks, enabling them to focus on creative, changing information, triggering actions and control- value-added activities. In view of the impending short- ling each other independently. This facilitates funda- age of skilled workers, this will allow older workers to mental improvements to the industrial processes extend their working lives and remain productive for involved in manufacturing, engineering, material us- longer. Flexible work organisation will enable workers age and supply chain and life cycle management. The to combine their work, private lives and continuing smart factories that are already beginning to appear professional development more effectively, promoting employ a completely new approach to production. a better work-life balance. Smart products are uniquely identifiable, may be lo- cated at all times and know their own history, current Global competition in the manufacturing engineering status and alternative routes to achieving their target sector is becoming fiercer and fiercer and Germany is not state. The embedded manufacturing systems are ver- the only country to have recognised the trend to de-ploy tically networked with business processes within fac- the Internet of Things and Services in manufacturing tories and enterprises and horizontally connected to industry. Moreover, it is not just competitors in Asia that dispersed value networks that can be managed in real pose a threat to German industry – the US is also taking time – from the moment an order is placed right measures to combat deindustrialisation through pro- through to outbound logistics. In addition, they both grammes to promote “advanced manufacturing”.
Industrie 4.0 5
6
Industrie 4.0 Industrie • • • • industrial policy decisions. The Industrie 4.0 4.0 Industrie areas: eight key the following The be Group decisions. Working policy industrial ac re implemented, successfully be to is 4.0 Industrie If of development continued technologies. CPS the as well as systems, 4.0 Industrie of result a as about come will that place work the in infrastructures social new the to paid be end and addit In engineering. of systems integration manufacturing of gration inte vertical and horizontal the into required is re search strategy, dual the implement to order In opment. devel and research into effort of amount huge a put to require will 4.0 Industrie towards The journey 4.0 Industrie sh of features following the strategy, CPS dual this of the goals deliver to order In products. and technologies CPS sup for markets leading new serve leading and create to necessary be the will it time, same the At become technologies. manufacturing can it by leadership high traditional its market into technology global communica and information its integrating consistently maintain to seek indus equipment manufacturing Germany’s dual a adopt to needs Germany 4.0, Industrie to produc industrial from shift the about bring to order In
- - ards and facilitate their implementation. their facilitate and ards these stand description of technical to provide a will architecture reference A developed. of set common is asingle if standards possible be only will partnership collaborative This networks. throughvalue companies different several of integration and involve networking will 4.0 Industrie reference and Standardisation ing systems manufactur networked and integration Vertical chain value the entire across End networks value through integration Horizontal s companied by the appropriate industrial and and industrial appropriate the by companied earch and development activities will need to be be to need will activities development and earch - to
- end digital integration of engineering engineering of integration digital end ould be implemented:
- lieves that action is needed in in needed is action that lieves Executive summary
-
tech strategies so that so strategies tech ion, attention should should attention ion, architecture: le o smart of plier
be needed - r should try Germany Germany strategy. -
to
- - - - end end tion tion - - - - - • • • • •
critical to the success of smart manufacturing manufacturing smart of success the critical to andSafety security security: and Safety partnercountries. its and Germany between withinGermany both and scale, massive expandedona tobe needs therefore Internet infrastructure Broadband 4.0. Industrie com high and comprehensive Reliable, industry: for infrastructure broadband comprehensive A models. such develop to required and tools with methods the equipped be therefore should Engineers complexity. growing this managing explana and planning Appropriate complex. more and aremore becoming systems manufacturing Productsand systems: complex Managing fosters learning, enabling lifelong learning and learning lifelong enabling learning, fosters work away that in toorganise and strategies training toimplement appropriate necessary It will profiles. competence and job radically workers’ transform will 4.0 Industrie develop professional continuing and Training projects. model reference launch learning to and measures lifelong and design work b will it possible, tobe this development.For personal their enhance and responsibility greater opportunity toenjoy the workers offer will organisation work to approach asocio of Implementation environment. cont work real Increasingly significantly. change employees will of the role design: and organisation smart In factories, Work content. development professional continuing and to training enhancements the relevant together identifiers, unique and architectures security and safety integrated of deployment the example, willfor This require, access. and unauthorised misuse against protected they contain information and and facilities both time, production same At the environment. or tothe people to either danger apose not do themselves products the and facilities production that to ensure It is important systems. munication networks are a key requirement for for requirement areakey networks munication - tory models c models tory ent, work processes and the working working the and processes work ent, products and in particular the data data the particular in and products e necessary to deploy participative e necessaryparticipative todeploy - time oriented control will transform will time control oriented an provide a basis for for a basis an provide
– therefore be
need to be to need
- technical technical are both are both - quality quality -
ment:
with
summary utive
Exec workplace-based CPD. In order to achieve this, • Resource efficiency: Quite apart from the high model projects and “best practice networks” costs, manufacturing industry’s consumption of should be promoted and digital learning large amounts of raw materials and energy also techniques should be investigated. poses a number of threats to the environment and security of supply. Industrie 4.0 will deliver gains in • Regulatory framework: Whilst the new manufac- resource productivity and efficiency. It will be turing processes and horizontal business networks necessary to calculate the trade-offs between the found in Industrie 4.0 will need to comply with the additional resources that will need to be invested in law, existing legislation will also need to be adapted smart factories and the potential savings generated. to take account of new innovations. The challenges The journey towards Industrie 4.0 will be an evolution-ary include the protection of corporate data, liability issues, handling of personal data and trade process. Current basic technologies and experi-ence will restrictions. This will require not only legisla-tion but have to be adapted to the specific require-ments of also other types of action on behalf of businesses – manufacturing engineering and innovative solutions for an extensive range of suitable instruments exists, new locations and new markets will have to be explored. including guidelines, model contracts and company If this is done successfully, Industrie 4.0 will allow agreements or self-regula-tion initiatives such as Germany to increase its global competitive-ness and audits. preserve its domestic manufacturing industry.
Industrie 4.0 7
Working group members Authors
Technical experts Technol of Institute Karlsruhe Beigl, Michael Dr. Prof. Automation and Engineering Manufacturing for Fraunhofer Bauernhansl, Thomas Dr. Prof. Reiner Dr. Prof. members Academic Ltd. ABB Zeidler, Christian KG Dr. & Co. AG Veit, Festo Eberhard Dr. AG Daimler Thomas Dr. Weber, Hewlett Smid, Volker AG Technologies Infineon Ploss, Reinhard Dr. PeDr. AG Software Jost, AG Dr. Wolfram DHL Post Deutsche Helbig, Johannes Dr. AG BMW Dräger, Klaus AG Dr. Telekom Arnold, Deutsche Heinrich Dr. AG ThyssenKrupp Achatz, Reinhold Dr. fromindustry Members GmbH Dr. 5 WG Artificial Intelligence) for Center Research (German DFKI Dr. Prof. Wahlster, Wolfgang 4 WG AG SAP Fischer, Stephan Dr. 3 WG AG Siemens Russwurm, Siegfried Dr. Prof. 2 WG AG WITTENSTEIN Manfred Dr. Wittenstein, 1 WG spokespersons WG Kagermann, Henning Dr. Prof. GmbH Bosch Robert Dais, Siegfried Dr. Co experts Technical Authors | members group Working - Heinz Derenbach, Bosch Software Innovations Software Bosch Derenbach, Heinz chairs ter Leibinger, TRUMPF GmbH & Co. KG & Co. GmbH TRUMPF Leibinger, ter – – – – –
- The Factor The Technology Beingsand Human Work Environment Economic The Environment Real The Factory Smart The ogy (KIT) ogy
Anderl, TU Darmstadt Anderl, TU
- Packard GmbH Packard
acatech
-
Institute Institute
and Electronic Electronic and Electrical (German ZVEI Diegner, Bernhard Dr. professional Industry Scholz Bernd Dr. Prof. München TU Reinhart, Gunther Dr. Prof. / Aachen RWTH WZL Klocke, Fritz Dr. Prof. Bremen University Jacobs Herzog, Otthein Dr. Prof. Paderborn Universität Gausemeier, Jürgen Dr. Prof. Offis / Oldenburg Universität Damm, Werner Dr. Prof. München TU Broy, Manfred Dr. Prof. Education Education of Ministry (Federal BMBF Zielonka, Clemens Dr. and Technology) Economics (Federal Ministry of Tettenborn,BMWi Dr. Alexander and Research) Education Ministry(Federal of Ingo Ruhmann, BMBF Research) and Education of Dr. Prof. Wolf and Technology) Economics of (Federal Ministry BMWi Goerdeler, Andreas Dr. Guests Bremen University Jacobs Staudinger, M. Ursula Dr. Prof. IAO Fraunhofer Spath, Dieter Dr. Prof. Unions) Trade DGB Sehrbrock, Ingrid Industries) German of BDI (Federation Schweer, Dieter Alliance vonScheel, Henrik Group Scheer, Scheer August Dr. Prof. Wilhelm Devrient & GmbH Giesecke Ottenberg, Dr. Karsten Technology, Science, Production Information of (Institute Lanza, KIT Dr. Gisela Prof. WBK, for Media) New and Telecommunications Engineering (German Association (Federal BITKOM VDMA Kempf, Dieter Prof. Federation) Glatz, Rainer
Authors and experts
and Research) and - Science Research Alliance Research and Science - Dieter Lukas, Lukas, BM Dieter
Manufacturers’ Association) Manufacturers’ associations
Global University University Global Karlsruhe Institute of Technology) of Technology) Karlsruhe Institute - Reiter, BIBA Reiter, (Confederation of German of (Confederation
BF (Federal Ministry BF (Federal
Industrie 4.0 Industrie
9
10
Industrie 4.0 Industrie Bremen University Jacobs Staudinger, M. Ursula Dr. Prof. and Automation Engineering Manufacturing Institute for Fraunhofer Seidelmann, Joachim AG Software Schöning, Harald Dr. KIT Peters, Steven WBK, Universit Jacobs Patzwaldt, Katja Dr. Federation) Engineering (German VDMA Lehmann, Jörn Köpfer Petra Fraunhofer Günter Hörcher, Dr. AG Telekom Heuer, Jörg AG SAP Geiger, Kerstin Dr. AG Siemens Bettenhausen, KurtDr. D. Co acatech Stumpf, AG Veronika Siemens Löwen, Ulrich Dr. Metall IG Kurz, Constanze Dr. AG Technologies Infineon Kaufmann, Thomas Dr. AG Siemens Marion Horstmann, WZL Aachen / RWTH Herfs, Dr. Werner acatech Ariane Hellinger, Glatz,VDMARainer Engin (German GmbH Innovations Software Bosch Stefan Ferber, Dr. New Media) and Telecommunications Technology, Information for Association (Federal BITKOM Dorst, Wolfgang Hewlett Diemer, Johannes Electronic and Electrical (German ZVEI Diegner, Bernhard Dr. KG & Co. GmbH Werkzeugmaschinen Trumpf Bauer, Klaus Authors - authors
–
- core team core Behncke, SAP AG Behncke,
Manufacturers’ Association) Manufacturers’
Authors and experts
- Packard GmbH GmbH Packard
-
Institut IPA eering Federation)
yBremen
Center for Artificial Intelligence) Artificial Center for Research (German DFKI Dengler, Dietmar Dr. Unions) Trade German of (Confederation DGB Anbuhl, Mathias AG Telekom Deutsche Aggarwal, Vinay Additional authors fr Passau Universität Kai Hofmann, Passau Universität Hornung, Gerrit Dr. Prof. RegulatoryChapter 5.7 framework Systems in Transportation SafeTRANS Niehaus, Jürgen Technology Information for Institute OFFIS Brucke, Matthias SafetyChapter 5.4 security and Michael Wetzel, Daimler AG Daimler Michael Wetzel, KG & Co. GmbH Werkzeugmaschinen Heinz Dr. IWB Philipp, Tobias Dr. Intelligence) Artificial for Center Research (German DFKI Ndiaye, Alassane Dr. Co.KGAG & Festo Kärcher, Bernd AG BMW Hilgenberg, Dirk KG + Co. GmbH Werkzeugmaschinen TRUMPF Haubelt, Andreas GmbH + Co.KG Werkzeugmaschinen Dr. GmbH Homag Holzbearbeitungssysteme Doll, Ulrich Gerhard Hammann, TRUMPF Hammann, Gerhard Detlef Pauly, Siemens AG Siemens Pauly, Detlef - Jürgen Prokop, TRUMPF Prokop, Jürgen
om the Working Groups
–
Safety Safety
Michael Vöth, Robert Bosch GmbH Bosch Vöth, Robert Michael AG Süd TÜV Vetter, Martin Dr. GmbH Epyxs Törl, Benjamin ZVEI Theobald, Carolin T Stephan, Winfried SIT Fraunhofer Steinebach, Martin Dr. GmbH Services BayerTechnology Speth, Dr. Walter KG & Co. Pilz GmbH Hansjörg Sperling Martin GmbH Rohr, accessec Sebastian BSI Mehrfeld, Jens VDMA Lehmann, AG Jörn Siemens Klasen, Dr. Wolfgang IT & Industrial Automation für Köln, Institut Klasen,Fachhochschule Frithjof Dr. Prof. Contact Phoenix GmbH Kalhoff, Co.KG & Johannes Security secunet Hartmut Kaiser, AG Technologies Security Innominate Lutz Jänicke, Dr. AG Technologies Infineon Houdeau, Detlef Dr. SIT Fraunhofer Henkel, Thorsten Dr. und Unix Netzwerk für Gesellschaft GeNUA Harlander, Magnus Dr. Association Manufacturers’ Electronic and Electrical ZVEI (German Gurke, Stephan Federation) Engineering (German VDMA Glatz, Rainer KG Co. & GmbH Pilz Glaser, Armin New Media) and Telecommunications Technology, Information Dorst, Wolfgang Hildebrandt Paul KG & Co. GmbH HIMA Ditting, Stefan Networks AG Security secunet Bulthuis, Willem GmbH Epyxs Bonev, Slavtcho Exploitation Image and Technologies System Optronics, of Institute Bier, Fraunhofer Christoph KG GmbH&Co. TRUMPF Werkzeugmaschinen Bauer, Klaus Frankfurtam Mainfortheir inputinto chapter 5.4 „Safetysecurity“and workshop held on 18January 2013 in We would like to thank the participants in the following technical expert workshops technicalexpert inthefollowing participants the liketothank would Schwibach, BASF SE BASF Schwibach,
BITKOM (Federal Association for for Association (Federal BITKOM
- Wohlgemuth,
- Systems International GmbH Systems
- Administration mbH Administration
Networks AG Networks
)
AG Siemens Böttcher, Georg Dr. KG& Co. GmbH TRUMPF Werkzeugmaschinen Bauer, Klaus ZVEI Till Barleben, 2013Berlinin for their inputinto chapter 5.7 „Regulatoryframework“ workshop onheld VDMA Zimmermann, Steffen WIBU Oliver Winzenried, VDMA Marc Wiesner, GmbH Holding Deutschland General Electric Dr. Alexander Walsch, Marc Wiesner, VDMA Marc Wiesner, Natalie BITKOM Rehse, Mario Dr. DLR Patschke, Christian Metall IG Mittag, Reinold Dr. BITKOM Kripko, Lars Würzburg Universität Sven Hötitzsch, Passau Universität Hornung, Gerrit Dr. Prof. Passau Universität Kai Hofmann, Johannes BITKOM Dehmel, Susanne GmbH Innovation VDI/VDE +Technik Botthof, Alfons
Authors and experts
Swann, Hewlett Swann,
Diemer, Hewlett Diemer,
- Packard GmbH Packard
- SYSTEMS AGSYSTEMS
- Packard GmbH Packard
28January
4.0 Industrie
11
1 Introduction
1 Introduction
1 Introduction
Securing the future of German manufacturing industry Powerful, autonomous microcomputers (embedded Germany has one of the most competitive manufactur-ing systems) are increasingly being wirelessly networked industries in the world. This is due to its ability to manage with each other and with the Internet. This is resulting complex industrial processes where different tasks are in the convergence of the physical world and the performed by different partners in different geographical virtual world (cyberspace) in the form of Cyber- locations. It has been successfully em-ploying information Physical Sys-tems (CPS). Following the introduction of 2 and communication technology (ICT) to do this for several the new In-ternet protocol IPv6 in 2012, there are decades – today, approxi-mately 90 percent of all now sufficient addresses available to enable universal industrial manufacturing pro-cesses are already direct network-ing of smart objects via the Internet. supported by ICT. Over the past 30 years or so, the IT This means that for the first time ever it is now possible to revolution has brought about a radical transformation of network resources, information, objects and people to the world in which we live and work, with an impact create the Internet of Things and Services. The ef-fects of comparable to that of mechanisation and electricity in the this phenomenon will also be felt by industry. 1 first and second Industrial Revolutions. The evolution of In the realm of manufacturing, this technological evolu-tion can be described as the fourth stage of PCs into smart devices has been ac-companied by a 3 trend for more and more IT infrastruc-ture and services to industriali-sation, or Industrie 4.0 (Fig. 1). be provided through smart net-works (cloud computing). Industrialisation began with the introduction of me- In conjunction with ever greater miniaturisation and the chanical manufacturing equipment at the end of the unstoppable march of the Internet, this trend is ushering 18th century, when machines like the mechanical loom in a world where ubiquitous computing is becoming a revolutionised the way goods were made. This first in- reality. dustrial revolution was followed by a second one that
Figure 1:
The four stages of the Industrial Revolution
First programmable logic 4. industrial revolution
controller (PLC), Modicon 084 based on Cyber- 1969 Physical Systemss
3. industrial revolution uses electronics and IT to
First production line, achieve further automation
Cincinnati slaughterhouses of manufacturing 1870
2. industrial revolution
follows introduction of complexity
electrically-powered mass
First mechanical loom production based on the 1784 division of labour
1. industrial revolution
follows introduction of water- and steam-powered
mechanical manufacturing
facilities time
End of Start of Start of 1970s today
18th century 20th century Source: DFKI 2011
Industrie 4.0 13
1 Introduction began around the turn of the 20th century and involved Using the Internet of Things electrically-powered mass production of goods based and Services in manufacturing on the division of labour. This was in turn superseded The Internet of Things and Services makes it possible by the third industrial revolution that started during the to create networks incorporating the entire manufactur- early 1970s and has continued right up to the present ing process that convert factories into a smart environ- day. This third revolution employed electronics and in- ment. Cyber-Physical Production Systems comprise formation technology (IT) to achieve increased auto- smart machines, warehousing systems and production mation of manufacturing processes, as machines took facilities that have been developed digitally and feature over not only a substantial proportion of the “manual end-to-end ICT-based integration, from inbound logis- labour” but also some of the “brainwork”. tics to production, marketing, outbound logistics and
Germany needs to draw on its strengths as the world’s service. This not only allows production to be config- leading manufacturing equipment supplier and in the ured more flexibly but also taps into the opportunities field of embedded systems by harnessing the spread offered by much more differentiated management and of the Internet of Things and Services into the manu- control processes.
facturing environment so that it can lead the way to- In addition to optimising existing IT-based processes, wards the fourth stage of industrialisation. Industrie 4.0 will therefore also unlock the potential of
Rolling out Industrie 4.0 will not only strengthen Ger- even more differentiated tracking of both detailed pro- 6 many’s competitive position but also drive solutions to cesses and overall effects at a global scale which it both global challenges (e.g. resource and energy effi- was previously impossible to record. It will also involve ciency) and national challenges (e.g. managing demo- closer cooperation between business partners (e.g. graphic change). However, it is crucial to consider suppliers and customers) and between employees, technological innovations within their sociocultural 7 providing new opportunities for mutual benefit. 4 context , since cultural and social changes are also As the world’s leading manufacturing equipment sup- major drivers of innovation in their own right. Demo- plier, Germany is uniquely well placed to tap into the graphic change, for example, has the potential to 8 transform all the key areas of our society, such as the potential of this new form of industrialisation. Germa- way that learning is organised, the nature of work and ny’s global market leaders include numerous “hidden health as people live longer lives and the infrastruc- champions” who provide specialised solutions – 22 of Germany’s top 100 small and medium-sized enterpris-es ture of local communities. This will in turn have signifi- (SMEs) are machinery and plant manufacturers, with cant implications for Germany’s productivity. By opti- 9 mising the relationship between technological and three of them featuring in the top ten. Indeed, many social innovation processes, we will be making an im- leading figures in the machinery and plant manufactur-ing portant contribution to the competitiveness and pro- industry consider their main competitors to be do-mestic 10 5 ones. Machinery and plant also rank as one of ductivity of the German economy. Germany’s main exports alongside cars and chemi- 11 cals. Moreover, German machinery and plant manu- facturers expect to maintain their leadership position in
The Internet of Things and Services is coming to the manufacturing environment:
In essence, Industrie 4.0 will involve the technical integration of CPS into manufacturing and logistics and the use of the Internet of Things and Services in industrial processes. This will have implications for value creation, business models, downstream services and work organisation.
14 Industrie 4.0
1 Introduction » Industrie 4.0 offers Germany the
chance to further strengthen its
position as a manufacturing loca-
tion, manufacturing equipment
supplier and IT business solutions
supplier. It is encouraging to see
that all the stakeholders in Ger-
many are now working closely
together through the Industrie 4.0
Platform in order to move ahead
with implementation. « Prof. Dr. Henning Kagermann
acatech – National Academy of Science and Engineering
Spokesperson of the Communication Promoters Group of the Industry-Science
Research Alliance and Co-Chair of the Industrie 4.0 Working Group
the future. 60% of them believe that their technological On the initiative of the Industry-Science Research Alli- competitive advantage will increase over the next five ance, the partners in the Industrie 4.0 Platform have years, while just under 40% hope to maintain their cur- therefore set themselves the goal of implementing the
12 rent position. Nonetheless, global competition in the German government’s strategic initiative to secure the
13 manufacturing engineering sector is becoming fiercer competitiveness of German industry. and fiercer. And it is not just competitors in Asia that pose a threat to German industry – the US is also tak- ing measures to combat deindustrialisation through The Industrie 4.0 initiative has huge potential: programmes to promote “advanced manufacturing”.
