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Welcome to the production of the future

Knud Lasse Lueth, the managing director of analyst company IoT Analytics, just lately interviewed Eberhard Klotz, the pinnacle of the Trade four.zero Marketing campaign at Festo, to speak about luck tales but additionally hindrances and important luck elements in Trade four.zero

Knud Lasse Lueth: Trade four.zero stays a sizzling subject of passion, steadily discussed alongside the similar traces as sensible manufacturing facility, IoT and digitalisation. Is it all of the similar to you or do you distinguish between those phrases?

Eberhard Klotz: At Festo we view Trade four.zero as the method during which we get to the manufacturing of the longer term. Festo has a holistic view of the adjustments within the manufacturing international, considers other views and, along with era, additionally takes different key issues into consideration, such because the interplay between guy and device, and the problem of coaching and qualifying junior and senior execs international.

Trade four.zero brings in combination quite a lot of actions underneath one umbrella and describes the trade this is enforcing new necessities on manufacturing techniques, machines and folks in lots of spaces. This features a virtual buyer adventure from first contacts by the use of internet serps, on-line product variety and dimensioning – simulation – equipment, and a whole virtual procedure finishing at a manufacturing facility’s device or meeting line – the sensible manufacturing facility.

Merchandise which are produced in keeping with Trade four.zero requirements generate a virtual illustration, a so-called virtual dual or shadow. This virtual reproduction lets in customers to all the time get entry to related product information, making sure very best high quality and balance in manufacturing. It additionally makes it more straightforward for providers so as to add provider like predictive upkeep, lifecycle optimisation, and general apparatus effectiveness (OEE) development.

Trade four.zero is the mix of Web of Issues (IoT) and digitalisation of services. The essence is networked international results in a more practical and environment friendly long run.

KLL: Numerous folks speak about Trade four.zero because the enabler for extra flexibility in production against lot measurement 1, however what about mass manufacturing?

EK: You might be proper, a number of industries use those new applied sciences and alternatives to reach a better level of customisation in small lot-sizes – which, by means of the best way, some industries like car have carried out for 30 to 40 years already. However Trade four.zero could also be crucial enabler for extra environment friendly mass manufacturing. I see numerous corporations that beef up their production websites by means of optimising power utilisation, specializing in apparatus effectiveness, and making use of giant information analytics to raised are expecting exact or upcoming shopper wishes.

KLL: What or who’re the principle drivers for Trade four.zero within your corporate?

EK: Festo began the Fourth Commercial Revolution with agile staff buildings to be told and undertake temporarily, impressed and guided by means of our CTO. To begin with, beginning in 2010, our headquarters in Germany were the focal point of innovation with actions round product innovation, R&D, manufacturing, IT infrastructure and worker qualification with Festo Didactic.

Our present projects come with numerous organisational subjects akin to setting up transparent roles and duties the place wanted, akin to in gross sales, HR, IT, logistics or buying, and adjusting our organisational construction by means of forming two new trade devices: electrical automation and digitalisation. The ones two devices in addition to our interior IT division power the subject. On most sensible of that, our subsidiary Festo Didactic had remarkable luck in supplying colleges and universities with cyber-physical – coaching – factories, basically in Europe.

KLL: Final 12 months in IoT Now, you elaborated for your analysis actions round Trade four.zero and the way you’re making your individual factories sensible. How has this image developed, specifically with the heavy investments you could have made into your individual era manufacturing facility in Scharnhausen, Germany?

EK: Festo has applied many new applied sciences within the closing 12 months in our new manufacturing facility. We are actually rolling out probably the most maximum a success ones to different vegetation out of doors Germany as a result of we see an excessively transparent payback state of affairs. Let me point out two of my private favourites. The primary instance is an information analytics venture that improves device efficiency, figures out bottlenecks and helped us to scale back cycle time by means of 15%. The setup is relatively refined: We’ve a big meeting line this is designed to function mass manufacturing in addition to lot measurement 1. Present consumers call for lot measurement 200-2000. The once a year manufacturing quantity is ready 1.2 million items at a cycle time of 13 seconds.

The technical foundation of this meeting line are the mechatronic subsystems in all device cells, that are operated by means of decentralised keep watch over techniques. The information to function and handle the road is supplied in a unified virtual layout and it’s shared with all checking out stations and high quality techniques. Information related for device operations is processed in the neighborhood in real-time. As well as, information from the road – 400 IP addresses in overall – is accumulated, condensed and equipped by the use of Open Platform Communications (