Furthermore, manufacturing is becoming more dynamic Meeting individual customer requirements • and complex all the time. For example, advances in la- Industrie 4.0 allows individual, customer-specific ser sintering technology mean that it is now possible to criteria to be included in the design, configuration,
“print” complex 3D structures to a high quality standard ordering, planning, manufacture and operation within a matter of hours. This is resulting in the emer- phases and enables last-minute changes to be gence of completely new business models and servic- incorporated. In Industrie 4.0 it is possible to es where the end customer is much more closely in- manufacture one-off items and have very low volved – customers can create their own designs and production volumes (batch size of 1) whilst still e-mail them to a “copyshop”, or they can have objects making a profit. scanned and “copied”.
Industrie 4.0 15
1 Introduction • Flexibility • Responding to demographic change in the CPS-based ad hoc networking enables dynamic workplace configuration of different aspects of business In conjunction with work organisation and processes, such as quality, time, risk, robustness, compe-tency development initiatives, interactive price and eco-friendliness. This facilitates continuous collabora-tion between human beings and “trimming” of materials and supply chains. It also technological systems will provide businesses means that engineering processes can be made more with new ways of turning demographic change agile, manufacturing processes can be changed, to their advantage. In the face of the shortage of temporary shortages (e.g. due to supply issues) can skilled labour and the growing diversity of the be compensated for and huge increases in output can workforce (in terms of age, gender and cultural be achieved in a short space of time. background), Industrie 4.0 will enable diverse • Optimised decision-taking and flexible career paths that will allow people to In order to succeed in a global market, it is becom- keep working and remain produc-tive for longer. ing critical to be able to take the right decisions, • Work-Life-Balance often at very short notice. Industrie 4.0 provides The more flexible work organisation models of end-to-end transparency in real time, allowing companies that use CPS mean that they are well early verification of design decisions in the sphere placed to meet the growing need of employees to of engineering and both more flexible responses to strike a better balance between their work and their disruption and global optimisation across all of a private lives and also between personal develop- company’s sites in the sphere of production. ment and continuing professional development. • Resource productivity and efficiency Smart assistance systems, for example, will provide The overarching strategic goals for industrial new opportunities to organise work in a way that manufacturing processes still apply to Industrie 4.0: delivers a new standard of flexibility to meet delivering the highest possible output of products companies’ requirements and the personal needs of from a given volume of resources (resource produc- employees. As the size of the workforce declines, tivity) and using the lowest possible amount of this will give CPS companies a clear advantage resources to deliver a particular output (resource when it comes to recruiting the best employees. efficiency). CPS allows manufacturing processes to • A high-wage economy that is still competitive be optimised on a case-by-case basis across the Industrie 4.0’s dual strategy will allow Germany entire value network. Moreover, rather than having to develop its position as a leading supplier and to stop production, systems can be continuously also become the leading market for Industrie optimised during production in terms of their 4.0 solutions. resource and energy consumption or reducing 14 their emissions. However, Industrie 4.0 will not pose an exclusively • Creating value opportunities through new technological or IT-related challenge to the relevant in- services dustries. The changing technology will also have far- Industrie 4.0 opens up new ways of creating reaching organisational implications, providing an op- value and new forms of employment, for portunity to develop new business and corporate example through downstream services. Smart models and facilitating greater employee engagement. algorithms can be applied to the large quantities Germany successfully implemented the third Industrial of diverse data (big data) recorded by smart Revolution (“Industrie 3.0”) during the early 1980s by devices in order to provide innovative services. delivering more flexible automated manufacturing There are particu-larly significant opportunities through the integration of Programmable Logic Con- for SMEs and startups to develop B2B trollers (PLCs) into manufacturing technology whilst at (business-to-business) services for Industrie 4.0. the same time managing the impact on the workforce
16 Industrie 4.0
1 Introduction through an approach based on social partnership. Its have also been successfully launched. The Industry- strong industrial base, successful software industry Science Research Alliance is now progressing this ini- 15 and know-how in the field of semantic technologies tiative at a cross-sectoral level through the Industrie 4.0 project. The establishment of the Industrie 4.0 Platform mean that Germany is extremely well-placed to imple- with a Secretariat provided jointly by the professional ment Industrie 4.0. It should be possible to overcome associations BITKOM, VDMA and ZVEI was the logical the current obstacles, such as technology acceptance issues or the limited pool of skilled workers on the la- next step in its implementation. The next task will be to produce R&D roadmaps for the key priority themes. bour market. However, it will only be possible to secure the future of German industry if all the relevant Securing the future of German manufacturing in-dustry stake-holders work together to unlock the potential – this is the goal that the partners in the Indus-trie 4.0 offered by the Internet of Things and Services for Platform have set themselves. The Platform in-vites all manufacturing industry. the relevant stakeholders to continue exploring the Since 2006, the German government has been pro- opportunities provided by Industrie 4.0 so that to- 16 moting the Internet of Things and Services under its gether we can help to ensure successful implementa- High-Tech Strategy. Several technology programmes tion of its revolutionary vision.
1 “Over the past thirty years, the ongoing computer revolution has transformed the world in which we information system. The highest level of computerised factory organisation is characterised by a strategy for live, probably more radically than anything in the previous 200 years. It has also had a radical impact integrating the individual subsystems.”, in: Spur, Günther: Evolution der industriellen Produktion, in Spur, on the world of work that can only be compared in scale to the first Industrial Revolution.” Quotation Günther (Ed.): Optionen zukünftiger Produktionssysteme, Berlin, Akademie Verlag 1997, p. 23.
from Kornwachs, Klaus: Ergänzung und Verdrängung der Arbeit durch Technik – Eine Herausforder- 8 With annual sales totalling 200.5 billion euros and a workforce of around ung für die Technikwissenschaften (Enhancement and Replacement of Jobs by Technology – a 931,000 (average figure for 2011), the machinery and plant manufacturing challenge for engineering science), in: ibid. (Ed.): Bedingungen und Triebkräfte technologischer industry is an extremely important part of the German economy.
Innovationen (Enablers and Drivers of Technological Innovation) (acatech DISCUSSES), Fraunhofer 9 Wirtschaftswoche Ranking, WiWo, 4/2013, pp. 40-50. IRB Verlag, Stuttgart 2007, p. 177 10 VDMA: Tendenzbefragung. Internationale Wettbewerbsposition des deutschen
2 Launched in the summer of 2012, Internet Protocol Version 6 (IPv6) replaces the previous version 4 Maschinen- und An-lagebaus (Survey of Current Trends. Global Competitive of the protocol. IPv6 uses 128-bit IP addresses instead of the 32-bit addresses that were previously Position of German Machinery and Plant Manu-facturers), October 2012.
in use, increasing the number of addresses available from 4.3 billion to 340 sextillion. 11 Federal Statistical Office, figures for 2011. Available online at:
3 The phenomenon that we refer to as Industrie 4.0 is given different names around the globe. Other http://de.statista.com/statistik/daten/ studie/151019/umfrage/exportgueter-aus-deutschland/
terms used include the “Industrial Internet” and the “3rd Industrial Revolution”, see also Chapter 6. 12 VDMA: Tendenzbefragung. Internationale Wettbewerbsposition des deutschen
4 For more on innovation and future technology scenarios, see acatech (Ed.): Technikzukünfte. Vorausden-ken – Maschinen- und An-lagebaus (Survey of Current Trends. Global Competitive Erstellen – Bewerten (Future Technology Scenarios. Planning, Production and Evaluation) (acatech Position of German Machinery and Plant Manu-facturers), October 2012.
IMPULSE), Heidelberg et al.: Springer Verlag 2012, p.16, which contains the following observation: 13 See the German government’s High-Tech Strategy (HTS) Action Plan, Strategic Initiative “When thinking about the future, it is crucial to avoid considering technological innovations outside of Industrie 4.0, p. 52ff. Available online at: http://www.bmbf.de/pub/HTS-Aktionsplan.pdf
their sociocultural context. For example, the future role of different energy carriers will be largely 14 See Vogel-Heuser, Birgit et al.: Forschungsfragen in “Produktautomatisierung der Zukunft“ (Research Issues in determined by how well they are accepted by society, the state of the economy and the global “Future Product Automation”), (acatech MATERIALS), Munich 2012, p. 28.
political situation. Terms like ‘innovation systems’ and ‘culture of innovation’ bear witness to the 15 Under the auspices of the “Internet of Services” flagship project, the German government funded the THESEUS recent trend to place greater emphasis on this broader sociocultural context.” research programme between 2007 and 2012 in order to promote the development and trialling of new, Internet-
5 This report focuses on discussing the potential of Industrie 4.0 with regard to technological innovation. based knowledge infrastructures geared towards making better use and maximising the value of the knowledge
6 Globalised manufacturing is already a reality today, as witnessed in the automotive industry, for example. available through the Internet. The research programme focused on semantic technologies that, instead of “German” cars are in fact now international products made with components from Asia, Europe and the US and detecting content (words, images, sounds) using conventional approaches (e.g. letter combinations), are are even assembled in their respective target markets. However, the use of information technol-ogy in this capable of recognising and classifying the semantic content of information. More information is available online context has hitherto largely failed to reflect the existence of these logistics and manufacturing networks. at: http://www.bmwi.de/DE/Themen/Digitale-Welt/ Internet-der-Zukunft/internet-der-dienste,did=360458.html Currently, IT systems still tend not to cross company or factory boundaries.
7 A look at the past also demonstrates IT’s huge potential for changing the way we do things: “From a 16 For more details, see: Promotorengruppe Kommunikation der Forschungsunion Wirtschaft – Wissen-
technical perspective, an end-to-end information flow will be key to future factory designs, with elec- schaft (Ed.): Im Fokus: Das Zukunftsprojekt Industrie 4.0 – Handlungsempfehlungen zur Umsetzung
tronic data processing enabling all parts of the factory to be connected to each other through a global (Communication Promoters Group Report), Berlin, 2012.
Industrie 4.0 17
2 The vision:
Industrie 4.0 as part of
a smart, networked world
vision 2 The
2 The vision: Industrie 4.0 as part of a smart, networked world
In a “smart, networked world”, the Internet of Things and me?”, “where should I be delivered to?”, etc. Its inter- Services will make its presence felt in all of the key faces with smart mobility, smart logistics and smart 1 grids will make the smart factory a key component of areas. This transformation is leading to the emergence tomorrow’s smart infrastructures. This will result in the of smart grids in the field of energy supply, sustainable transformation of conventional value chains and the mobility strategies (smart mobility, smart logistics) and 2 emergence of new business models. smart health in the realm of healthcare. In the manufac- turing environment, vertical networking, end-to-end en- Industrie 4.0 should therefore not be approached in gineering and horizontal integration across the entire isolation but should be seen as one of a number of value network of increasingly smart products and sys- key areas where action is needed. Consequently, tems is set to usher in the fourth stage of industrialisa-tion Industrie 4.0 should be implemented in an – “Industrie 4.0”. interdisciplinary man-ner and in close cooperation with the other key areas (see Fig. 2). Industrie 4.0 is focused on creating smart products, procedures and processes. Smart factories constitute a 2.1 Shaping the vision of Industrie 4.0 key feature of Industrie 4.0. Smart factories are capa-ble of managing complexity, are less prone to disrup-tion and Achieving the paradigm shift required to deliver Indus- are able to manufacture goods more efficiently. In the trie 4.0 is a long-term project and will involve a gradual smart factory, human beings, machines and re-sources process. Throughout this process, it will be key to en- communicate with each other as naturally as in a social sure that the value of existing manufacturing systems network. Smart products know the details of how they is preserved. At the same time, it will be necessary to were manufactured and how they are intend-ed to be come up with migration strategies that deliver benefits used. They actively support the manufacturing process, from an early stage (see also Chapters 3 and 5.4). answering questions such as “when was I made?”, “which Nev-ertheless, innovations constituting a quantum leap parameters should be used to process may arise in some individual sectors.
Figure 2: Industry etof S 4.0 and smart e factories as part ern
nt rv I ic e of the Internet s of Things and Services Smart Mobility Smart Logistics
Smart Grids Smart Factory Smart Buildings
CPS
Smart Product
n I gs t in
ernetofTh
Industrie 4.0 19
2 The vision 2 The
In the fields of production and automation engineering and IT, horizontal integration refers to the integration of the various IT systems used in the different stages of the manufacturing and business planning processes that involve an exchange of materials, energy and information both within a company (e.g. inbound logistics, production, outbound logistics, marketing) and between several different companies (value networks). The goal of this integration is to deliver an end-to-end solution.
In the fields of production and automation engineering and IT, vertical integration refers to the integration of the various IT systems at the different hierarchical levels (e.g. the actuator and sensor, control, production management, manufacturing and execution and corporate planning levels) in order to deliver an end-to-end solution.
If German industry is to survive and prosper, it will 2.2 What will the future look like under Industrie 4.0? need to play an active role in shaping this fourth industrial revolution. It will be necessary to draw on Industrie 4.0 will deliver greater flexibility and robust- the tradition-al strengths of German industry and ness together with the highest quality standards in the German re-search community: engineering, planning, manufacturing, operational and logistics processes. It will lead to the emergence of • Market leadership in machinery and dynamic, real-time optimised, self-organising value plant manufacturing chains that can be optimised based on a variety of • A globally significant cluster of IT competencies criteria such as cost, availability and resource con- • A leading innovator in embedded systems sumption. This will require an appropriate regulatory and automation engineering framework as well as standardised interfaces and har- • A highly-skilled and highly-motivated workforce monised business processes. • Proximity to and in some cases close cooperation between suppliers and users The following aspects characterise the vision for In- Outstanding research and training facilities • dustrie 4.0:
In implementing Industrie 4.0, the aim is to create an • It will be characterised by a new level of socio- optimal overall package by leveraging existing techno- technical interaction between all the actors and logical and economic potential through a systematic resources involved in manufacturing. This will innovation process drawing on the skills, performance revolve around networks of manufacturing resourc- and know-how of Germany’s workforce. Industrie 4.0 es (manufacturing machinery, robots, conveyor and will focus on the following overarching aspects: warehousing systems and production facili-ties) that
are autonomous, capable of controlling themselves • Horizontal integration through value networks in response to different situations, self-configuring, • End-to-end digital integration of engineering knowledge-based, sensor-equipped and spatially across the entire value chain dispersed and that also incorporate the relevant • Vertical integration and networked planning and management systems. As a key manufacturing systems component of this vision, smart factories will be embedded into inter-company value networks and These aspects are considered in more detail in will be characterised by end-to-end engineering that Chap-ter 3 in the context of the dual strategy. encompasses both the manufacturing process and the manufactured
20 Industrie 4.0
vision 2 The
The Internet of Things and »
Services harbours huge
po-tential for innovation in
man-ufacturing. If we also
suc-ceed in integrating
Web-based services into
Industrie 4.0 we will
increase the scope of this
potential immeasurably. «
Dr. Johannes Helbig Deutsche Post AG
Member of the Communication Promoters Group of the Industry-Science
Research Alliance
• In the future under Industrie 4.0, it will be possible product, achieving seamless convergence of the to incorporate individual customer- and product- digital and physical worlds. Smart factories will specific features into the design, configuration, make the increasing complexity of manufacturing ordering, planning, production, operation and processes manageable for the people who work recycling phases. It will even be possible to incor- there and will ensure that production can be porate last-minute requests for changes immedi- simultaneously attractive, sustainable in an urban ately before or even during manufacturing and environment and profitable. potentially also during operation. This will make it
possible to manufacture one-off items and very • The smart products in Industrie 4.0 are uniquely small quantities of goods profitably. identifiable and may be located at all times. Even while they are being made, they will know the • Implementation of the Industrie 4.0 vision will details of their own manufacturing process. This enable employees to control, regulate and means that, in certain sectors, smart products will configure smart manufacturing resource networks be able to control the individual stages of their and manufacturing steps based on situation- and production semi-autonomously. Moreover, it will context-sensitive targets. Employees will be freed be possible to ensure that finished goods know up from having to perform routine tasks, enabling the parameters within which they can function them to focus on creative, value-added activities. opti-mally and are able to recognise signs of They will thus retain a key role, particularly in wear and tear throughout their life cycle. This terms of quality assurance. At the same time, information can be pooled in order to optimise flexible working conditions will enable greater the smart factory in terms of logistics, compatibility between their work and their deployment and maintenance and for integration personal needs. with business management applications.
Industrie 4.0 21
2 The vision 2 The fairly a mon g all t he st akeh olde rs in t he v alue c hain , in - cludin g th e n ew on es. Br oad er r egul ato ry re quir em ents s uch a s cutti ng CO 2 emissi ons ( see C hapt er 5.8) can and sho uld b e int egr ated into thes e busi ness mod els so that the y can be met collectiv ely by t he part ner s in t he b usines s netw orks (se e Fi g. 3 ) .
• Implementation of the vision for Industrie 4.0 will require further expansion of the relevant network
infrastructure and specification of network
service quality through service level
agreements. This will make it possible to meet Indust rie 4 .0 us e cas e sce nari os r elatin g e. g. to “n et - w orke d m anu factu ring ”, “ self - or ganisi ng a daptiv e logi s - tics ” a nd “custo me r - i nteg rat ed e ngin eerin g” will req uire busin ess models tha t will pri marily be i mple men ted by wh at co uld b e a highly dyna mic n etwo rk of busin esses rat her tha n by a singl e co mpa ny. This will r aise a nu m - ber of questi ons reg ardi ng fin ancin g, d evelo pme nt, reli - ability, risk, lia bility a nd IP a nd k now - how pro tectio n. As f ar as the or ganis ation of t he n etwo rk an d th e qu alified diffe ren tiatio n of it s ser vices is c once rne d, it will be c ru - ci al to ensu re that res ponsi bilities a re c orr ectly as - sig ned within the busin ess n etwor k, ba cked up by th e rel evan t bin ding docu men tatio n.
the need for high band-widths for data-intensive
applications and for service providers to guarantee run times for time-critical applications.
2.3 Novel business opportunities and models
Industrie 4.0 will lead to the development of new busi- ness and partnership models that are far more geared
Detailed mo nitori ng o f the busi ness mod els in real time 3 will als o pla y a k ey r ole in docu men ting proc essin g ste ps an d syst em st atus es to de mons trat e th at th e co ntr actual and re gulat ory c onditi ons have bee n co m - towards meeting individual, last-minute customer re- quirements. These models will also enable SMEs to use services and software systems that they are unable to afford under current licensing and business models. The new business models will provide solutions to is-sues such as dynamic pricing that takes account of customers’ and competitors’ situations and issues re-lating to the quality of service level agreements (SLAs) in a context characterised by networking and coopera-tion between business partners. They will strive to en-sure that the potential business benefits are shared
Figure 3: Horizontal value
network
Engineering
External Designer Factory 1 Marketing and Engineering Sal es Source: Hewlett - Packard 2013
22 Industrie 4.0
vision 2 The plied with. The individual steps of the business pro- proving the productivity of the workforce. It will be es- cesses will be tracked at all times, providing documen- pecially important to increase the proportion of older tary evidence of their completion (see also 5.7). In people and women in employment. The latest research order to ensure efficient provision of individual indicates that individual productivity does not depend on a services, it will be necessary to establish exactly what person’s age but is instead connected with the amount of the rele-vant service life cycle might look like, which time they have been in a particular position, the way that promises can be guaranteed and which licence their work is organised and their working environment. If models and con-ditions would allow new partners – productivity is to be maintained and in-creased over the especially SMEs – to join the business networks. course of longer working lives, it will therefore be
In view of the above, it is likely that Industrie 4.0 will necessary to coordinate and transform several different aspects of the workplace, including health management give rise to unpredictable global effects and a highly and work organisation, lifelong learning and career path dynamic environment. The disruptive nature of new 4 technologies and their impact on legal issues (e.g. with models, team structures and knowledge management. regard to technology, sensitive corporate data, liability, This is a challenge that will have to be met not just by data protection, trade restrictions, use of cryptography, businesses but in particular also by the education system. etc) can pose a threat to the enforceability of existing legislation. Short innovation cycles result in the need Thus, it will not only be new technical, business and for constant updating of the regulatory framework and legal factors that determine Germany’s future cause chronic failings in terms of enforcement. It will competitive-ness, it will also be the new social therefore be necessary to adopt a new approach infrastructures in the Industrie 4.0 workplace that whereby technologies are tested for their compatibility have the capacity to achieve far greater structural with the law both prior to and during their development involvement of workers in the innovation process. (see Chapter 5.7). Another factor that is key to the suc-cess of the Industrie 4.0 initiative is the topic of An important role will also be played by the paradigm safety and security (see Chapter 5.4). Once again, a shift in human-technology and human-environment far more proactive approach will be required in this interaction brought about by Industrie 4.0, with novel area. Fur-thermore, it will be important to ensure that forms of collaborative factory work that can be per- the concept of Security by Design is not simply formed outside of the factory in virtual, mobile work- confined to func-tional components. places. Employees will be supported in their work by smart assistance systems with multimodal, user-friend-
ly user interfaces. 2.4 New social infrastructures in the workplace In addition to comprehensive training and CPD meas- Industrie 4.0 will bring a number of innovations to a ures, work organisation and design models will be key country that is in the throes of demographic change – to enabling a successful transition that is welcomed by Germany has the second oldest population in the world, the workforce. These models should combine a high after Japan, whilst the average age of the work-force at degree of self-regulated autonomy with decentralised many German manufacturing companies is in the mid- leadership and management approaches. Employees forties. The number of young employees is in constant should have greater freedom to make their own deci- decline and there is already a shortage of skilled labour sions, become more actively engaged and regulate their own workload. and applicants for apprenticeships in cer-tain professions. In order to ensure that demographic change does not The socio-technical approach of the Industrie 4.0 occur at the expense of current living standards, it will be initiative will unlock new potential for developing ur- necessary for Germany to make better use of its existing gently needed innovations, based on a greater labour market reserves for In-dustrie 4.0 whilst at the aware-ness of the importance of human work in the same time maintaining and im- innovation process.
Industrie 4.0 23
vision 2 The 2.5 Novel service-based, real- • Support for mobile end devices time enabled CPS platforms • Support for collaborative manufacturing, service, analysis and forecasting processes in The strategic initiative Industrie 4.0 will give rise to business networks. novel CPS platforms geared towards supporting collabora-tive industrial business processes and the In the context of the business networks, there is a par- associated business networks for all aspects of ticular need for IT development work with regard to the orchestration of services and applications on shared smart factories and smart product life cycles. The services and applications provided by these plat- CPS platforms, since this is where the specific forms will connect people, objects and systems to each requirements for horizontal and vertical integration of other (see Fig. 4) and will possess the following features: CPS, applications and services arise in industrial business processes (see also Chapter 5.1). For In- dustrie 4.0, it is important to interpret the term ‘or- • Flexibility provided by rapid and simple orchestra-tion of services and applications, chestration’ more broadly than is usually the case in including CPS-based software the context of web services. It should explicitly include • Simple allocation and deployment of business the setting up of shared services and applications in processes along the lines of the App Stores model collaborative inter-company processes and business • Comprehensive, secure and reliable backup of networks. Issues such as safety and security, confi- the entire business process dence, reliability, usage, operator model convergence, • Safety, security and reliability for everything real-time analysis and forecasting will all need to be from sensors to user interfaces reviewed for the orchestration and subsequent effi-
Internet of People Figure 4: The Internet of Things and 106-108 Social Web
Services – Networking
people, objects and systems
CPS- platforms
Smart Grid
Business Web Smart Factory
Smart Building
Smart Home
Internet of Things Internet of Services 107-109 104-106 Source: Bosch Software Innovations 2012
24 Industrie 4.0
vision 2 The cient, reliable, safe and secure operation of collabora- Availability of a secure and efficient network infrastruc- tive manufacturing and service processes as well as ture with high bandwidths will be key to guaranteeing the for the execution of dynamic business processes on necessary secure data exchange (see Chapter 5.3). CPS platforms. Among other things, this will involve addressing the challenges posed by the wide range of 2.6 The road to Industrie 4.0 different data sources and end devices. The require- ments referred to above are currently met in only a Implementing the vision of Industrie 4.0 will involve an evo- very rudimentary fashion by generic cloud infrastruc- lutionary process that will progress at different rates in in- ture initiatives. Inter-company use of CPS platforms by dividual companies and sectors. A survey on the “pros-pects IT, software and service providers and by the users for Industrie 4.0” carried out at the beginning of the year by themselves will require an Industrie 4.0 reference ar- the professional associations BITKOM, VDMA and ZVEI chitecture that will need to take account of the differ- confirmed the importance of this topic for the ent perspectives of the ICT and manufacturing indus- competitiveness of German industry and documented the need for fuller and more targeted information (see Fig. 5). tries (see Chapter 5.1). Modelled methods will be 5 required to develop new applications and services for Some 47 percent of the companies in the survey said that these CPS platforms, in order to manage the com- they were already actively engaged with Industrie 4.0. 18 plexity resulting from increasing functionality, customi- percent of these companies said that they were in-volved in sation, dynamism and cooperation between different research into Industrie 4.0, whilst 12 percent claimed that disciplines and organisations (see Chapter 5.2). they were already putting it into practice.
Figure 5: Results Are you already engaged with Industrie 4.0? What are the greatest challenges connected of survey with implementing Industrie 4.0? on Industrie 4.0 (you may select more than one answer) Yes: 131* Standardisation 147 trends (January 2013) No: 133 Process/work organisation 129 Product availability 98 How are you engaging with this topic? New business models 85 Obtaining information Security know-how protection 78
112
about it Lack of specialist staff 70 Involved in research 51 Research 64 Training and CPD 42 33 Putting it into practice Regulatory framework 30 140 0 20 40 60 80 100 120 0 20 40 60 80 100 120 140 160
How important is Industrie 4.0 What support measures would you like to assist you with implementation of Industrie 4.0? for your competitiveness as a: Manufacturer: 4 / important** Opportunity to share experiences 162 1 2 3 4 5 6 Regular newsletter 109 Not at all important Indispensable Involvement in working groups 78 Training courses/seminars 66 User: 3 / average Involvement in research projects 60 1 2 3 4 5 6 Online forums 41 Not at all important Indispensable 0 20 40 60 80 100 120 140 160
278 companies took part in the survey, mainly from the machinery and plant manufacturing industry. 205 of the companies that took part had fewer than 500 employees.
* The figures refer to the number of companies ** Average score based on answers provided by all companies Source: BITKOM, VDMA, ZVEI 2013
Industrie 4.0 25
vision 2 The The three greatest challenges connected with imple- • Business processes in manufacturing are menting the vision were identified as standardisation, currently often still static and implemented work organisation and product availability. through extremely inflexible software systems. Alongside active involvement in working groups, other However, they cannot simply be replaced support measures requested by companies to aid them overnight by service-oriented systems. It will be with implementation of Industrie 4.0 include targeted essential to integrate new technologies into older seminars where they can share experiences and regu-lar ones (or vice versa) – old systems will need to newsletters. The professional associations will play an be upgraded with real-time enabled systems. important role in ensuring a steady flow of communi- • The rate of development of new business cation, working closely with the social partners, the models for manufacturing in the Internet of academic community and the public. Approximately 50 Things and Services will approach the rate of percent of the companies surveyed said that they had development and dynamism of the Internet itself. already received information about Industrie 4.0 through • Employees will be involved at an early stage in their professional associations. the innovative socio-technical design of work
In addition to the above, the Working Group considers organisa-tion, CPD and technological development (see Chapter 5.5). the following measures to be key to enabling a smooth transition to Industrie 4.0 for businesses: • In order to achieve the transition to Industrie 4.0, it will be necessary for the ICT industry (that is accustomed to short innovation cycles) to work • Implementation of real-time enabled CPS solutions will closely with machinery and plant manufacturers place high demands on the availability of services and and mechatronic system suppliers (who tend to network infrastructure in terms of space, technical think in terms of much longer innovation cycles) quality and reliability. In order to secure Germany’s in order to develop business models that are competitiveness internationally, harmoni-sation of acceptable to all the partners. services and business models through the introduction of the relevant international standards should be supported by policymakers both nationally and globally (see also Chapters 5.1 and 5.3).
TAKE-HOME MESSAGE: In conjunction with smart production, smart logistics, smart grids and smart products, the increasing use of the Internet of Things and Services in manufacturing will transform value chains and lead to the emer-gence of new business models. The strategic initiative Industrie 4.0 will leverage the existing technological and commercial potential. Indus-trie 4.0 offers the prospect of new business opportunities and innovative new social infrastructures in the workplace.
1 In 2009, the Industry-Science Research Alliance identified five key areas for action: climate/energy, 3 “Real time” refers to data processing that occurs synchronously with events in mobility, health, security and communication; more information online at: www.forschungsunion.de. the real world, as opposed to data processing where a delay is involved. 2 Since the 3rd industrial revolution, ICT has not only been used in manufacturing in order to optimise costs and 4 See Altern in Deutschland, Vol. 9: Gewonnene Jahre, Empfehlungen der Akademiengruppe, Nova
efficiency, but also in processes that touch on or overlap with manufacturing such as logistics, diag-nostics, Acta leopoldina NF No. 371, Vol. 107, Stuttgart 2009, p. 49, 56. Immigrants and low-skilled workers (if
quality assurance, maintenance, energy management or human resource planning. However, the different IT they receive further training) also constitute sources of untapped potential for the labour market, see
systems have developed separately over time and the separate evolution and predominantly closed nature of OECD: Zuwanderung ausländischer Arbeitskräfte: Deutschland, 2013, available online at:
their architectures means that technically it would be extremely complex to integrate them. This makes it http://www.oecd-ilibrary.org/social-issues-migration-health/zuwanderung-auslandischer-arbeitskrafte- deutschland-german-version_9789264191747-de exceptionally difficult to achieve comprehensive networking of IT systems and flexible reconfiguration of 5 278 companies participated in the survey, Source: BITKOM, VDMA and ZVEI, January 2013. manufacturing systems, meaning that it is often simply not possible to take advantage of the potential offered by this approach. In Industrie 4.0, these restrictions will no longer apply.
26 Industrie 4.0 EXAMPLE APPLICATION 1: Reducing the energy consumed by a vehicle body assembly line while it is not in use
Today, energy efficiency is already an important requirement for machinery. A key enabler for meeting this require-ment is the ability to systematically power down inactive parts of a line during breaks in production. Industrie 4.0 will make greater use of the opportunities that exist to do this by ensuring that this capability is consistently inte-grated into the planning and operation of production facilities.
Today Currently, many production lines or parts thereof Potential savings during planned and continue running and consuming high quantities of unplanned breaks in production energy during breaks, weekends and shifts where
there is no production. For example, 12 percent of the total energy consumption of a vehicle body as-sembly line that uses laser welding technology occurs during breaks in production. The line operates five days a
week on a three shift pattern. Although this complex Electricity Electricity consumption piece of machinery is not in use over the weekend, it remains powered up so that it can resume production
immediately once the weekend is over. 24 hours 90 percent of power consumption during breaks in pro- Source: Siemens 2013 duction is accounted for by the following: robots (20 to
30 percent), extractors (35 to 100 percent) and laser
sources and their cooling systems (0 to 50 percent).
Tomorrow Measures to leverage energy efficiency potential: Potential savings over the weekend In the future, robots will be powered down as a matter of course even during short breaks in production. Dur- ing longer breaks in production they will enter a kind of 1 standby mode known as Wake-On-LAN mode. The extractors will use speed-controlled motors that can be
adjusted to meet requirements instead of motors that Electricity Electricity consumption cannot be controlled in this way. In the case of the laser sources, completely new systems are the only Wed Thu Fri Sat Sun Mon Tue way of delivering improvements. Day Taken together, these measures enable a reduction of Quelle: Siemens 2013 12 percent of total energy consumption to be achieved
(from 45,000kWh/w to approx. 40,000kWh/w), together with a 90 percent cut in energy consumption during
breaks in production. These energy efficiency considerations should be taken into account right from 1 The robots are controlled using PROFIenergy the earliest stages when designing CPS.
POTENTIAL BENEFITS Coordinated power-up and power-down of parts of a vehicle body assembly line leads to improved energy efficiency. Whilst the cost/risk ratio and cost-effectiveness of upgrading existing machinery are not very attractive, this approach will become an established technical standard for the new machines that will be developed by Industrie 4.0’s leading suppliers, enabling improved energy efficiency to be achieved.
3 The dual strategy: becoming a leading
market and supplier
strategy dual 3 The
3 The dual strategy: becoming a leading market and supplier
The fourth industrial revolution (Industrie 4.0) holds huge existing facilities with CPS capabilities as part of potential for manufacturing industry in Germany. In- the strategy for migrating to Industrie 4.0. At the creased deployment of CPS in German factories will same time, it will be necessary to develop models strengthen German manufacturing industry by improving and strategies for designing and implementing the efficiency of domestic production. At the same time, CPS manufacturing structures at new sites. the development of CPS technology offers significant • If Germany wishes to achieve its goal of lasting opportunities for exporting technologies and products. leadership as a supplier of Industrie 4.0 equipment, Consequently, the implementation of the Industrie research, technology and training initiatives should 4.0 initiative should aim to leverage the market be promoted as a matter of priority with a view to 1 potential for German manufacturing industry developing methodologies and pilot applica-tions in the field of automation engineering modelling and through the adoption of a dual strategy comprising system optimisation (see Chapter 5.2). the deployment of CPS in manufacturing on the one hand and the marketing of CPS technology and • Another key challenge will be to use the products in order to strength-en Germany’s technol-ogy to create novel value networks. manufacturing equipment industry on the other. This will involve developing new business models, particularly ones that link products with
the appro-priate services. 3.1 Leading supplier strategy
The leading supplier strategy addresses the potential of 3.2 Leading market strategy Industrie 4.0 from the point of view of the equipment supplier industry . German equipment suppliers provide The leading market for Industrie 4.0 is Germany’s domes- manufacturing industry with world-leading technological tic manufacturing industry. In order to shape and suc- solutions and are thus in pole position to become global cessfully expand this leading market, close networking of leaders in the development, production and worldwide parts of businesses located at different sites will be re- marketing of Industrie 4.0 products. The key is now to find quired, together with closer cooperation between differ- smart ways of combining outstanding technological ent enterprises. This will in turn require logical, end-to- solutions with the new potential offered by information end digital integration of the different value creation technology, in order to achieve a quantum leap in in- stages and the life cycles of products, product ranges and novation. It is this systematic combination of information the corresponding manufacturing systems. One par- and communication technology with traditional high-tech ticular challenge will be to achieve simultaneous inte- strategies that will enable rapidly changing markets and gration into these emerging new value networks of both increasingly complex global market processes to be large-scale undertakings that already operate globally managed so that companies can carve out new market today and SMEs that often still operate only at a regional level. The strength of Germany’s manufac-turing industry opportunities for themselves. is in no small measure due to a balanced structure
comprising a large number of small and medi-um-sized • Existing basic IT technologies need to be adapt-ed enterprises and a smaller number of large-scale to the specific requirements of manufactur-ing and undertakings. However, many SMEs are not prepared for continue to be developed with this particular application in mind. In order to achieve economies the structural changes that Industrie 4.0 will entail, either of scale and ensure widespread effectiveness, it because they lack the requisite specialist staff or be- will be necessary to enhance the manufacturing cause of a cautious or even sceptical attitude towards a technology and IT systems of technology strategy that they are still unfamiliar with.
Industrie 4.0 29 3 The dual strategy 30
Industrie 4.0 Industrie working arrangements (see Chapter 5.5). Chapter (see arrangements working complex for designs organisational efficient and ised custom developing simultaneously whilst 5.6) Chapter (see workers skilled train and educate to important be will it parallel, In 5.3). Chapter (see transmission high including infrastructure, technological the of development and use the celerate ac to essential be will it possible, this make to order In CPS with their in them own businesses. acquainted impleme and becoming board on them taking methodologies, SMEs to tech barriers and the remove tools would This suppliers. leading the of nologies organisational and methodological medium and and visible small more chains large value networked of of potential the networks make to help could SMEs and undertakings of examples transfer technology practice best applications and pilot example,For initiative. and knowledge comprehensive a of implementation and design the therefore is networks value global into SMEs integrating for strategy key One
- ie etrrss o dp the adopt to enterprises sized
- speed broadband data data broadband speed - cl in scale
convince - dustrial nt
also - ing - - - »
• • • civ a tbe oiin n h fc o hgl volatile highly of whilstflexibly markets value their ac adapting creation face the in position stable a achieve to manufacturers for enablers key the are features These 2.1): Chapter also (see features key three incorporates strategy The strategy. the dual as to referred be will approach this Hereafter, poten strategies market leading and supplier leading the if possible be only will goals 4.0’s Industrie of delivery Optimal 3.3The strategy dual its and key features
manufacturing systems withinbusinesses systems manufacturing the integra and product vertical and implementation Development, the both of system manufacturing associated chain value end Digital integration through horizontal networks and inter of Development
cannot allow industry allow to cannot development future its absolutely key to be 4.0 will Implemen industries. energy and manu and machinery plant its in char is Germany’s economy Federal Ministry of Economics and Technology Economics of Ministry Federal Secretary State Parliamentary Ernst Burgbacher standstill.a to come - tial benefits complement each other. other. each complement benefits tial - dustrial base, particularly base,particularly dustrial -
tion of flexible and reconfigurable reconfigurable and flexible of tion - are coordinated to ensure that their their that ensure to coordinated are acterised byacterised i - - to facturing, automotivefacturing, - end engineering across the entire entire the across engineering end - tation of Industrie Industrie tation of
- opn vle cha value company
ts strong strong ts
«
–
ins ins we we
-
strategy dual
3 The tivities in response to changing market requirements. 3.3.2 End-to-end engineering The features outlined under this dual CPS strategy will across the entire value chain allow manufacturing companies to achieve rapid, on- The following key question arises in connection with time, fault-free production at market prices in the con- the goal of achieving end-to-end digital integration text of a highly dynamic market. throughout the engineering process so that the digital and real worlds are integrated across a product’s 3.3.1 Horizontal integration through value networks entire value chain and across different companies Models, designs and implementations of horizontal whilst also incorporating customer requirements: in-tegration through value networks should provide an-swers to the following key question: How can CPS be used to deliver end-to-end busi- ness processes including the engineering work- How can companies’ business strategies, new val- flow? ue networks and new business models be sustain- ably supported and implemented using CPS? In this regard, modelling plays a key role in managing the increasing complexity of technological systems This question applies in equal measure to the (see Chapter 5.2). The appropriate IT systems should realms of research, development and application be deployed in order to provide end-to-end support to (see Fig. 6). In addition to “business models” and the entire value chain, from product development to “forms of coop-eration between different manufacturing system engineering, production and companies”, it is also neces-sary to address topics ser-vice (see Fig. 7). A holistic systems engineering such as “sustainability”, “know-how protection”, ap-proach is required that spans the different technical “standardisation strategies” and “medium to long- disciplines. For this to be possible, engineers will need term training and staff development initiatives”. to receive the appropriate training.
Figure 6: Horizontal integration through value networks
Source: Siemens 2012
Figure 7:
End-to-end
engineering Services
across the entire Production value chain
Production engineering
Production planning
Product design and development
Source: Siemens 2012
Industrie 4.0 31
32
Industrie 4.0 Industrie 2 The equipment su equipmentThe 2 Mnfcuig indust Manufacturing 1 systems manufacturing networked and integration Vertical Figure 8: algorithms8). and Fig. (see communication associa the (topolo structure case a on used be can that defined IT be will rules of configuration set a Instead, predefined. and fixed be not will In factory. the tomor is integration vertical for setting The systems? manufacturing figurable recon and flexible create to used be CPS can How answered: to be needs question following key as far As systems manufacturing networked integration and Vertical 3.3.3 systemsand solutions and software companies that supply e.g. Product Lifecycle Management semi andmaterials raw processingby manufacturingsystem a in product physical a manufacture) companies and making Germany’s manufacturing equipment industry into a leading supplier. leading equipment a into manufacturing industry Germany’s making and companies deliv towards devel 4.0 Industrie initiative strategic the of Implementation verti enable end provide level, strategic integra a at networks value horizontal create to serve can 4.0 Industrie TAKE - finished finished products.This includes both machining process and - o’ sat atre, manu factories, smart row’s -
by - pet n ipeetto measures implementation and opment - pplier industry includes machinery and plant manufacturers, suppliers of automation products,automation of suppliersmanufacturers,plant and machineryincludesindustry pplier HOME MESSAGE: HOME - - case basis to automatically build a specific a build automatically to basis case tion across the entire value chain of the business process level, including engineering, and and engineering, including level, process business the of chain value entire the across tion
ted re ted vertical integration is concerned, the the concerned, is integration vertical y nlds l cmais ht auatr (r ae oen else someone have (or manufacture that companies all includes ry - cally integrated and networked design of manufacturing systems. manufacturing of design networked and integrated cally -
- - y fr vr stain icuig all including situation, every for ) gy ering the twin goals of creating a leading market among Germany’s manufacturing manufacturing Germany’s among market leading a creating of goals twin the ering quirements in terms of models, data, data, models, of terms in quirements
3 The dual strategy
atrn structures facturing
- basedprocessing.
–
should therefore be based on on based be therefore should - foremen and operators will need to be trained to to system. the manufacturing of operation and running approach trained these be of impact to the need understand will operators de and foremen capability system smart network to systems, manufacturing hoc develop to ad necessary be also enable to order in strategies reuse and modularisation will It level. ERP right levels different across signals sensor end ensure to essential is it integration, vertical deliver to order In Topology refers to theway that a manufacturing system isconfigured using manufacturingresources (e.g. – machines, jobs, logistics) and the associated interactions (e.g. material flow). material interactions (e.g. and the associated logistics) machines, jobs, (PLM) systems, manufacturingor logistics softwareapplications o
both in terms of research funding and concrete concrete and funding research of terms in both - to - n dgtl nerto o atao and actuator of integration digital end - n ad eofgrblt of reconfigurability and ing
- a dual strategy geared geared strategy dual a gether with the appropriate the with gether - r business r planning software systems. 3 citos Moreo scriptions.
Source: Siemens 2012 Source: Siemens - -
s n the on es to p o the to up - end
ver, ver,
EXAMPLE APPLICATION 2: End-to-end system engineering across the entire value chain
Benefits: End-to-end digital system engineering and the resulting value chain optimisation will mean that customers no longer have to choose from a predefined range of products specified by the manufacturer but will instead be able to mix and match individual functions and components to meet their specific needs.
Today Today’s value chains – from customer requirements to A variety of interfaces between IT support systems product architectures and production – have often aris- en over a period of many years and tend to be
relatively static. IT support systems exchange information via a variety of interfaces, but can only use
this information with regard to specific individual cases. There is no global overview from the perspective of the product that is being manufactured.
As a result, customers cannot freely select all of their product’s functions and features, even though Source: Siemens 2013 technically it would be possible to allow them to do so.
For example, it is possible to order a rear windscreen wiper for an estate car, but not for a limousine made by the same company. Further-more, IT system
maintenance costs are currently still very high.
Tomorrow The model-based development enabled through CPS End-to-end system engineering allows the deployment of an end-to-end, modelled,
across the entire value chain digi-tal methodology that covers every aspect from custom-er requirements to product architecture and manufac-ture of the finished product. This enables all
the interdependencies to be identified and depicted in an end-to-end engineering tool chain. The
manufacturing system is developed in parallel based on the same para-digms, meaning that it always keeps pace with product development. As a result, it Source: Siemens 2013 becomes feasible to manu-facture individual products.
It is possible to preserve the value of the current in- stalled base by migrating to this tool chain gradually over a number of stages.
POTENTIAL BENEFITS 1. Higher sales thanks to a larger market and higher customer satisfaction. 2. Reduction of internal operating costs through digital end-to-end integration of the value chain.
4 Research requirements
requirements 4 Research
4 Research requirements
Although Industrie 4.0 will largely be implemented by proaches and best practice examples will need to industry itself, there is still a fundamental need for fur- be disseminated across the different levels of the ther research. The Industrie 4.0 Working Group identi- value networks in order to achieve cross-discipline fied and presented the main medium- and long-term knowl-edge and technology transfer. It is for this research requirements and actions in October 2012. reason that the section on the dual strategy (see These are summarised in the following section. Chapter 3) has already provided an in-depth look at The main aim of Industrie 4.0 is to implement a dual three of the five central research themes: strategy (see Chapter 3) based on coordination of the leading supplier and leading market strategies. This 1. Horizontal integration through value networks should be supported by research activities. In Industrie 2. End-to-end engineering across the entire 4.0, it is expected that the revolutionary applications value chain will come about principally as a result of combining 3. Vertical integration and networked ICT with manufacturing and automation technology. manufacturing systems For this to happen, existing CPS features will need to be adapted in the medium term for deployment in man- In the long term, this technology-driven research ufacturing systems. This will require machine and plant cen-tred around manufacturing system applications manufacturers’ strengths as integrators to be pooled with will re-sult in an increase in inter-company or inter- the competencies of the ICT and automation in-dustries divisional interdisciplinary cooperation that will act to establish targeted, creative development processes for as a strategic enabler for predominantly small and creating new CPS. The new level of net-working required medium-sized ma-chinery and plant manufacturers. to achieve end-to-end integration of product models, This will allow the in-dustry to respond much more manufacturing resources and manu-facturing systems is swiftly to market require-ments and establish itself going to necessitate a huge re-search and development as the leading supplier of a wide range of new effort in the longer term. products, services and business models. The priority for future research is shifting towards However, interdisciplinarity will not come about purely the investigation and development of fully describ- through greater cooperation between engineers and able, manageable, context-sensitive and controlla- automation engineers. The significant impact of the ble or self-regulating manufacturing systems. fourth industrial revolution on the industrial jobs of to- In the long term, these will consist of functional CPS morrow is something that will have to be addressed components drawn from cross-discipline, modular tool- both through research and at a practical level. This kits that can either be configured using help functions brings us to the fourth research requirement: or integrate themselves synergistically into an existing infrastructure during production. It should also be pos- 4. New social infrastructures in the workplace sible to achieve significantly enhanced integration of In the interests of social responsibility, it will be neces- virtually planned and real manufacturing processes. In sary to increase the involvement and promote the en- the long term, it will therefore be necessary for re- gagement of employees in terms of using their skills searchers to develop modular CPS and the corre- and experience with regard to both creative design sponding component catalogues as a key feature of and planning processes as well as in the operational any model smart factory. work-ing environment. CPS will therefore require new A quantum leap in innovation will only be achieved if work organisation structures covering the entire value existing basic technologies are developed in an applied net-work in order to boost employees’ productivity and manner to meet the specific requirements of the manu- pro-vide organisational structures that support facturing environment. The resulting methods, ap- individuals’ lifelong development.
Industrie 4.0 35 4 Research requirements 36
Industrie 4.0 Industrie niern. frhr e t sces il e the be will other success to Among architectures. reference key practical of establishment further A engineering. automa of requirements the to adapted be to need technolo ICT basic the competencies, and resources with industries and panies com different in used be can they that ensure to order In una manufacturing of widely still currently are engineering automation and realm the in work collaborative m practical that indicates above presented overview basic The designers. and tors doc scientists, occupational and social gonomists, er team psychologists, experts, IT a engineers, comprising of expertise the on drawing issues, these approach interdisciplinary An - vailable in many areas. many in vailable
things, the relates need aspect to this to
ethods and basic technologies to enable enable to technologies basic and ethods
different IT systems, technical systems, IT different
should be adopted to to adopted be should
- - gies tion - - - »
trie 4.0 Working Group, including contributions from contributions Group, including 4.0 trie Working the through received feedback The section. this in described areas research five the into down broken been have requirements research consolidated The 5. Cyber ac wher area final the to us brings This the appropriateestablishment of web services. the through networks business shared of creation spread and wide the companies enable to different order in orchestrated by technologically used be can they that so standar be to need will infrastructures These 2. ter Chap in upon touched already as integration horizontal and vertical for platforms ICT to) belonging (or as tures service establish -
tion are still required for Industrie 4.0: Industrie for tionare stillrequired user interfaces bring will tancesystems multimodal with versa.Smart industrialassis humanbeings and not vice thatadapt to theneeds of interaction.It will bemachines shift humanin bealso enabling aparadigm ThroughIndustrie 4.0 we will of the the of theMember Communication Group Promoters of GmbH) (DFKI Intelligence Research forArtificial German CEOCenter the of Dr h. mult. Dr nat. c. Prof. rer. Wahlster Wolfgang rectlyintothe workplace tal learningtechnologies di - Physical Systems technology Systems Physical Industry - ae, real based, - Science ResearchAlliance - technology - ie nbe infrastruc enabled time
e research and and research e
« digi
- Indus - dised -
- - - -
requirements 4 Research the business and research communities, builds on the requirements of automation and manufacturing recommendations of the Communication Promoters engi-neering, including the continuation of efforts to Group that were submitted to the Industry-Science Re- address general research requirements in this search Alliance in two reports in January and Septem-ber regard. They should also be regarded as a concrete 2011. It remains desirable to implement these rec- description of the actions required in order to ommendations, together with the outcomes of the BMBF- implement the vision described above for the sponsored project “Integrated Research Agen-da Cyber- specific application of “indus-trial engineering”. 1 Physical Systems” and the BMWi study “Das In order to provide ideas and guidance for the wirtschaftliche Potential des Internets der Dien-ste” (The make-up of the relevant funding programmes, the Economic Potential of the Internet of Servic-es). Industrie 4.0 Working Group has furthermore Consequently, they should be understood as refer-ring to identified the key ac-tions and research the need to adapt basic ICT technologies to the requirements for the medium to long term.
TAKE-HOME MESSAGE: An intensive dialogue between the relevant ministries and the Industrie 4.0 Platform will be required in order to put together a comprehensive funding package for industry and the research community. The Industrie 4.0 Platform should ensure that its Industrial Steering Committee and Scientific Advisory Committee in-clude experts from the realms of manufacturing, automation and IT, legal and management experts and so-cial scientists. The Industrie 4.0 Platform’s Working Groups should invite additional experts from the re-search and business communities to assist with the immediate task of drawing up comprehensive R&D roadmaps that adapt the consolidated research recommendations to the specific requirements of each working group. In addition to facilitating discussions and informal exchanges within the Industrie 4.0 community, the Indus-trie 4.0 Platform should also identify potential synergies between the various projects and partnerships that are currently in existence.
1 See research recommendations for CPS in manufacturing: “The deployment of Cyber-Physical Systems in and economic barriers and accelerating the implementation and deployment of smart factories.”
manufacturing systems creates smart factories whose products, resources and processes are all characterised by Quotation from: acatech (Ed.): Cyber-Physical Systems. Innovationsmotor für Mobilität, Gesundheit,
Cyber-Physical Systems. Their specific qualities offer advantages over conventional manufacturing systems with Energie und Produktion (Cyber-Physical Systems. Driving force for innovation in mobility, health, regard to quality, time and costs. As part of the “Industrie 4.0” initiative launched in 2011, we recommend the energy and produc-tion) (acatech POSITION PAPER), Heidelberg et al.: Springer Verlag 2011, p. 35. establishment of a project geared towards removing technological
Industrie 4.0 37
5 Priority areas for action the Internet of Services Internet the Internet the for connecting architecture Reference Figure 9: allthe of and services products to the applies that i architecture reference The complete these The of architecture. referredthe as is to reference provisions implementation exchanged. and be description to technical is that mation infor the and mechanisms cooperation the stipulating efforts devel Standardisation be oped. to need will standards appropriate the 3), Chapter (see networks value through integration and inter enable to is 4.0 Industrie If standardsafor reference architecture 5.1 orderthe to implementationshape in process. established was Platform 4.0 Industrie The implemented. be deci to recommendations the for order business in taken be to sions and policy industrial concrete for need the where areas priority key the on focus sections following The dations. medium of lection col comprehensive a presented Group Working 4.0 trie Indus the 2012, October In areas. overlapping partially initiative complex a is 4.0 Industrie for action areas 5 Priority
Standardisationand open
of Things with Things of
okn Gop eivs ht hr i a is there that believes Group Working
-
n long and
Services - em eerh recommen research term s thus a general model model general a thus s Business Processes Business Mobility il ed o ou on focus to need will - that embraces several embraces that company networking networking company Compiling and networking of functions, data and data functions, of networking and Compiling
Services Management end devicesManagement of and systems
Town
Energy
Solutions
App
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• • h eape f auatrn sse sre to serves system manufacturing a of example The inter part the require will This approach. common single, one the together pull to is architecture reference the of role the models, ness busi different very with companies different several comprises 4.0 Industrie in network value the Since in provided 9). Fig. e.g. (see services and software applications is It Industrie 4.0. to relevant systems technological the of operation and integration development, structuring, the for framework a provides It companies. partner Industry 10): Fig. (see architecture w out
ould need to be integrated into a reference reference a into integrated be to need ould servers, workstations, Web access devices, etc accessdevices, servers, workstations, Web devices, mobile devices, operating controllers, logic devices, programmable fieldbuses, devices, field (smart) as system, such manufacturing a in networked specific devices of The perspective functions transport and processing of in terms process manufacturing the of perspective The Company - - line some of the different perspectives that that perspectives different the of some line Services
- 5 Recommended actions ners to agree on the basic structural principles, principles, structural basic the on agree to ners faces and data. and faces Business Processes Business
processes Buildings Services
se divergent approaches into into approaches divergent se
the shape of software software of shape the
& & service Source: Source: Bosch SoftwareInnovations 2012 Internet Applications of Services of of Things of Internet Internet system Level - platforms based
automation automation Access to markets to Access business areas business and applications and and customers and Knowledge of Knowledge Requirements Model development Connectivity platforms (IPv6) 4.0 Industrie - based
-
39
architecture reference 4.0Industrie the in included perspectives the different of Examples Figure 10:
Perspective:Software Perspective: Manufacturingprocess
5 Recommended actions
Industrie 4.0 Referencearchitecture
Perspective: Engineering Perspective: Perspective: Devices Perspective:
s e n i s u B e m e g a n a m n o i t c u d o r P e r a w t f o s t n e m e g a n a m s
Source: olContr nt software
n rguai o wre twar n sof ulatio reg and
Siemens
2013
rdc dsgnan vl m nt pme evelo nd n d a desig Product Production
Production engineering Production
planning Services Production Services
• • •
operation and maintenance into account. into maintenance and operation taking also whilst online, brought and upset is system manufacturing where the the point automa and electrical their of mechanical, terms in machines optimise successively to possible be would subsequently It resources). human bothand of machinery (in terms resources necessary the to plan process manufacturing deri data using involve this could example, For Management/PLM). (ProductLifecycle system manufacturing a in perspective engineering The environment with manufacturing the integration and interfaces relevant the including networks, logisti company inter management, and planning business e.g. for businesses, or more one used by applications software the of perspective The etc functions, optimisation and planning analysis, trend archiving, data, process data, machine data, operational interlocking, control, control, continuous acquisi data as such environment, the manufacturing in applications software the of perspective The - - tion through sensors, sequential sequential sensors, through tion tion technology pro tion technology
cs or supporting value value orsupporting cs ved from the from ved
perties, right up to up perties, right
- • • • y d a e r l a e r a s d r a d n a t s d e h s i l b a t s e l a r e v e s h g u o h t l A . y g o l o n i m r e t c i s a b n o m m o c a n o e e r g a o t e b l l i w p e t s t s r i f e h t , s r o t c e s e r a w t f o s d n a g n i r e e n i g n e n o i t a m o t u a , g n i r u t c a f u n a m t n a l p d n a y r e n i h c a m e h t n i s e i n a p m o c n e e w t e b n o i t a r e p o o c e r i u q e r l l i w 0 . 4 e i r t s u d n I e c n i S . h c a o r p p a n o m m o c a h s i l b a t s e d n a f o s m l a e r e h t n i t s i x e y l t n e r r u c t a h t s g n i h t g n i e e s f o s y a w d e h s i l b a t - s e t n e r e f f i d e h t r e h t e g o t l l u p o t s i e g n e l l a h c t s r i f e h T Challenges
IT and the InternetIT andthe and engineering automation engineering, process engineering, mechanical engineering, production
i n u s e b y t h e v a r i o u s t e c h n i c a l d i s c i p l i n e s , p r o f e s s i o n a l a s s o c i a t i o n s a n d w o r k i n g g r o u p s , a c o o r d i n a t e d o v e r
- v i e w o f t h e s e s t a n d a r d s i s c u r r e n t l y l a c k i n g .
I t i s t h e r e
- f o r e n e c e s s a r y f o r e x i s t i n g s t a n d a r d s e . g . i n t h e f i e l d o f a u t o m a t i o n
( i n d u s t r i a l c o m m u n i c a t i o n , e n g i n e e r i n g , m o d e l l i n g ,
I T s e c u r i t y , d e v i c e i n t e g r a t i o n , d i g i t a l f a c t o
- r i e s ) t o b e i n c o r p o r a t e d i n t o a n e w g l o b a l r e f e r e n c e a r c h i t e c t u r e .
40 Industrie 4.0
actions 5 Recommended The reference architecture cannot be developed in a • Open development tools: a community top-down manner since it will need to integrate several comprising over 1,500 developers and millions different perspectives and a top-down approach would of users develops software for demanding in any case take far too long. It therefore makes sense modelling applications. for the reference architecture to be developed incre- mentally and from a variety of starting points. In this • Open communication infrastructure: “Requests regard, it will be necessary for strategies that are cur- for Comments” are technical and organisational rently often implemented in a project-specific manner documents published through the Internet based on local circumstances to be gradually convert- Society that were first established as long ago as ed into an international standard. In doing so, it will be 07.04.1969. Their widespread acceptance and important to ensure that interfaces remain technically use has converted them into de facto standards. stable for many years to come and to preserve the val- Well-known examples include the Internet ue of the installed base. On the Internet, the approach protocol (TCP/IP) and e-mail protocol (SMTP). to standardisation is based on different paradigms to those that are currently the norm in the machinery and These paradigms enable standardisation efforts to plant manufacturing industry, for example be progressed far more rapidly. Finally, it will be important to build trust in the
reference architecture. This is particularly relevant with • Open operating systems: in the case of Linux, a regard to know-how protection (see Chapter 5.7). It will community of businesses, research institutions and individuals comprising more than 2,000 developers also be key to ensure that the full range of intended in over 100 countries develops and maintains one users of the reference architecture are appropriately of the world’s most successful operating systems. engaged in its design right from the early stages.
Recommended actions
The Industrie 4.0 Working Group recommends the establishment of a Working Group under the auspices of the Industrie 4.0 Platform to deal exclusively with the topic of standardisation and a reference architecture. The Working Group’s remit would include the following tasks:
• Building a shared understanding of the goals, benefits, potential and risks, possible content and imple-mentation strategies with a view to creating the mutual confidence needed to support joint implementa-tion measures. The professional associations should take the lead with regard to the implementation of confidence-building measures. • Alignment of the key terminology and subsequent production of a common “Industrie 4.0 glossary”. In addition, detailed attention should to be paid to those aspects of the following issues that are relevant to the specific content of Industrie 4.0: • Model universals (underlying core models, reference models, architecture designs) • Standards for the Industrie 4.0 service architecture • Standards for a supra-automation level procedural and functional description • Terminology standards and the use of ontologies • Understanding of autonomous and self-organising systems, including their planning, operation and security • Characteristics maintenance and system structure description • Approach to migrating existing architectures
Industrie 4.0 41
42
Industrie 4.0 Industrie A fundamental distinction can be drawn between between of model: two types drawn be can distinction fundamental A of is and world 4.0. Industrie of context the in importance central digital the in strategy important conside under issue the include to relevant only are that that aspects those scenario hypothetical or real a grow this managing for enabler an as act can Modelling betweeneration different companies. forms changing rapidly the and organisations and disciplines technical different of integration creasing in the requirements, delivery dynamic increasingly customisa tion, product increasing functionality, increasing more becoming are systems manufacturing associated their and Products 5.2 Managingcomplex systems control of highly dynamic technological manufacturing processes. manufacturing technological highly dynamic of control end associ include could architectures reference for topics Other integrationvaluenetworks. through horizontal on architecture focused reference possible architectu reference of deployment and development successful the demonstrate to projects flagship appropriate of establishment the recommends also Group Working The • • • •
te tss omn pr o te okn Gops r Group’s Working the of part forming motivation. and communication evaluation, recommendations, tasks Other commu anand appropriate model licensing a suitable will This require longer term. in it the out maintain and the technical for responsible feels that companies different severalfrom with members community” 4.0 an “Industrie of Development addressed. be also should models Licensing the standards. of and use development the in engaged be should stakeholders al and transparent and be open should structure The individuality. and between standardisation balance a sensible tostrike order in adopted be should approach A holistic constraints. and time a of onproduction the work Starting covered. currently are not that themes of clusters identifying and 4.0 Industrie of context the in migration and development further the on located be then would examples and approaches architecture” reference “automation established Current, a bottom of Production - ing complexity. Models are a representation of of representation a are Models complexity. ing
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5 Recommended actions
44
Industrie 4.0 Industrie SMEs in the mechanicalSMEs in engineering sector who are of employees Currently, opportunities. career appropriate the with experts these rel provide should the companies that evant important therefore is It experts. be qualified only can simulation and Modelling operation. including stages, subsequent the in also de the during just not productively used be cost should they developed that models of success the to key is impor an plays also activities individual make customer or percent only The they volumes products. if so small do to manufacture likely less are They sector). strin with industries or industry) automotive the as (such • • • • Working The engineering. manufacturing of realm the tasks: following the include should remit Group’s in the particularly under systems, Group complex Working managing exclusi a deal to of Platform 4.0 establishment Industrie the the of recommends auspices Group Working 4.0 Industrie The Recommendedactions
- recom In topics. relevant the input on their to provide tools engineering specific for groups user existing invite end integration, to relation manufac tool to provide order in group, user target manufacturing” plant and “machinery the be on should the focus initiative, 4.0 Industrie the under suppliers leading As the situations. other’s each of understanding mutual a better gaining participants view to a with trainers and (product architects) managers, manufacturers tool for toolusers, groups user common of establishment the encourage should Group The Working answe for shop a as act one would that pools expert and communities for provided be also should Moderation 2). Chapter associations, professional bythe conducted survey the in expressed information more barrier entry of discussion to enable arranged be should virtual start modularisation, could include themes decision and practitioners both among modelling of importance fundamental promote to order in SMEs, among particularly out, be carried should sharing Best practice important most the to area subject broad very this down of implementation. terms in aspects narrow to order in modelling, of field m the establish to out carried be should survey representative A ge
addition, the Working Group should work on the development of the appropriate guidelines and and guidelines appropriate the of development the on work should Group Working the addition, t aey tnad (uh s h avionics the as (such standards safety nt
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n hs ra r lrey eadd s “oddballs”. as regarded largely are area this in - case basis. Last basis. case ost pressing requirements in the the in requirements pressing ost - essary functionality, enable them to be to them enable functionality, essary tory will also have to be considered on considered be to have also will tory
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• • • should do tothe more meet wishesshould of businesses. opera Network […] performance. application on pact im direct a have they since key, are connections stable Guaranteed applications. gineering en automation and engineering mechanical for crucial are availability link data and reliability operational “High be and Germany partner manufacturing coun its and Germany in both scale, expanded massive be to needs infrastructure Internet broadband Yearbook, Infrastructure Digital 2011 the in and presented Summit service IT National the the of recommendation with of keeping In quality bandwidth. guarantee available universally reliability, provide times, to latency networks communication existing of enhancement the therefore is 4.0 Industrie communica qual higher significantly enables that infra an build to necessary be terms general in will it basis, widespread a on out rolled are CPS If broadband infrastructurefor industry Delivering5.3 a comprehensive
manufacturing industry vs. pro vs. industry manufacturing (engi situations different in modelling of value the demonstrate to order in tools and methods modelling existing test and de to projects flagship appropriate the of establishment the recommends also Group Working The of requirements the towards geared 5.6). and 5.5 Chapters (see companies manufacturing specifically be should content Training engineers. experienced ap both includes This engineering. systems and modelling to regard with provision development professional continuing the of activities the to addition In provision of the relevant technical aids relevant the of provision especially debugging/tracing, link data for Support Level and Availability (Service SLAs reliable Agree and Binding - ity data exchange than provided by current current by provided than exchange data ity - ments) - tion networks. A core requirement for for requirement core A networks. tion
- performance of traffic capacity of traffic performance neering vs. operation, mass production vs. small volumes or individual products, products, individual or volumes small vs. production mass operation, vs. neering - rpit tann poiin o yugegnes n aporaeCD me CPD appropriate and engineers young for provision training propriate - - oue n higher and volume cess industry, i industry, cess aec tms and times latency Platform, targeted efforts should be made in terms of training and and training of terms in made be should efforts targeted Platform,
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- ailability and affordability. and ailability recep Satellite availableembedded SIM cards Widely roaming global Affordable ba (fixed ofservice Quality service ofmobile contracts control Cost Programming Tariff management all covering activation/deactivation) card (SIM providers provisioning Application for (APIs) Interfaces Standardised notification status operators network mobile delivery SMS available/guaranteed widely broadband) (fixed/guaranteed traffic capacity of Provision frastructure that is accessible to a large number number large a to accessible is that frastructure 5 Recommended actions - ers are simplicity, scalability, security, security, scalability, simplicity, are ers - tion [N.B. in sparsely populated areas].” populated in sparsely [N.B. tion - company, production vs. logistics, etc). logistics, vs. production company, - based solutions for areas with no no with areas for solutions based
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- 45
46
Industrie 4.0 Industrie ubr f diinl aey n scrt require security Industrie arise. to ments areset and safety additional of number a 4.0, Industrie of advent the With fixes. partial vide pro only frequently and implemented be to slow ten ofare particular in measures Security resolved. fully hav 4.0) Industrie of version” “beta (the 3.0 Industrie in arose that issues security and safety the of Many problem. a also was security that parent ap became gradually it safety, operational of dence evi hard provide to complex more far became fa it that the to addition In environment. manufacturing the in requirements security and safety in increase 3.0 (Industrie the 1960s of end the towards electronics and mechanics with contact into came first technology information Since such systems. of operation and construction the governing standards and tions regula of host whole a by regulated many is Safety years. for make they products the and facilities ing manufactur of design the in consideration important is safety security, to contrast In (security). access unauthorised and misuse against know products and cilities fa production both other the on whilst (safety), ment or people to either danger a pose not they products should they hand, one theOn panel). info the (see make and facilities manufacturing to regard with aspects key two are security and Safety factorssuccessthefor Industrie of 4.0 5.4Safety an In accordance with the recommendations of Working Group 2, the Industrie 4.0 Working Group also also Group Working 4.0 recom Industrie the 2, Group Working of recommendations the with accordance In to order in applications concrete of studies out carry to necessary re and bandwidths exact the establish be will It Summit. IT National 2011 the at Infrastructure” “Digital 2 Group Working by proposed infrastructure Internet broadband Germany’s ing for recommendations the of implementation recommends strongly Group Working 4.0 Industrie The Recommendedactions - how they contain contain they how
- mends expansion of Germany’s broadband Internet infrastructure. Internet broadband Germany’s of expansion mends d security d critical as –
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------
2. 1. the following points areputinto points practice: the following i con the in arise issues security of range new whole a that at and third for potential hypothetical networks least extensive the issues, safety tional entire the of erties prop always are security and safety However, 3). and 2 Chapters (see chain value the across involved is tors ac of number greater far a time, same autono the At mously. act which of many components, system cal occu exchange information High chines. ma and components automation systems, IT beings, human of numbers large incorporating structures tem sys networked highly involve systems manufacturing mple
confer a high degree of confidentiality, integ confidentiality, of degree ahigh confer to order in implemented and developed be to need stand and architectures strategies, security IT aspects be design All time. to need security, particular in in and safety, to point relating later some the at to on system features security add to simply enough CPS In access as such restr measures physical by provided usu was attacks external against security past, the In principle. design key a as Design by Security - et f nuti 40 I wl ol b psil to possible be only will It 4.0. Industrie of text - ment Industrie 4.0 and get people to accept it if it accept to people get and 4.0 Industrie ment cin o ohr etaie scrt measures. security centralised other or ictions - based manufacturing systems, it is not not is it systems, manufacturing based ed into the systemoutset. the from ed into - oue n otn time often and volume
system. Thus, in addition to opera to addition in Thus, system.
rs between the technologi the between rs - party access mean access party - rtcl aa and data critical
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actions 5 Recommended rity and availability on the interactions between these availability) and vice versa (“does a particular highly networked, open and heterogeneous compo- critical safety function of a subsystem increase the nents. They also need to provide an appropriate, reli- risk of cyber-attacks?”). able and affordable solution for protecting the digital Furthermore, in view of the current situation, a dual process know-how, intellectual property rights and data strategy is also required for Industrie 4.0 with regard to in general of each individual manufacturer and safety and security. Firstly, existing factories will have to operator, both vis-à-vis the outside world and with be upgraded with the safety and security measures regard to components belonging to different opera-tors needed to meet the new requirements. The typically long and/or manufacturers vis-à-vis each other (see also service lives of machinery and short innovation cy-cles, Chapter 5.7). together with heterogeneous and in some cases very old infrastructures that are difficult to network mean that this In Industrie 4.0, it is therefore always necessary to will not be an easy task. Secondly, solu-tions for new adopt a global approach to safety and security. It is factories and machinery will have to be developed. The essential to consider the impact of security measures transition from the third to the fourth industrial revolution (cryptographic processes or authentication proce- should be as seamless as possible and should be dures) on safety (time-critical functions, resource implemented in a way that can be clearly
“Safety” refers to the fact that technological systems (machines, production facilities, products, etc) should not pose a danger either to people or to the environment, whilst “security” refers to the fact that the system itself needs to be protected against misuse and unauthorised access (access protection, security against attacks, data and information security). Various aspects of safety and security are relevant to Industrie 4.0, making it essential to draw a clear distinction between the two terms:
Security/IT security/cyber-security: The protection of data and services in (digital) systems against mis-use, e.g. unauthorised access, modification or destruction. The goals of security measures are to increase confidentiality (the restriction of access to data and services to specific machines/human users), integrity (accuracy/completeness of data and correct operation of services) and availability (a means of measuring a system’s ability to perform a function in a particular time). Depending on the technological system in ques-tion and the data and services that it incorporates, security provides the basis for information privacy, i.e. the protection of individuals against infringements of their personal data rights. It also enables know-how protection, i.e. protection of intellectual property rights.
Safety: The absence of unacceptable risks and threats to people and the environment resulting from op- eration of the system. “Safety” requires both operational safety and a high degree of reliability. Depending on the technological system in question, safety may also involve additional aspects such as prevention of mechanical or electrical hazards, radiation protection, prevention of hazards relating to steam or high pres- sure, etc. Operational safety refers to the aspects of safety that are dependent on the correct operation of the system or that are provided by the system itself. The elements required to deliver operational safety in- clude low fault rates, high fault tolerance (i.e. the ability to keep operating correctly even when faults occur) and robustness (the ability to guarantee basic functionality in the event of a fault). Reliability refers to the probability of a (technological) system operating correctly for a given period of time in a given environment.
Industrie 4.0 47
48
Industrie 4.0 Industrie creasingly aware of the value the awareof creasingly in becoming are manufacturers plant and Machinery to competence. them for of and level higher trust) a & (security competence have other’s each in confidence to partners for cooperation necessary be and networking will it chain, value a in partners different several between increased involve will fac the of view In industries. different cur are in awareness security regardingthe level of discrepancies There issues. security IT to particu role, key a plays often awareness indu other many fordeveloped originally were solutions security and safety since especially infrastructure, existing upgrade or expand to done be can that little often is There drivers. cost as regarded become merely not do they that imple so cost their of terms in industry of ments require specific the security to tailored and been have that safety solutions adequate implementing for forms plat operating standardised fully lacks currently dustry psycho commercial, and address to have safety also will successful solutions security challenges, technical the apart from Quite 4.0. Industrie of context the in security and safety facing challenges different of variety a are There Challenges the and issues security relevant architec and safety a on reach to consensus the chain all value entire for the is throughout strategy actors the of pillars both for aspect key One stakeholders. relevant the all by understood oia ad dctoa ise. o eape in example, For issues. educational and logical
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- - - - ein. t h mmn, aey n scrt ise are issues security and safety moment, the At design). by security to regard with (especially case the been erto hith has than security and safety to approach proactive more much a require will 4.0 Industrie terms, general In they available by board on taken processes properly manufacturing been yet not has that maintain and delivering in role important increasingly an playing Flame or Duqu Stuxnet, as such malware surrounding debate public the since industry automation the in discussed be to started only has security IT Industrial threats. IT relevant the about of number ma and the in rise manufacturing in found sharp components software a in resulting ware, indiscriminate cyber vi of spread the stop is to help would areas information these any if little abo exchanged re and security, with IT industrial particularly monitor indicators, insufficient assessment is there moment, the cross comprehensive support provide to important a as approached also is it times, response fast achieve to order In process. be instead should and functional but into components safety down broken be Consequently, simply cannot problem. security relevant the to both im is solutions perman a belated deliver to fails often also and costly security and this safety of However, plementation occurred. already have prob security or safety specific and over is process o tn ny asd eciey ne h development the once reactively raised only ften - chinery. However, too little is often still known still often is little too However, chinery. - ing security and safety, but this is something something is this but safety, and security ing have yet to be implemented. be have yet to ut safety and security incidents. Ac incidents. security and safety ut - attacks. - sectoral information ex information sectoral Mroe, otae s also is software Moreover, . –
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from the individual machine to networks of machines and the application stage. The reference reference The stage. application the and and new to certificates machines and toexist especially classifications security of issuing for basis networks a as serve to also could architectures machine individual the from every at systems of security and safety overall the test to used be could that established be to cilities fa testing and defined be to procedures test enable also would architectures reference these 4.0, dustrie and approaches of standardisation the ensuring to addition In Unique and secure IDs for products, processes and machines and processes products, for IDs and secure Unique engineering electrical indus aerospace and automotive the IT, and and mechanical strategies and the automation enable adapt by would process enhanced be to industries This the approach. in this used for currently basis processes a as developed be should pool” syst entire the throughout methods and principles relevant the of application systematic with together strategies, security and safety modified require will 4.0 Industrie and standards architectures strategies, security and Integrated safety “security passport” containing details of the risks that were already taken into account and and account into taken already were secu the wouldalso contain passports The user. or that operator risks the of int the by considered be to needthat risks theand development during counteracted details containing passport” “security electro unique in the for necessary af the mac to applies This 4.0. Industrie of success and acceptance the to key is process manufacturing entire the throughout exchange information Secure • • • 6
of the top 10 most critical threats currently facing Industrial Control Systems (ICS). The Industrie Industrie The (ICS). Systems Control Industrial facing currently threats critical most 10 top the of ulig n hs srtge, aey n scrt acietrs o manufacturi 3.0 systems. Industrie for existing with compatible backwards be should these possible, architectures as far As initiative. security 4.0 Industrie the for architectures and reference as defined be safety should strategies, these on Building industries. aerospace and automotive the as such industries other with exchanged proof secure as such topics on projects research security and with safety other coordinated closely is and systems strategies the relevant of development and research that to ensure It is important indus all to applicable to be engi theas mechanical such sectors individual for be developed initially could that scenarios threat on based be should collaborativ open, hypothetically for strategies and security safety to develop needed is Research - etd rcse ad h ognstoa uis novd T eal ti ecag, t is it exchange, this enable To involved. units organisational the and processes fected of identity, cyber of e subsystems belonging to different manufacturers and operators. These strategies strategies These operators. and manufacturers different belonging to e subsystems i Is Fur IDs. nic - ing subsystems. This approach subsystems. This ing - dividual machines, processes, products, components and materials to possess possess to materials and components products, processes, machines, dividual - - security or the protection of critical infrastructure and that knowledge is knowledge that and infrastructure critical of protection or the security - security issues, the Federal Office for Information Security (BSI) drew up a a up drew (BSI) Security Information for Office Federal the issues, security neering or automotive supply industries, but which wo which but industries, supply automotive neering or - thermore, it would be desirable to issue components with a kind of of kind a with components issue to desirable be would it thermore, - tries.
-
ing the safety and security strategies and processes employed by by employed processes and strategies security and safety the ing - tries to the specific requirements of Industrie 4.0. Industrie of requirements specific the tries to
would thus form part of the migration thestrategy. formpartof thus would nd security: nd hines, their components, the data being exchanged, exchanged, being data the components, their hines,
5 Recommended actions procedures that is key to the success of In of success the to key is that procedures
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4.0 Industrie
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50
Industrie 4.0 Industrie 6. Secure protection against product piracy product against protection 6. Secure ones. physical as well as incorporate products should and virtual “processes” and “machines” “products”, coun threat potential the product, the of value the account into take would rating securityThe itself. production during developmentand its during both environment, manufacturing the in CPS passports these ID, secure a of part As 5. 4. 3.
loss of know of loss and image corporate to damage include also but sales on impact its to confined not are phenomenon this key therefore is protection property intellectual market, global a In piracy. product by targeted be to going inevitably are products Successful with associated risks the of manufa down shutting of calculation clearer enable will cost the and 4.0 Industrie that methods develop to necessary cause damage against insurance out taken have manufacturers few now custom from claims down, breaks machinery When factors. there cost be to going always are security and safety Inevitably, the problem is no longer restricted to the often rather complex physical replication of products products of replication or conf software of the form physical complex rather often the know product and to of corporate theft targeted restricted longer no is problem the operation right up to and including maintenance. including and to up right operation the from account into taken be should factors These user possess nec therefore conse user not are that applications and processes using avoid to tend People Safety and security in a business management context management business a in security and Safety User subsequent be then would which measures the of a list of establishment and threats and weaknesses identify to order in analysis situation a goals, security arr be imple be individual to enables solutions that security model process standardised a of development the require also will strategy cu the of assessment abovementioned the to addition in Consequently, solutions. security IT for standards common of development the hamper all facilities Ind to conversion time)for them some considerable andprepare for use toremain in arelikely (which 3.0 facilities current Industrie of security improvethe gradually to be would migration strategy a of goal The str A migration 4.0. - emaue. h srtgc ntaie n Scr Iette” hud hs e xadd o include to expanded be thus should Identities” “Secure on initiative strategic The termeasures.
However, the heterogeneity, long service lives and individual nature of existing manufacturing manufacturing existing of nature individual and lives service long heterogeneity, the However, - friendly safety and security solutions security and friendly safety can be both a direct impact (e.g. lower turnover) and an indirect impact (e.g. compensation compensation (e.g. impact indirect an and turnover) lower (e.g. impact direct a both be can - ived at by adapting existing (generic) IT security processes, based on the definition of individual of definition the on based processes, security IT (generic) existing adapting by at ived quences for safety and security solutions, especially in a highly networked environment. environment. networked highly a in especially solutions, security and safety for quences - how. In the most extreme cases, erstwhile pirates can even become com become even can pirates erstwhile cases, extreme most the In how. - - essary to develop safety and security solutions that are geared towards users’ needs, needs, users’ towards geared are that solutions security and safety develop to essary friendly interfaces and therefore guarantee execution of the application in question. question. in application the of execution guarantee therefore and interfaces friendly ategy from Industrie 3.0 to Industrie 4.0 Industrie to Industrie 3.0 ategy from - ers, suppliers and partners or damage to the company’s image). However, until until However, image). company’s the to damage or partners and suppliers ers, cturing facilities in the event of a real or suspected IT threat. IT orsuspected a real of event the in cturing facilities - effectiveness of the relevant security solutions as opposed to the alternative alternative the to opposed as security solutions the relevant of effectiveness igurations that are currently still easy tocopy. arecurrently that still igurations - mented rapidly, pragmatically and cost and pragmatically rapidly, mented
to the survival of high of survival to the could form the basis of a system for rating the overall security of a of security overall the rating for system a of basis the form could
- how is now also becoming increasingly common, especially in especially common, increasingly becoming also now is how 5 Recommended actions
-
wage economies. initial design phases through engineering and and engineering through phases design initial
rrent status of existing facilities, a migration migration a facilities, existing of status rrent implemented.
s and the modified or appropriate appropriate or modified the and s -
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d by IT issues. It is therefore therefore is It issues. IT by d - The problems associated with with associated The problems friendly. This can have fatal fatal have can This friendly. petitors. Moreover, Moreover, petitors.
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ensure that this advantage is used to its p its full to advantage used is thatthis ensure to swiftly act to important be will It systems. embedded and engineering mechatronic processes, automation for industry security Indust own its build to opportunity an has Germany products, CPS and the CPS to of parallel development In Israel. and US the as such countries other in produced predominantly are products curity across right reputation anexcellent enjoy experts security and safety Germany’s whilst safety, of field the in and solutions security IT complex both in leader world a is Germany to having without facilities existing wait in implemented focus promptly the be that can that recommended solutions is pragmatic It on be machines. should individual of security inherent the also but components and deliv to how just not consider to important be will it 4.0, Industrie for solution optimal the envisaging When requirements. of list a producing or roadmap a up drawing to view n will Platform 4.0 Industrie The 8. 7. t within transparency and know business critical protecting trust guarantee that to solutions levels law find competition and corporate the at particular in and level technical a at work to necessary higher much the of view in 4.0 Industrie in importance greater even assumes piracy product against Protection education institutions would help prepare institutions workforce prepare education wouldhelp the of Chapter also (see future 5.6). current the awareness Appropriate are solutions security 4) point When ev product, engineering. technical a plant install to simply of enough not is field it business, a the in implemented in working raise engineers to planning crucial and is It developers organisation. an i of involved members people the the all all among for awareness essential is issues security IT of knowledge A
Data Protection Commissioners and the trade unions and company works councils (see 5.7). Chapter councils company and works tradeunions the and Commissioners Data Protection initia self informational to right the recom on focus much is there where many, pe of use The systems. assistance smart through or factories smart in machines the via health employees’ about information analyse and record to possible Indus and (in Training “Community building” for data protection in Industrie 4.0 in Industrie data protection for building” “Community for thelonger for rie 4.0, drawing on the competitive advantage provided by its specific know specific its by provided advantage competitive the on drawing 4.0, rie - tive on “Secure Identities”, the Federal Office for Information Security (BSI), the Federal and regional and Federal the (BSI), Security Information for Office Federal the Identities”, “Secure on tive trie 4.0 will require tougher data protection arrangements, for example because it will be technically be will it because example for arrangements, protection data tougher require will 4.0 trie degree of cooperation between the different partners in the value network. It is therefore therefore is It network. value the in partners different the between cooperation of degree - mended that the topic of data protection should be addressed in close cooperation with th with cooperation close in addressed be should protection data of topic the that mended –
mlye as ne t b aeutl tand ih ead o h rlvn scrt requirements. security relevant the to regard with trained adequately be to need also employees hrcmns n hs ra wis te nrdcin f oploy lse o ti tpc t higher at topic this on classes compulsory of introduction the whilst area, this in shortcomings - - term “ideal” solutions to be developed (see Chapter 2.1). Chapter (see developed tobe solutions term “ideal” house) CPD house) - raising campaigns targeted at the manufacturing environment could help to over to help could environment manufacturing the at targeted campaigns raising eed to engage in an in an in engage to eed
- how.
pouto, rm kle mcie prtr t scrt software security to operators machine skilled from production, n otential in Industrie 4.0. otential in rsonal information is an especially sensitive issue in Ger in issue sensitive especially an is information rsonal - depth discussion in order to establish priorities with a with priorities establish to order in discussion depth
5 Recommended actions er secure communication between machines machines between communication secure er he platform whilst at the same time time same the at whilst platform he
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5 Recommended actions 52
Industrie 4.0 Industrie sively on overcoming the technological challe technological the onovercoming sively exclu focus to allowed be cannot efforts Innovation sensor based, widespread knowledge controlled, the automatically of deployment through advantage competitive existing mobilise to productivi and possible innovation of reserves determine is it will not questions or whether these to answers The fair? and safe good, are jobs people’s that ensure real and in by characterised future a In changes? these to respond work of world the should How commonplace? are CPS where economy tech business by met be to have will responsibilities will What workplace? impact What age industrial thedigital design in andwork organisation 5.5 Work
- time oriented control systems, how can we can how systems, control oriented time - es and society in a decentralised high decentralised a in society and es - equipped man equipped nuti 40 ae n the in have 4.0 Industrie - ufacturing systems. ufacturing raig automation creasing ty and secure a secure and ty nges.
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place). work the (within organisation social innovative an into embedded smartly be to need will they technologies tomorrow’s of integration successful in achieve result, to a order As lives. private people’s and change ic health regulation, time working bility, flexi for repercussions have will trans that way a dramatically in formed be will environment working the and processes work content, Work interactions. tem human extensive and forms virtua open, in increase the of result a as significantly change will role their that likely is It tions. innova technological assimilating and implementing in part key a play will employees since skills, ployees’ to ened wid consistently be to needs innovation of remit The State Secretary State Research and Education of Ministry Federal Schütte Dr. Georg Industrie4.0 require will the work organisationwork and work businesses.Worker specialistknow saryadvantagetake to ofthe enterprises. It will beneces ofsmall and medium thatareadapted totheneeds andorganisational solutions developmentoftechnological keyimplementation. toits place
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actions 5 Recommended
Challenges It is very likely that the nature of work in Industrie 4.0 alised of its own accord. It will be crucial to employ will place significantly higher demands on all members work organisation and design models that combine a of the workforce in terms of managing complexity, ab- high degree of individual responsibility and autonomy straction and problem-solving. Employees will also be with decentralised leadership and management ap- expected to be able to act much more on their own ini- proaches that allow employees greater freedom to tiative and to possess excellent communication skills make their own decisions, be more involved and regu- and the ability to organise their own work. In short, late their own workload, whilst at the same time also greater demands will be placed on employees’ subjec- enabling flexible working arrangements. tive skills and potential. This will provide opportunities It is possible to use the technology for very different ends. in terms of qualitative enrichment of their work, a more Systems can be set up to impose restrictive con-trol over interesting working environment, greater autonomy every minute detail of a person’s work, or they can be and more opportunities for self-development. configured as an open source of information that
Nevertheless, the demands of the new, virtual work-place employees use as a basis for taking their own deci-sions. also present a threat to the maintenance and In other words, the quality of people’s work will not be safeguarding of human capital. As the degree of tech- determined by the technology or by any techno-logical nological integration increases, there is a danger of em- constraints but rather by the scientists and man-agers ployees being required to be more flexible and perform who model and implement smart factories. more demanding tasks, as well as a growing tension It is therefore necessary to adopt a socio-technical between the virtual world and the world of workers’ own approach where work organisation, continuing pro- experience. This could result in workers experienc-ing a fessional development measures and technology loss of control and a sense of alienation from their work and software architectures are developed in close as a result of the progressive dematerialisation and con-junction with each other to provide a single, virtualisation of business and work processes. It is also consist-ent solution focused on enabling smart, possible that “old” and “new” threats could com-bine to cooperative and self-organised interactions take on a new dimension, resulting in significant creativity between employees and/or technology operating and productivity losses and a tendency for employees to systems across the en-tire value chain. overwork themselves.
Finally, it is important to consider the impact that the “Better, not cheaper” as an opportunity and increasing presence of IT in manufacturing industry benchmark for industrial change will have on headcount. It is likely that the number of This socio-technical approach argues that adopting an simple manual tasks will continue to decline. This even more extreme version of the Taylorist approach to could pose a threat to at least some employee groups, work organisation based on frequent repetition of highly notably semi-skilled workers. Such a scenario would standardised and monotonous tasks is hardly the most be unacceptable both for the employees themselves promising way to go about implementing the Industrie 4.0 and from the wider public’s point of view in terms of initiative in partnership with employees in a way that the social inclusion dimension. Moreover, it would se- allows new efficiency gains to be achieved. The fact that riously hamper the successful implementation of the smart factories will be configured as highly complex, dy- Industrie 4.0 initiative. namic and flexible systems means that they will need employees who are empowered to act as decision-mak- A consistent approach to technology and work ers and controllers. For this to be possible, they will need organisation to be supported by customer-oriented job profiles Smart factories provide an opportunity to create a new requiring broad-based training, work organisation mod-els workplace culture geared towards the interests of the that promote learning, and comprehensive continu-ing workforce. However, this potential will not simply be re- professional development that fosters autonomous
Industrie 4.0 53
54
Industrie 4.0 Industrie ards and pathways for creating good and fair jobs and jobs fair and good creating for pathways and ards robu towards way the point could not “better, cheaper” of banner the under unions trade the by promoted being strategy innovation the context, this In to them enabling lives, realistic work a achieve private and work bound employees’ clear establishing time same the be will at whilst manufacturing flexible more enable to necessary It circumstances. social and the economic with specific accordance in together configured estab and be lished should models organisation work and goals development ad technological 4.0, career Industrie In and vancement. development staff pro systematic for instrument moting active an as designed is and work • • • Recommendedactions
management, thi management, knowledge innovative to In addition levels. international and national both at companies of outside inside and stakeholders between transfer knowledge effective should arrange Platform The 4.0. Industrie of implementation thewith as solutions and potential problems advances, the key of discussion and identification transparent to enable partners the social between dialogue a regular up should set Platform The goals: three main exper interdisciplinary an 4.0” through in Industrie and “People of Work issue the study to continue should Platform 4.0 Industrie The 3. 2. 1.
To promote innovative approaches to participative work organisation and lifelong learning that that learning emb lifelong and organisation work participative to approaches innovative promote To socio the implementing and developing projects reference relevant with the together approach, for aids risks) practical and and guidelines (opportunities provide To employment and work on impact employee achieve to required actions with the together the document and ascertain To
race the entire workforce, irrespective of age, gender orqualifications gender age, of irrespective workforce, the race entire - s will also require the establishment of broad of establishment the require willalso s
life balance. 5 Recommended actions
re between aries t working group. The working group’s remit should comprise comprise should remit working group’s The group. working t t stand st
- - - - also socially sustainable. socially also technologica for search the ini forward a of 4.0 part form Industrie they Rather, the of technolog context the in exclusive jobs, good co worker and innovation Consequently, industry. of future the securing for basis the as leadership cheaper” not global “better, of demands the flex greater meeting for need the and of competitiveness capable still is it co labour rights, participation enhanced a with design organisational incorporates strategy em their The and sites ployees. manufacturing for future secure a - determination - oriented labour and training training and labour oriented - based social networks. based social and training opportunities. Nonetheless, opportunities. training and 8
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5.6 Training and continuing professional development for Industrie 4.0
As described above, the implementation of Industrie studies and place greater emphasis on transferable 4.0 should result in a labour-oriented socio-technical skills such as business or project management. It is factory and labour system. This will in turn pose new businesses and their customers who should drive the challenges for vocational and academic training and changes made to the academic training of IT experts. continuing professional development (CPD). These In keeping with the principles underpinning Industrie challenges include the need to expand provision for 4.0, this will also involve close convergence of IT and the developers of manufacturing engineering production engineering training. The relevant learning compo-nents and their users. content for Industrie 4.0 will thus need to be identified
It is likely that Industrie 4.0 will significantly transform and the appropriate didactic and methodological ap- job and skills profiles as a result of two trends. Firstly, proaches will need to be developed. It is possible that traditional manufacturing processes characterised by a in particular some of the creative areas of businesses very clear division of labour will now be embedded in a such as interdisciplinary product and process develop- new organisational and operational structure where ment could require completely new qualifications. they will be supplemented by decision-taking, These would form part of a dual strategy that would coordination, control and support service functions. enable companies to respond to the challenges of a Secondly, it will be necessary to organise and coordi- shrinking labour market and high market volatility. nate the interactions between virtual and real ma- In this context, it will be key to develop professional adult chines, plant control systems and production man- education provision (teaching methods, career profile). agement systems. 9 Skills assessments should be used to improve mobil-ity Effectively, what this means is that the convergence between vocational and academic education and be- of ICT, manufacturing and automation technology tween the different training and CPD programmes and and software will result in many tasks now being systems, as well as to improve recognition of skills that per-formed as part of a much broader technological, are still relevant in the workplace despite not being con- or-ganisational and social context. nected to an employee’s specialist area. There is a grow- Industrie 4.0 will also require fundamental changes to ing need for people to have a grasp of the overall context the way IT experts are trained. The ability to identify and to understand the interactions between all the ac-tors application requirements in different industries and involved in the manufacturing process. Consequent-ly, in recruit development partners from around the world will addition to increased demand for metacognitive skills, increasingly take precedence over purely techno-logical social skills are also gaining in importance owing to the expertise. The extremely wide range of poten-tial growing significance of real-life and computer-based applications means that there is a limit to what can be interactions resulting from greater integration of formerly achieved through standardised training pro-grammes. It demarcated departments and disciplines. In technical will become more and more important to engage in a terms, much greater emphasis will be placed on dialogue with manufacturing industry in order to ensure interdisciplinary skills, an area where much work still remains to be done. that the requirements of the digital economy are reflected in training provision. As such, training In order to ensure that individuals’ training potential can partnerships between businesses and higher education be recognised and described transparently, it will be nec- institutions will be even more important in the future essary to develop standards for the recognition of non- than they are today. Short basic training programmes formal and informal education. The goal is to teach peo- will need to be followed by work place-ments and ple the principles of a new, holistic organisational model advanced study courses. It will be impor-tant to open and ensure that systems are described transparently so up access to science and engineering that employees are confident in what they are doing.
Industrie 4.0 55 5 Recommended actions 56
Industrie 4.0 Industrie Academy Cube though the actors Networking different Figure 12: www.academy at: is available information More securityprotection. and data and logistics processes and manufacturing an curricula full analysis, data automation, big such as fields includes content Learning 4.0. Industrie areaof the in sixcourses offering been has programme the 2013, March Since at launched 2013. officially CeBIT was and Summit IT National the at Society Digital the for Research and Education best The concept Cube Academy The content. its to regard with transparency vacan job provide top to the directed are automatically candidates and training the of standard These the about certificates. corresponding that the ensure curricula, with standard on them based are that issuing certificates, also whilst vacancies, specific for apply po and cloud a via achieved tar grad unemployed offers Cube Academy The abroad. and country home in their both knowledge and skills their use to able be might they how about parties interested to information wh Europe, southern from workers skilled targets specifically provision Current 4.0. Industrie from arising content by enter launched been has that initiative an is Cube Academy The AcademyThe Cube *
graduatesGermany (Source:in BITKOM 2012). 10,100 additional ICTexperts are needed in Italy,18,300 Commission in Poland,41,800 Sp Europeanin (Source: Europe in professionals ICT 700,000 of shortage a be already will there 2015 unemployment2012, In Spainstoodat in - ee qaiiain ad ep pt hm iety n oc wt idsra etrrss Ti is This enterprises. industrial with touch in directly them put helps and qualifications geted
- prises together with public institutions in order to address the need for new training formats and and formats training new for need the address to order in institutions public with together prises st specific job vacancies. The platform helps job seekers to obtain the training they need to to need they training the obtain to seekers job helps platform The vacancies. job specific st ere unemployment* rates are particularly high. The Academy Cube provides online online provides Cube Academy The high. particularly are rates unemployment* ere
- 27 percent,27 unemploymentyouthwhilst Spainandpercentwas inas52Greece(Source: Eurostat 2012). ashigh European The Com ae pafr wee opne ad ntttos rvd e provide institutions and companies where platform based
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cies of the participating companies. participating the of cies es 2..02; IKM aclts ht hr i a ana sotal f ,0 IT 9,000 of shortfall annual an is there that calculates BITKOM 20.3.2012); News, -
and SAP AG SAP and seekers potential employers can be confident confident be can employers potential discovernew careerpaths German and international industrial industrial international and German ainand 87,800 in Germany (Source: Eurostat 2012 2. Students2.
find highly find 3. employees Employers - chaired Working Group 6 on on 6 Group Working chaired - skilled
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actions Recommended 5 Whilst all the different levels of the training system are tiveness of in-house versus out-of-house learning affected, special priority should be attached to the ex- and general versus vocational education should be pansion of CPD. In particular, CPD in the workplace the sub-ject of further research. should address the importance of health, physical ac- In addition, Industrie 4.0 jobs will be designed to tivity and lifestyle in ensuring a lengthy working life. use technologies such as CPS in order to enhance com-munication between employees and integrate By organising work in a way that fosters learning and job sup-port, learning tasks and physical training in implementing appropriate training strategies, it should the work-place into the standard working day at be possible to achieve a human-centric approach to suitable intervals. This will require employees’ manufacturing that takes account of differences in em- workload to be monitored on an ongoing basis. ployees’ education, experience and skills sets in a way Job design should also take into account the different that strengthens the innovative capacity of both indi- roles performed by employees (from unskilled and viduals and businesses. The organisation of work in a skilled workers or employees with advanced vocational way that fosters learning is also a key requirement for and technical qualifications to staff members with aca- lifelong learning. In view of the rapid technological demic qualifications such as bachelor’s and master’s changes expected as a result of the introduction of degrees or qualified engineers) as well as differences CPS-based systems, it should therefore also be one of in their circumstances such as age, education, experi- the goals of the smart factory. The comparative effec- ence or cultural background.
Recommended actions
The Industrie 4.0 Working Group recommends the following measures with regard to qualifications, training and CPD in the context of Industrie 4.0: 1. Promotion of model projects Projects should incorporate actions that can be used to develop training and CPD strategies. These should include strategies to promote mobility between vocational and academic training and between different training and CPD courses and systems as well as to recognise additional skills that employees possess outside their specific area of expertise. 2. Establishment and promotion of “best practice networks” In order to guarantee knowledge transfer and sustainability, training and CPD “best practice networks” should be established by competitive tender. These networks would be charged with developing and documenting case studies, networking the various actors and supporting knowledge transfer. 3. Investigation of new approaches to knowledge and skills acquisition in the workplace, develop- ment of digital learning techniques Digital media and innovative learning technologies (e-learning) will play a prominent role in knowledge transfer and skills development. In view of technological and demographic change and the fact that different learners have different requirements, it will be necessary to develop new teaching methods and learning assistance systems. 4. Promotion of cross-cutting approaches to work organisation All Industrie 4.0 qualification, training and CPD measures will need to be accompanied by comprehensive research in the shape of research and implementation partnerships.
Industrie 4.0 57
58
Industrie 4.0 Industrie 5.7 increase the complexityincrease regulatory the relevant of signifi does it territory, regulatory uncharted com pletely tread whole, the on not, does 4.0 Industrie While tech with pace to keep fails regulation current whereby deficit” “enforcement technolo cy innovation enforce to legisla existing impossible almost becomes it that great the down tech new slow and acceptance pro innovation issues its protection inhibit data could and liability associated the or technology new a of legality the regarding certainty un hand, one the On challenges. interconnected two regulatory existing the with confronted themselves find will 4.0 Industrie with associated processes manufacturing new the tion, innova technological fundamental other any like Just 6. 5.
Regulatory framework as opposed to developing completely completely developing to opposed as digita and engineering) (delta systems existing to adaptations of development real the or contemplating engineering mechatronic modelled as the such aspects methodological between as well interaction as descriptions, formal the appropriate of modelling includes This IT under increa will engineers Bysame the process. token, R&D the of early stages be should the from involved experts Legal law. the and technology between interface atthe be necessary adopt anintegrated view of to and and other’sapproaches positions each of toacquire disciplines amutualunderstanding the different require will This approach. engineering asystems IT) and todeliver engineering automation engineering, (e.g. disciplines all cooperationbetween benecessaryinterdisciplinary topromote It will 4.0 Industrie of Promotion professional develcontinuing a significantnumber present of for thechallenges need training and CPD,including for comprehensive the trainingdevelop appropriate strategies, analysis methodsOverall, and management models. will this life Inincreased expectancy. order to organise work way in a fosters learning,w that it include shouldalso This how the issue of workers older can retain employability their a against back management and cooperation, with impact their together fundamental willimportance be It of investigate to relating to issues work organisation, design, process - based modelling of technological systems technological of based modelling
gies can result in the danger of a chronic chronic a of danger the in result can gies - - oois n bsns mdl cn e so be can models business and nologies standing of the legal issues so that they can engage in a full dialogue with their legal counterparts. legal their with dialogue engage afull they that can in so issues legal the of standing - cess. Conversely, the de facto power of power facto de the Conversely, cess. ls n te irpie aue f new of nature disruptive the and cles - tion. Consequently, short technological technological short Consequently, tion.
framework, a situation that raises raises that situation a framework, - nological nological change. - opmentprovisionleast to and changes some at of parts the training system. strategy, business processes and systems. Interdisciplinary research will also also will research processes systems. Interdisciplinary and strategy, business specific learning content and interdisciplinary cooperation interdisciplinary and content learning specific
new systems from scratch. from systems new
- cantly 5 Recommended actions
- - -
company, but will instead comprise highly dynamic dynamic highly newvalue completely and companies of networks comprise instead will but one company, just involve longer no will models business ver, Mo increase. will generated data corporate the of in established becomes detail of level the and volume the both factories, Things smart of Internet the As data corporate 1. Protecting Challenges ph use. in are already they until left being rather than R&D the during possible as early as begin anal regulatory the require factors Both contracts. law common through this achieve to possible be often will it 4.0, Industrie of context the In innovation. facilitates that way a in de and law reconcile to the with comply technologies new the that ensure to required are criteria of formulation the technology: and regulation things Two issues. on the evolution of work the evolution andon training of in 4.0. Industrie - velopment of the regulatory framework framework regulatory the of velopment
singly need to acquire a basic abasic acquire singly to need - ysis of new technologies to to technologies new of ysis l worlds, including the the including worlds, l ill be ill neces
manufacturing manufacturing
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reo ase ase
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actions 5 Recommended 10 fore necessary to develop new contractual models that chains, as demonstrated by the RAN Project , for ex- allow businesses to retain sovereignty over “their” data ample. Data will be generated and transmitted auton- whilst still facilitating entrepreneurial flexibility. omously by smart machines and these data will inevi- tably cross company boundaries. A number of specific 2. Liability dangers are associated with this new context – for When sensitive data are exchanged between different example, data that were initially generated and ex- companies, there is a risk that they may be used changed in order to coordinate manufacturing and lo- and/or disclosed illicitly, or that they may be hacked by gistics activities between different companies could, if third parties if, for example, the recipient fails to read in conjunction with other data, suddenly provide implement adequate IT security measures. One third parties with highly sensitive information about one of the partner companies that might, for example, give solution to this problem is provided by a type of them an insight into its business strategies. New contractual clause al-ready in widespread use that instruments will be required if companies wish to pur- sets out the requisite technical and organisational sue the conventional strategy of keeping such knowl- arrangements and any ad-ditional measures (e.g. the edge secret in order to protect their competitive ad- duty to provide notification of any security problems or vantage. New, regulated business models will also be breaches) and stipulates penalties in the event of non- necessary – the raw data that are generated may con- compliance. However, in Industrie 4.0 manufacturing tain information that is valuable to third parties and facilities are responsible for a wider range of matters companies may therefore wish to make a charge for than in the past. They may now be subject to a liability sharing them. Innovative business models like this will action not only if they fail to meet their primary also require legal safeguards (predominantly in the responsibilities (in terms of the prod-uct’s durability, shape of contracts) in order to ensure that the value- correct operation and appearance), but also for failings in their role as part of a network of smart objects. added created is shared out fairly, e.g. through the use of dynamic pricing models. In these scenarios, the issue of liability and responsibil-ity
Current regulation of the protection of corporate data only becomes even more important – when autonomous addresses some aspects of these dangers and generally systems are deployed in networks, a lack of structural requires the data to be classified as business or trade transparency could make it almost impossible to explic- secrets. Furthermore, it usually only applies to cases of itly determine who performed a particular action, result- illegal disclosure. As a rule, confidential infor-mation that ing in uncertainty with regard to legal liability. It is true that has been acquired legally, e.g. with the per-mission of its businesses employing manufacturing systems that use owner, may subsequently be used for other purposes. autonomous data processing are legally liable for the However, self-regulation such as confi-dentiality security of their manufacturing facilities and prod-ucts vis- agreements should make it possible to close these legal à-vis third parties. Current tort and product lia-bility law loopholes. Contract law offers a means of achieving already provides adequate solutions in this area. highly specific regulation of a variety of differ-ent However, if the other partners in a network wish to avoid scenarios. This will require the sensitivity of the data and being held jointly liable, or if they want at least to have the degree of protection needed to be determined on a recourse against the other partners, then it is es-sential case-by-case basis – under certain circumstanc-es, for their responsibilities to be contractually stip-ulated individual data protection law principles could pro-vide a from the outset and/or for actions to be clearly attributed model in this regard. to the owners of the respective systems. This also has
However, contracts do have their limitations when it implications for the insurability of residual risk and the comes to managing large volumes of voluntary legal ar- way that the insurance industry calculates the relevant premiums. rangements, since a disproportionately large amount of work is involved in calculating the risks and negotiating Correct attribution of liability will be facilitated by the pro- separate contracts for each individual case. It is there- vision of precise documentary evidence concerning the
Industrie 4.0 59
60
Industrie 4.0 Industrie agreements and agreements agreements, it although company in this achieve to through point, a to up possible, be may It data. handling for per practical solution and unambiguous legally a for need growing a have therefore Businesses re protection data is it practice in cli for impossible that meaning Europe, of outside protection data local stand since computing), cloud of al models processing data Outsourced problems. these address adequately to fails regulation Current in value result networked could globally chains. This for Europe. constraints in problematic found those than standar ap particularly is restriction informa personal containing data corporate of Europe outside disclosure the or group) be companies (including (EEA) Area (EU) Union European the outside compa to factories smart in captured data of analysisthe of outsourcing the law onrestrictions strict places protection data German regard. this in problematic self informational w Scenarios to right to threat a employees’ pose could issue This work. their of quality the or signs vital their location, employee’s an about tion informa record that systems assistance of true pecially the of empl detail individual for of held level data personal in and volume CPS the and will so employees creases, between interaction the As data personal 3. Handling will a play tures far roleimportant inmore Industrie 4.0. or personal as such dures technology problems). Consequently, law protection data cause could individuals specific to relating data protocol detailed highly (al though statuses system and steps manufacturing different - ready encountering difficulties (e.g. in the realm realm the in (e.g. difficulties encountering ready - ards are generally not applicable in countries countries in applicable not generally are ards
s n h cuty re country the in ds
- os bnig oprt rules, corporate binding house ith an international dimension are particu internationaldimension are an ith - ent companies to comply wit comply to companies ent - sponsibilities. 5 Recommended actions - ae dcmnain proce documentation based
- - - This employees. about tion evn te aa r lower are data the ceiving device lcbe f aa protection data if plicable or Euro or
- - ae dgtl signa digital based longing to the same the to longing ye. hs s es is This oyees. - pean Economic pean - determination. - nies located nies collec
h their h their - sonal - - larly are are tive
------processing that the built the that processing data of kind the restrict and happening from this prevent w they which for purposes for them use who customers end of session pos the into come eventually may they process, manufac turing the during used be initially may components these Whilst product. end the into components cessing In to relevant t is example, for especially 4.0, dustrie is that issue in One application question. and product the on depend will features prod custom for requirements law protection data The 4.0. Industrie of teristics take to adapted be to need would instruments these event, any In standards. protection data existing undercut circumstances any under not did these that ensure to important be would rporpi cmoet ae ul it larger trade. to barrier into significant a become could and 4.0 Industrie built in increase un legal are This facilities. manufacturing components cryptographic already extent some pres if areas grey legal to in operate to forced themselves finding global are markets a key have tomorrow’s to wishing destinations. companies other many for restrictions goods use dual as classed encryption are of they but US, the and shipment Canada Japan, as such countries hand, other other certain to and Europe within allowed is technologies the on EU, th In licence. under permitted only are en products cryption of exporting and importing sale, use, the China, as com such markets, CPS emerging many of in However, integrity munication. and confidentiality the ensure necessa both in are technologies and Encryption restrictions. trade national ternational to indi subject be that may likely components vidual increasingly becomes in it deployed 4.0, are Industrie systems complex more and more As restrictions 4. Trade strictly is what necessary as defined la byprotection data to confined be should capabilities their y n dsrd y utmr i odr to order in customers by desired and ry r nt rgnly nedd I odr to order In intended. originally not ere
- charac specific the of account
in components can be used for, used be can components in he incorporation of data pro data of incorporation he 11
n sbet o export to subject and certainty will only only will certainty w.
vn today, Even - ne in ence - uct e ------various working groups from a from working groups various nec Asbe will it market. such, 4.0 Industrie the in advantage competitive genuine a with Germany provide could experts between lines these along partnership A counterparts. legal their with dialogue full increas will legal that ensure the to from right important involved are be experts will It research. interdisciplinary require will regulation with contact into comes technology where areas the in 4.0 Industrie by posed challenges the terms, general more In Organiz Trade the through World example for regulations, international common promote to term long to medium the in undertaken be should efforts 4.0, Industrie for supplier en to regard with especially restrictions, trade of field the in harmonisation for need urgent an also is There be areacurrently this exists. still in need the that for legislation level atEU is will it Nonetheless, standards. security IT with neces compliance of certification or audits as such ures data corporate partie third tosensitive belonging of handling confidential and secure the to regard With rights. protection data ees’ com employ upon encroach not do sample 4.0 Industrie of requirements the that containing ensure to order in developed models be should practice best protection, data employee for As another. to partner one overfrom handed are items where points critical at particularly evidence, documentary provide support the concerned, is liability as far As pos as precisely as partners new value any that ensuring also whilst hand, one the on secrets trade and business of protection guarantee to need models contract New clauses. contract model important and checklists especially be will that aspect One among above outlined problems the of awareness associa professional byengaging SMEs raise to important be entail will not it will Moreover, “solutions” elements. these part, most the in For will succeed. but to legislation, is initiative 4.0 Industrie the if them described challenges regulatory The Recommendedactions - cryption product cryption
business models is shared out fairly. It will therefore be necessary to define the roles of the various various the of roles the define to necessary be willtherefore It fairly. out shared is models business - sary to legislate on certain issues. These include outs include These issues. certain on legislate to sary - ingly need to acquire a basic understanding of the legal issues so that they can engage in a a in engage can they that so issues legal the of understanding basic a acquire to need ingly - s. In order to ensure that Germany can successfully sustain a position as a leading leading a as position a sustain successfully can Germany that ensure to order In s. essary for the Industrie 4.0 Platform to ensure that legal experts are involved in the the in involved are experts legal that ensure to Platform 4.0 Industrie the for essary - stead require a mix of instruments comprising regulatory, regulatory, comprising instruments of mix a require stead s, it would be desirable to engage in efforts to promote self promote to efforts in engage to desirable be would it s, - sible (including new roles such as different types of information broker). information of types different as such roles new sible (including n early stage.
earliest stages of the R&D process. By the same token, engineers engineers token, same the By process. R&D the of stages earliest above are not trivial and it will be essential to find solutions to to solutions find to essential be will it and trivial not are above - tions and government ministries to act as multipliers. as act to ministries government and tions provided should focus on data security and the requirement to to requirement the and security data on focus should provided
for SMEs is the development of practical guidelines, guidelines, practical of development the is SMEs for
ourcing of data processing activities, although it although activities, processing data of ourcing 5 Recommended actions
ation. - added generated through the the through generated added
- regulation through meas through regulation technical and policy policy and technical engineers and legal legal and engineers pany agreements agreements pany
4.0 Industrie
- - 61
62
Industrie 4.0 Industrie 3. 2. 1. Assessments, footprintingAssessments, carbon are Cycle (Life measurements metrics these perform to available now of range A resource efficiency. resource calculating calculating on is prod emphasis the scenario, possible lowest the first In the output. given to a resources achieve quantity of using on or resources, given of a quantity with achieved output the maximising on focus resour these howof terms In between three catego distinction a draw to possible is It network. the within com both companies, manufacturing by used resour of amount the is point starting The consumption reallyenergy can influenced. be and material and where areas only the machinery are these since of plant, design the and of processes chance facturing any have to manu are in changes involve will this Ultimately, succeeding. they if years many over alternative find or be sus to effortsHowever, will need sources. these resources and con its energy reduce of to sumption efforts major undertaking is dustry m which be supply to of need security and environment the to risks entails situation this involved, costs high the to addition In electricity. and energy primary the of also consumer is principal it sector, private the with Together nations. in materials raw of consumer largest the far by is it that means industry manufacturing of nature The Resource 5.8 efficiency
Financial resources, i.e. the necessary necessary the i.e. costs operating and investment resources, Financial i.e.labour human resources, Human con including carriers, energy of kinds different the all operat additives, materials, Raw - uctivity, whilst in the second scenario the focus is on is focus the scenario second the in whilst uctivity, ay tef n truhu te et f h value the of rest the throughout and itself pany - version from one type of energy into another energyinto of one type from version
- ries of resources and howthey resources and areused: of ries nmsd y euain Cneunl, in Consequently, regulation. by inimised
5 Recommended actions ces are used, it is possible to possible is it used, are ces 12 , etc). ,
ing supplies and and supplies ing
industrialised ces that are that ces
- tained
- - -
yai cniin, uh s rqet tpig and stopping frequent as such conditions, dynamic under processes the of stability the also but functions basic only not consider to important is it processes ing manufactur efficient implementing When regard. this ( ( Federation Engineering Ed of istry Min Federal joint the of outcomes The production. ing dur used equipment and machinery the by and whole a as processes manufacturing industrial during con sumed resources the reducing of ways implement and terms, general In Challenges productivity and efficiency on a case efficiency and productivity deliv provides 4.0 Industrie logistics. curement distribution and pro intralogistics, control, engineering, production during manufacturing, used resources of amount total the on based gains efficiency and productivity source suf generate can ture infrastruc associated the and CPS of deployment the in invested resources additional the that demonstrate to be will 4.0 Industrie for challenges key the of One (semi requirements failure), read levels of inventory be and needed not risk in may build the resources to minimise important is to it redundancies (so down break can equipment Manufacturing considered. be to needs repaired be to product the require turn in which issues quality in result that processes unstable preventing of terms in productivity consider to necessary therefore is It energy). and materials of waste sta Effizienzfabrik rting and prevention of faulty products (which are a a are (which products faulty of prevention and rting - ery of the overarching goals of resource resource of goals overarching the of ery ucation and Research ( Research and ucation
or completely remade. Availability also also Availability remade. completely or )
13 Industrie 4.0 will need to investigate investigate to need will 4.0 Industrie
initiative could serve as a model in in model a as serve could initiative - finished and finished goods). finished and finished ficient opportunities to deliver re deliver to opportunities ficient
the opportunity to optimise optimise to opportunity the VDMA may not be in line with with line in be not may
“fiiny Factory” “Efficiency ) - ily available when when available ily BMBF
- by ) and German German and ) - case basis. case
------9 8 7 6 5 4 3 • • • • tas following the shouldinclude Group’sremit Working In the through established be should Group Working a that recommends Group Working 4.0 Industrie The Recommendedactions Ainc ( tr drvd rm h wrs “aviation” words the from derived term (a Avionics 2 technologicalexample for scenarios,hypothetical or real of variety wide very a addresscan Models 1
of the task and domain and the extent to whichindependentdecisionto extent theand domain andtask the of complexity the on based levels skill eight establishes(DQR) FrameworkQualifications German The Ziegler(Ed.): Zukunft des Industriesta Astrid Allespach/ Martin In: Mitbestimmung? Innovationsführerschaft durch Schroth: Fondel/Jochen Tanja See how internationallyactive(s are most companiesthat byaffectedproductpiracy, 93% risingtocompanies for with1,000more than employees whichgenerallyare the j 37,000 for pay recuperbe couldway this in lost money the If ago. yearstwo survey last the since plantand manufacturing sectorlost just under 8 billioneuros worthofsales to piracy in2011, risea of 24 percent Accordingto the latest survey carriedby outthe German Engineering Federation (VDMA), Germany’s BSI Cyber deployedin manufacturing 1969,in Chaptersee 1. logic programmable first The German its and 2006/42/EG Directive Machinery European transposition in theshape of theNinth theRegulation of the Equipment and Product Safety Act, 9. ProdSV. include regulations these of Examples Gipfels IT Nationalen InfrastrukDigitale (Ed.): des 2 Arbeitsgruppe from: taken is quotation following The “electronics”) refers tothe all electricaland electronic equipment on board an aircraft. or effects and interactions organisations,organisationale.g. structures chemical and business processes orflows. or physical interactions, biological or behaviour human e.g. manufacturing entire or resources manufacturing products, as such systems Gestaltungdes Deutschen Qualifikationsrahmens, 2007, 10.p. open future Gesamtmet and current in independently act the
- resource transparent, take to required data with basic the together account, into taken be also Index should decision of development The initiatives. and projects eco and efficiency and productivity resource assess to used are being that indicators) (key performance KPIs and metrics various the account of take to necessary willbeIt i orsector industry the of account take should assessments required. These automation equipment type the and of ones new building or lines production onmodernising decisions totaking comes it when resources of categories different generated. shoul This savings infrastructurepotential the and associated their trade assessment and of Calculation issues. oravailability productivity of avoidance on the based environment manufacturing in the efficiency and productivity enhanced of resource terms in savings resource of Demonstration initiative. Factory” “Efficiency the BMBF/VDMA of the outcomes of development and Adoption dustrie 4.0 Platform to deal exclusively with the topic of resource productivity and efficiency. The The efficiency. and productivity resource of topic the with exclusively deal to Platform 4.0 dustrie
- industry’sprofessional associations and trade union, “skills” are defined as “theindividual ability to Schutz,Produktpiraterie 2012, November 2012). - all, VDMA, ZVEI (Ed.): Die Anforderungen des Beschäf des Anforderungen Die (Ed.): ZVEI VDMA, all, - obs in the industry. Almost two thirds of the companies that participated in the survey are now are survey the in participatedthat companies the of thirds two Almostindustry. the in obs Security Analyses, BSI Analyses, Security - oriented investment decisions, pa decisions, investment oriented - turen. Jahrbuchturen. 2011 ndortesDeutschland 2020, Marburg, 2012, pp. 174 ee VDMA: Studie der ArbeitsgemeinschaftderStudieVDMA:Produktee -
A
- - CS 004, Version 1.00, 12.4.2012. 1.00, 004, Version CS otolr Mdcn 8) was 084) (Modicon controller ne ad ope stain” i: BITKOM, in: situations”, complex and ended /2012, 2012, pp. 176 /2012, –
from the Latin avis, or bird bird or avis, Latin the from
n question and whether the value network is regional or global in scope. in regionalorglobal is network thevalue whether and n question
tigungssystems. Ein Beitrag zur Beitrag Ein tigungssystems. - taking is involved. Accordingtoinvolved. is taking - offs between the additional resources required to deploy CPS and to required and CPS deploy resources additional the between offs - ated, it would be enoughto be would it ated,
systems, living things, living systems, - - 177. 192.
rticularly in the area of industrial automation. industrial of the area in rticularly -
und Know und machinery
–
and
- ks: - 3 h on BB Fdrl iity of Ministry (Federal BMBF joint The 13 Life12 Cycle Assessments (LCAs)inv Thetermused,goods”“dualuseparticularly11 is export control,field ofthedescribe toin goods usedbe thatmay (RFID RAN The 10 supporting KPIs such as the Green Production Production Green the as such KPIs supporting information is resource for solutions integrated of development the enable to order in projects individual different the across trends pl The Manufacturing”. in Efficiency “Resource priority funding BMBF the under groupedtogetherprojects 31 the of findings researchplatformdisseminatesFactory”innovation“Efficiency the product’s impacton climatechange. a to down LCAs of scope the narrowsindicator this words, other In cycle. life entire its throughoutemissions forre thephaseand marketing declarationsduringformulateproducthelp to wellas sustainable,as be to designed is product the that ensure ISO also see fuels; and additives stand materials, raw relevant the of production (e.g. processes downstream and upstream associated the as well as disposal, subsequent and use manufacture, its including cycle, life substancesreleased into theenvironment, such as waste or emissio CO2 any and oil, crude or ores as such manufacture, their for environment the from extracted anything (including specifications) meanthat they canalsobe used for militarypurposes. civilianperformanceapplications,producedprimarilytheirpropertiescontainormaterialsfor theirthe(e.g.they Alt technologies). or software machines, (e.g. purpose one than more for improvebusin to used be can they broker”)that so companies (“informationdifferent between exchanged be infrastructure to data IT ID auto enabling standardised a developing is 3 Workstream cost processes. for methods and approaches newinvestigating is project The automotiveindustry. the in controlprocess optimal andtransparent medium and small for systems “AUTONOMI Technology’s and Economics of Ministry Federal
substitution processes resulting from from resulting processes substitution 5 Recommended actions rs 44 ad 44) LA a b ue drn te rdc pann ad ein hss n re to order in phases design and planning product the during used be can LCAs 14044). and 14040 ards - fiin mnfcuig ht a sbeunl b md aalbe o neetd opne. More companies. interested to available made be subsequently can that manufacturing efficient
availableonline www.effizienzfabrik.de.at: essprocesses. More information isavailable at: www.autoran.de. - Based Automotive Network) project is one of 14 projects under the auspices of the of auspices the underprojects 14 of one is projectNetwork) AutomotiveBased - design purposesdesign olvecomprehensivea analysisofproduct’s a totalimpact on theenvironment
- ie etrrss tcnlg porme RN is o deliver to aims RAN programme. technology enterprises” sized dcto ad eerh ad DA Gra Egneig Federa Engineering (German VDMA and Research) and Education d also be done for the be for done d also - - fetv inter effective friendlin . A product’sgreenhousetotalA footprint carbon its to refers. gas
- opn mngmn o odr fulfilment order of management company ess in current in current ess
S Atnmu, simulation Autonomous, CS:
ns) through og hs gosmy ae been have may goods these hough tom oue o analysing on focuses atform -
out thecourse entireof its
4.0 Industrie
- based - tion) 63
EXAMPLE APPLICATION 3: Supporting custom manufacturing:
how an individual customer’s requirements can be met
The dynamic value chains of Industrie 4.0 enable customer- and product-specific coordination of design, configu-ration, ordering, planning, production and logistics. This also provides the opportunity to incorporate last-minute requests for changes immediately prior to or even during production.
Today Today’s automotive industry is characterised by static Rigidly sequenced car production lines (with predefined sequences) which manufacture on a production line are hard to reconfigure to make new product variants. Software-supported Manufacturing Execution Systems (MES) are normally designed with narrowly defined Workstation 1 Workstation 2 functionality based on the production line’s hardware and are therefore equally static. Workstation 3 Workstation 4 The nature of employees’ work is also determined by
the production line’s functionality and is thus usually very monotonous. Individuality is not encouraged.
As a result, it is not possible to incorporate individual
customer requests to include an element from another product group made by the same company, for exam- Source: Hewlett-Packard 2013 ple to fit a Volkswagen with Porsche seats.
Tomorrow
Industrie 4.0 results in the emergence of dynamic pro-
Decoupled, fully flexible and highly duction lines. Vehicles become smart products that
integrated manufacturing systems move autonomously through the assembly shop from
one CPS-enabled processing module to another. The
dynamic reconfiguration of production lines makes it
Workstation A possible to mix and match the equipment with which Workstation T Workstation O vehicles are fitted; furthermore, individual variations
(e.g. fitting a seat from another vehicle series) can be
Workstation X Workstation H implemented at any time in response to logistical is-
sues (such as bottlenecks) without being constrained
by centrally prescribed timings. It is simple to execute
this type of reconfiguration and the cars move autono-
Workstation F Workstation K
mously to the relevant workstation. The Manufacturing
Execution System IT solution now constitutes a central
component from start to finish – from design through to
Source: Hewlett-Packard 2013
assembly and operation.
POTENTIAL BENEFITS The first apps, MOS solutions and shared IT platforms as described above will start to appear relatively soon, i.e. within the next few months. However, it will be some years before we see end-to-end, CPS-enabled dynamic production 64 Industrie 4.0 lines. Nonetheless, implementations focused on specific parts of the manufacturing process can be expected to occur somewhat earlier. EXAMPLE APPLICATION 4: Telepresence
Remote Service is an instrument that manufacturers have been using for several years in order to provide custom-ers with fast and efficient support by remotely accessing and controlling machines. Increased networking of manufacturing systems opens up new potential to deliver additional productivity gains.
Tod
Remote Service is enabled by the establishment ay of individual communication solutions between the ma-chine supplier and the user. The technician connectsgenerally to the machine directly via a modem. Remote Since the advent of the Internet, VPN connections Service (Virtual Private Networks) have also gained in popularity, since they allow secure access to the customer’s cor-porate network. The goal of this approach is to re-motely diagnose and control the Source: machine in order to Trumpf 2013 reduce the duration of unscheduled stoppages and downtime. The configuration and administration of the communication links involves a significant amount of management work, since the conditions of use need to be agreed separately with each customer. Moreover, this approach can currently only be used to provide reactive services, i.e. to carry out maintenance after an incident has occurred. Tomorro
In Industrie 4.0, technicians will no longer manually w con- nect to the machine they are servicing. Manufacturing systems will operate as “social machines” – in networks that are similar to social networks – and will automati- cally connect to cloud-based telepresence platforms in order to search for the appropriate experts to deal with the situation in question. The experts will then be able to Telepre use integrated knowledge platforms, sence videoconferencing tools and enhanced engineering platform Source: Trumpf 2013 ditionalmethods remote to perform maintenance tra- services more efficiently via mobile devices. Moreover, machines will continuously enhance and expand their own capabilities as the situation requires by automatically updating or loading the relevant functions and data via standardised, secure communica-tion links with the telepresence platforms. By shifting complex computational tasks (e.g. simulations and projections) away from the machines to the portals it will be possible to employ huge amounts of processing power to ensure that they are performed in the shortest pos-sible time, thus delivering additional productivity gains.
POTENTIAL BENEFITS The first cloud-based telepresence portals that have recently become available hint at what may be possible in the fu-ture. Rapid development of these portals will open up new horizons, revolutionising manufacturing systems over the next few years.
6 How does Germany compare with the
rest of the world? selected countries* industry sales in Mechanical engineering Figure 13: refer to specifically to of digitalnetworking produc China Europe, in used are Factory” “Smart or Manufacturing” “Smart Production”, “Smart terms The own right. revolu genuine a as processes manufacturing of auto the from resulting industry of transformation mass mechanical first, the of part as of production) In second establishment the (the including Revolution by either at is arrived number This Revolution. Industrial third a of terms in digitalisation towards trend the and Things of Internet the to refer to customary is it level, EU at and world speaking Eng the in Especially 4.0. Industrie of of phenomenon variety a the describe to world However, the around used are terms different forward. going industry turing stra as processes dustrial Internet (Industrial ing the manufactur in Things identified of Internet the have using towards trend to country only the not is Germany does Germany 6 How 3, 4
1 ad t dsutv ipc o in on impact disruptive its and )
ei calne fr manufac for challenges tegic 500 600 700 800 100 200 300 400 0 * Mechanical engineering industry not including services such as installation, maintenance; repair and as such services including not * Mechanical engineering industry
as far as possible, the sales figures include all the companies that manufacture in the respective countries respective the in manufacture that companies the all include figures sales the possible, as far as in billions of euros of billions in 2006 2
or not counting the third the counting not or
compare with the rest of theof the rest world? with compare
and the US the and
2007
- tion in itsintion - Russia USA China Germany EU (27) -
- dustrial mation
- lish
5
- - - -
h goa fnnil rss rgee a dra a triggered crisis financial global the percent, 38 byapproximately rose output when 2008, and 2004 between growth spectacular of period a Following market International trends. to these responses engineering, policy different illustrate to serve countries selected electrical of examples the areconcerned, ICT and automation manufacturing, and machinery for markets plant global the as far As enviro manufacturing the in trends modernisation of spectrum broader a embraces ing” Manufactur “Advanced term fashionable equally the whereas systems, manufacturing smart create to tion toe o ae p h gon ls drn te crisis. 2013. growthfor forecast the during nor to lost returned now ground has Demand the up make to companies strove as 2009 of middle the as early as again up Howev manufacturers. plant Germa among production and orders 2008 6 International comparison
2009
r bsns satd o pick to started business er,
trends 2010 - mal, with two percent percent two with mal, nment. - ny’s machinery and machinery ny’s
Source: VDMA, Stand November 2012 November Stand VDMA, Source: - ai sup in slump matic 6
4.0 Industrie 2011
-
67
6 International comparison 68
Industrie 4.0 Industrie mestic and export demand. The press in the US has US the in The press demand. export and mestic si recovery gradual 2010. and 2002 between percent 25 by fell industry the in employed people of number The imports. on pendency de sector’s engineering mechanical US the in crease the of parts other large 2002, Since 13). Fig. also (see picture. heterogeneous extremely an veals re countries selected in industry engineering chanical me the of position the at glance A 2011. in euros lion aro to came sector engineering mechanical the in sales Global Italy. and US the from competitors by distantly only followed ones, domestic as petitors as themselves com main their regard and leaders see world’s the among still firms engineering chanical German of majority the (VDMA), Federation ing Engineer German the by survey recent a to According 8
oee, hr hv be sm sgs f a of signs some been have there However,
ol hv rsle i a hr in sharp a in resulted have world - c 21, ih ie i bt do both in rises with 2010, nce to production of transfers scale und 2.1 tril 2.1 und me
------»
trade fair, is already the fourth largest export market export largest already is fourth the tradefair, cou partner official the is which Russia, 2010. since plant and machinery for demand Russia’s in rise pronounced a been There has percent with of 10.2 share a the market. machinery, of exporter largest fourth world’s the become yea previous the to compared percent 20 than more of increase an euros, billion 87.7 the 2011, worth goods exported In industry goods investment Chinese front. exports the on efforts its redoubled also has China time, same the At 2011. in euros billion of sales with manufacturer, machinery largest world’s the become to risen has it years, five past the Over sition. mechanical po its market its strengthening of and technology terms engineering in countries other with up ing a devoting also is China per boom” “insourcing and “reshoring” as such terms on seize to quick been
- of t of intomorrow’s success world enjoyto continue global andengineering mechanical manufacturing technology competencies in fieldsthe of necessarysesses all the Germany apparent that pos togetherwork it becomehas ourDuring of course the Services Services ceives as a fundamental sea change. sea a as fundamental ceives Co GmbH Bosch Robert Dais Siegfried Dr. - Chair of the Industrie 4.0 Working Group 4.0 Working the Industrie of Chair he Internetof Things and «
10
ntry of this year’s Hannover Hannover year’s this of ntry huge amount of effort to catch to effort of amount huge
to describe what it already already it what todescribe
. t hs ep for leapt thus It r.
- ward to to ward -
563
9 - -
comparison
6 International for German mechanical engineering firms, behind Chi- The global turnover of the ICT industry is forecast to rise na, the US and France. Germany is also Russia’s by 4.6 percent this year to 2.69 trillion euros. At 5.2 and number one machinery supplier, with a 22.6 percent 4.2 percent respectively, the two key segments of market share. The Russian government is forecasting information technology and telecommunications are both continued growth of the Russian market over the next experiencing strong growth. However, there are few years and is supporting this growth through a significant disparities in market trends across different funding programme worth billions of euros. In the regions. Whilst the industry is booming in newly-indus- longer term, there is significant potential for German trialised countries, throughout most of Western Europe it machinery and plant manufacturers to export Industrie is either flat or in decline. Between them, China, India and 4.0 products to Russia. Russia already account for one seventh (14 per-cent) of
In 2011, the global electrical engineering market was global ICT demand this year. The Chinese mar-ket alone worth 3,414 billion euros. At 116 billion euros, the Ger- is forecast to grow by 6.6 percent to 235 billion euros in man electrical engineering market is the fifth largest in the 2013, overtaking Japan (221 billion eu-ros) as the world’s world, after China (1,119 billion euros), the US (486 billion second largest ICT market. The US market remains the euros), Japan (284 billion euros) and South Korea (155 undisputed leader in terms of de-mand for ICT. The latest billion euros). In recent years, the growth of the global figures put its total value at 725 billion euros, an increase electrical engineering market has largely been due to of 5.8 percent. Growth in western Europe has been more newly-industrialised countries whose total market volume sluggish than in the rest of the world. In 2013, ICT sales of 1.7 trillion euros reached the same level as that of the are expected to rise by a modest 1.3 percent to 625 industrialised nations for the first time in 2011. It is billion euros. The German information technology market, expected that growth will remain signifi-cantly higher in on the other hand, is forecast to grow by 3.0 percent in the newly-industrialised countries than in the 2013 to 75 billion euros. Germany’s software market is industrialised nations during 2012 and 2013. also set to experience strong growth, rising by 5.1 percent The global automation market recently reached 350 to 17.8 billion euros. The market for IT services such as billion euros, meaning that it now accounts for more than out-sourcing and maintenance is forecast to grow by 3.0 one tenth of the global electrical engineering mar-ket. In percent to 35.9 billion euros, whilst the hardware mar-ket the past few years, China has risen to become the single is expected to return a modest growth figure of 1.2 largest regional market. Its market is current-ly worth 100 percent. billion euros, giving it a 29 percent share of the global market and meaning that it has now over-taken Europe, With SAP, Software AG and Telekom, together with where the market is worth just 93 billion euros. Trailing major subsidiaries of US (e.g. IBM and HP) and some way behind these two markets are the US (12 Asian companies, Germany has a globally percent or 40 billion euros) and Japan (8 percent or 26 significant level of IT competencies clustered billion euros). At 21 billion euros (6 per-cent), Germany is closely together. This pro-vides a new opportunity the world’s fourth largest market. for Germany to take a leading role in Industrie 4.0. China’s lead is even greater when it comes to Industrial policy funding initiatives in selected countries automa-tion product manufacturing. China accounts for 30 percent of global production, or 103 billion Other countries are also supporting the modernisation euros out of a total of 350 billion euros. The US and of manufacturing industry through funding Japan are more or less tied for second place with programmes and research initiatives. However, the roughly eleven per-cent each, closely followed by available informa-tion suggests that in the US and Germany, with ten per-cent. However, Germany is China, for example, the transformation envisaged by the world’s largest exporter of automation products the Industrie 4.0 initia-tive is regarded as no more than and systems (29 billion euros), followed by China one trend among many, for example the introduction of 11 (27 billion euros) and the US (21 billion euros). new materials and technologies.
Industrie 4.0 69
7 0
Industrie 4.0 Industrie the field of advanced manufacturing. advanced of the field dol Ac Innovation and Jobs administration’s US the Finally, field. this in initiatives private and university ernment, gov between networking facilitate to intended is and tal Manufa Advanced the for responsible also know and facilities research of the provision through industry manufacturing domestic to port sup technical provide allocated to funding of dollars million been100 has standardisation, for responsible body the is which (NIST), Technology and Standards of Institute National the this, of top On dollars. billion 2.2 to percent 19 by increased being is manufacturing advanced for earmarked funding the budget, 2013 the funding R&D more making is administration Obama the addition, In in and investment US crease in manufacturing facilities. businesses US of competitiveness global improve the to order in excellence” manufacturing for hubs ar Partnerships, Private Public of form the take which institutes, These (NNMII). Institutes Innovation Manufacturing of Network National 16 recommendations detailing report a submitted AMP the 2012, July In Techno and United Gamble & Procter Grumman, Northrop Johnson, & Hon Johnson Intel, (in Ford, enterprises Chemical, Dow US Corning, leading Caterpillar, of CEOs the emerg and GIT) and Michigan CMU, engin Stanford, the Berkeley, top UC (MIT, the of Presidents of the of development up made is Committee Steering AMP The technologies”. the furthering and investing for “course a chart to communities political busi research, the of representatives together 2011, of private a (AMP), summer of Partnership the reshoring In encourage Manufactur Advanced the launched Obama US. President and the to jobs manufacturing create to order in policy industrial active an pursue to seeking now is It sec engineering mechanical the to priority greater attach to started again once has administration US The US 15 - -
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comparison 6 International a research group as long ago as 2009 with a remit that ly submitted its “Vision for Manufacturing 2.0”, that includes the investigation of CPS applications in auto- is intended to serve as a discussion document for 20 mation engineering. China has also established an future research funding initiatives under the Eighth “IoT innovation zone” in the city of Wuxi in Jiangsu Frame-work Programme for Research – “Horizon Prov-ince with 300 companies employing more than 2020” (2014-2020). Horizon 2020’s proposed 70,000 people. China’s leaders are planning to invest budget of 80 billion euros will make it the world’s 23 a total of 800 million US dollars in the IoT industry largest R&D fund-ing programme. 21 between now and 2015.
EU India
At EU level, research into the Internet of Things is cur- Innovation funding is one of the core priorities of In-dia’s rently benefiting from increased support through the Five-Year Plan (2012-2017) which provides for an Seventh Framework Programme for Research (2007- increase in public and private R&D investment to two 24 2013). The largest budgetary allocation of in excess of 9 percent of GDP. In 2011, the “Cyber-Physical Sys- billion euros is earmarked for the ICT funding priority. tems Innovation Hub” project was launched under the Within the programme, there are a variety of cross-bor- auspices of the Ministry of Communications and Infor- der initiatives geared towards implementing the Inter-net mation Technology to conduct research into a variety of of Things in manufacturing industry. The Sie-mens-led areas, including humanoid robotics. Moreover, Bosch “IoT@Work” project has been given a budget of 5.8 founded the Centre for Research in CPS in Bangalore in million euros to develop the Plug&Work concept in a November 2011. Both the Fraunhofer-Gesellschaft and practical setting. Meanwhile, a total of 2.4 billion euros several top Indian research centres are participat-ing in has been invested in the ARTEMIS technology platform this project in an advisory capacity. The partner-ship, to promote R&D projects in eight sub-pro-grammes that which is funded to the tune of 22.8 billion euros, aims to include both “Manufacturing and Pro-duction Automation” create an optimal research and working envi-ronment for 22 and CPS. In addition, 1.2 billion euros have been the IT specialists of the future. In future, support will also be provided to industry and the re-search community, for awarded to the Public-Private Partner-ship initiative 25 “Factories of the Future” which launches annual calls for example through research con-tracts. Even today, proposals for projects in the area of smart, ICT-driven according to a recent study by the Zebra Tech Company, manufacturing. Under the auspices of this initiative, the Indian businesses are world leaders in terms of take-up 26 SAP-led project “ActionPlanT” recent- and use of IoT technology.
Industrie 4.0 71
72
Industrie 4.0 Industrie 10 9 8 7 6 5 4 3 2 1
Atlas der Globalisierung Globalisierung Atlas der in: Asien, in liegt Industrie der Zukunft Die Diplomatique: Monde Le See Tendenzbefragung. VDMA: Trends.GlobalCompetitive Position of German (seeMachineryand Plant Manufacturers], October 2012). survey VDMA the Mas in deutschen des WettbewerbspositionInternationale participated companies 483 of total A AmericanLeadership in Advanced Manufacturing, June 2011, p. ii). us is term particular this how of typical is trends,technology oncommittees advisory important administration’s most US the of one (PCAST), Technology and Science on Advisors of Council President's the by produced was which definition, t advanced new from emerging products new of manufacture the and products, existing manufacture to waysnew bothinvolves It biology. andchemistry,nanotechnology, example of mater coordination edge and use the on depend that automation,cuttinginformation,usecomputation, software,of networking,sensing, make and and/or activities of family a is manufacturing Advanced (SMLC), more informationavai smartmanufacturing.comblog Smartthee.g. ManufacturingSee ortheinitiative Leadership Coalition printing;see Hill, Jürgen:Das Potential von 3D material new of use the and productivity resource in increasedramatic a2011), World, the Economy, and theEnergy,Transforming Power Is LateralHow Revolution: Industrial Third new a with connected also is Revolution characteris cycle Industrialinnovation third the surrounding discourse the extent, some To “advanced revolutionbrings ofindustry back Europeto (press release),10 October 2012). promotion the 4.0: Industrie to tech enabling relevant “key andtechnologies” manufacturing directly are areas these of Two actors. private and states member the EU, the by future the in strengthened be should that areas key six Tajconsultation,public a following later, months few A 2012.). June Magazin, Industrie und Unternehmen In: Europe. in Revolution Industrial New a Building Commission: European (see Entrepreneurship,Ant and Industry Commissionerfor European the by statementmade the underpinningreasoning the is This Internet. Pushingthe Boundariesof Minds Machine and (GE study),November 2012,p. 7f. e.g. see used, is term this how on details For Internet. Industrial Pushingthe Boundariesof Minds Machine and (GE Study), Marco:November 2012, p. 4) C./Annunziata, Peter Evans, (See respectively. dollars billion efficiency in transportrail whilst and freight and healthcare the dollars, in gains billion 30 of savings generating years, 15 over percent 1 by cut be could sector travel air commercial the in consumption fuel that calculates It industries. range a in IoT the of deployment through savings global significant deliver to differentareas, manufacturingonly plays a minorrole. GEbelieves that thereispotential (IoTThingsofInternet the on the At end2012, of US In: The Global Manufacturer, October 2012, and The Economist: Economist: The and The Insourci See Fishman, Charles: 2012, October 2012. January Report, Special home, Coming manufacturing. Reshoring Manufacturer, Global The In: Builds. Reshoring Manufacturing U.S. for Evidence Steve: Minter, See inter Germany’s of detailedanalysis more a out carry to established be should project research separate A implementedmeasures and plannedsucceeding by Germany are in delivering goal. this un should Platform 4.0 the Industrie The 4.0. in Industrie Things of of area the in pacesetter global a Internet become to placed well is theGermany that believes Group Working 4.0 using Industrie for trend the recognised also manufacturing have competitors Germany’s of Many TAKE
- as n eegn cpblte eald y h pyia ad ilgcl cecs for sciences, biological and physical the by enabled capabilities emerging and ials n - ational competitors and the markets it should be targeting over the next ten to 15 years. to 15 ten next the over targeting it be should markets the and competitors ational HOME MESSAGE HOME - basedcompany GeneralElectric (GE) publicly launchedbroada d y h ue n epnin f eeal eeg (e eg Rfi, eey The Jeremy: Rifkin, e.g. (see energy renewable of expansion and use the by ed onio Tajani, when he proclaimed a third Industrial Revolution in May 2012May Revolutionin Industrialthird a proclaimed whenhe Tajani,onio ). Although GE’s “Industrial Internet” strategy has applications in a huge variety ofhugevariety a applications“IndustrialAlthoughInternet”hasinstrategyGE’s ).
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26See CXO today News Desk:Indian CIOs keen on adopting Internet of Things,11 October 2012. Voigt,21 See Kevin: Chinalooks to lead Internetthe of Things, (CNN), 28November 2012. 17 Inthese areas, thePlan speaks emphatically of “leapfrogging”. 15Online at:www.manufacturing.gov. recommendations ofthe President’s Council ofAdvisors Scienceon Technologyand (PCAST). In 2012its report 2012. November innovation, and growth global of era next The Systems) (acatech STUDY), Heidelberg STUDY), Systems)e (acatech Cyber Growth.An Inclusive Manufac Seventh the through funded initiative an is FrameworkProgramme Researchfor whichcoordinates European (IERC) research activities in thisarea. Things of Internet the on Cluster Research Heidelberg STUDY), Verlagal.:Systems) et 2012. (acatech Springer Cyber http://en.cbf.net.au/Item/639.aspx the encourage to policies formulate should “We entitled weimproveindustry; traditional restructureand technology informationto of article use make must an in topic this highlighted also Yizhong, Li Technology, Information speeches several in development China’s for technology Implicationsofthe 12th Five Year Plan For GermanMachinery Manufacturers, April 2012). Nürnbe (see development and research on spends currently Germany that amount dollars,appearsit that isonly specifically one focused onthe useof CPSmanufacturing. in Advanced in Advantage Competitive Domestic Capturing Manufacturing.AMP Steering C PCAST: in: Report, Workstream de of aspects product different on focus will that institutes research intend is 15 This manufacturing. advanced of total a establish to is aim The government.central of behalf oninvestmentdollar billionone a complementedby be will businesses (NSTC):National StrategicPlan Advanced for Manufacturing, February 2012. Commit Steering industrialisednations, is doinghardly anything about atit a policy level. administratio US the advises which PCAST, Manufacturing”, Advanced in Advantage Competitive Domestic “Capturing on - - Physical Systems (agendaCPS. Integrated Research Agenda Cyber Agenda Research Integrated Systems (agendaCPS. Physical Resear Integrated Systems (agendaCPS. Physical - turing”project will identify potential development strategies manufacturingfor up 2050.to , rud ht h U i lsn is oiin s laig auatrn nto ad ulk other unlike and, nation manufacturing leading a as position its losing is US the that argued n, - eomn wti etrrss se lo pedx : ehooy Development Technology 1: Appendix also (see enterprises within velopment - tee Report, July 2012; see also National Science and Technology CouncilTechnology and Science Nationalalso see 2012;July Report, tee Approach to theApproach to Twelfth October Plan, Year Five 115.2011, p. ommit - -
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EXAMPLE APPLICATION 5: Sudden change of supplier during production due to a crisis beyond the manufacturer’s control
Circumstances beyond the manufacturer’s control, such as unexpected natural disasters or political crises, mean that they often have to change suppliers suddenly during production. Industrie 4.0 can help to make these chang-es substantially smoother by running simulations of the affected downstream services, thus allowing different suppliers to be evaluated and the best alternative to be selected.
Today
In the event of unexpected supplier failure, it is currently difficult for manufacturers to assess the impact on current production and downstream processes and come up with a timely response. Sudden supplier failures result in significant additional costs and delays in production and thus entail major risks to companies’ business. They need to take quick decisions about which alternative supplier to use as cover, how to execute the logistics for goods that are currently in production, how long current stocks are likely to last, which products already contain compo-nents from the failed supplier and whether the alternative suppliers actually have the ability and skills needed to provide the required capacity by the relevant deadline. Currently, it is only possible to provide partial IT support for these decisions.
Tomorrow
In Industrie 4.0 it will be possible to simulate all the steps in the manufacturing process and depict their influence on production. This will include simulation of inventory levels, transport and logistics, the ability to track the usage history of components that have already been used in production and provision of information relating to how long components can be kept before they expire. This will enable product-specific set-up costs to be calculated and reconfiguration of production resources to be kept to a minimum. It will also be possible to assess the relevant risks. It will thus be possible to simulate the different costs and margins of alternative suppliers, including simula-tion of the environmental impact associated with using one supplier over another. Extensive networking of manu-facturing systems will make it possible to analyse alternative suppliers and their capacity in real time.
It will be possible to contact and engage suppliers directly via the appropriate secure channels in the supplier cloud.
POTENTIAL BENEFITS IT innovations such as Big Data and the Cloud allow real-time optimised simulations to be performed. The necessary software designs already exist. The value drivers in favour of prompt implementation of this approach include time and cost savings and the ability to minimise risks to the business.
7 Outlook
7 Outlook 7 Outlook
Germany has the potential to become a leading market spread basis. At the same time, it will also be neces-sary and leading supplier for Industrie 4.0. If this is to be to research and develop innovative solutions for new achieved then, in addition to meeting the technological manufacturing sites and new markets. If this is done challenges, it will be essential for the different industries successfully, Germany will be in a position to be-come a and their employees to work together in order to shape leading supplier for Industrie 4.0. Moreover, the developments. The Industrie 4.0 Platform constitutes a establishment of a leading market will serve to make crucial step towards ensuring that the innovation poten- Germany a more attractive manufacturing location and tial of Industrie 4.0 is leveraged across all industries. help preserve its domestic manufacturing industry.
The journey towards implementing the Industrie 4.0 The Industry-Science Research Alliance launched the vi-sion will involve an evolutionary process that will strategic initiative Industrie 4.0 in early 2011. As of pro-gress at different rates in individual companies April 2013, the industry’s professional associations and sectors. Demonstration projects should BITKOM, VDMA and ZVEI will be joining together with therefore be developed and new products brought actors from the business and research communities to market as soon as possible. and civil society in order to ensure that implementation of the initiative is progressed in a coherent manner. A Implementation should be addressed through a dual systemic approach in which all the stakeholders are in- strategy. Existing basic technologies and experience volved in a mutual exchange of technological and will need to be adapted to the requirements of manu- social innovations will provide a sound basis for facturing engineering and rolled out rapidly on a wide- successful cooperation in this regard.
Industrie 4.0 75
The strategic
initiative Industrie 4.0
Background The strategic initiative Industrie 4.0
Industrie 4.0 is a “strategic initiative” of the German Since 2006, the German government has been pursu- government that was adopted as part of the High-Tech ing a High-Tech Strategy geared towards interdepart- Strategy 2020 Action Plan in November 2011. It was mental coordination of research and innovation initia- launched in January 2011 by the COMMUNICATION tives in Germany with the aim of securing Germany’s Promoters Group of the Industry-Science Research Al- strong competitive position through technological in- liance (FU). Its initial implementation novation. The current incarnation is known as the recommendations were formulated by the Industrie 4.0 High-Tech Strategy 2020 and focuses on five priority Working Group between January and October 2012 areas: climate/energy, health/food, mobility, security under the coordi-nation of acatech –National Academy and communication. The strategy revolves around a of Science and Engineering. The Working Group was number of “strategic initiatives” through which the In- chaired by Dr Siegfried Dais, Deputy Chairman of the dustry-Science Research Alliance is addressing con- Board of Man-agement of Robert-Bosch GmbH, and crete medium-term scientific and technological devel- Prof. Henning Kagermann, President of acatech. The opment goals over a period of ten to fifteen years. The recommenda-tions were submitted as a report to the initiatives have formulated concrete innovation strate- German govern-ment at the Industry-Science gies and implementation roadmaps designed to make Research Alliance’s Im-plementation Forum held at Germany a leader in supplying solutions to global the Produktionstechnisches Zentrum Berlin on 2 challenges. October 2012. Going forward, further implementation measures will be progressed through a number of This report presents and expands upon the recom- working groups under the Indus-trie 4.0 Platform which mendations put forward by the Industrie 4.0 was recently established by the industry’s professional Working Group in October 2012 and will provide a associations BITKOM, VDMA and ZVEI and which basis for the work of the Industrie 4.0 Platform that now has the support of its own Secretariat. will com-mence in April 2013
Home page of the Industry-Science Research Alliance: forschungsunion.de
High-Tech Strategy Action Plan available at: bmbf.de/pub/HTS-Aktionsplan.pdf
Industrie 4.0 Working Group reports: acatech.de/industrie4.0
Industrie 4.0 77
The Industrie Industrie The 4.0 Platform 78
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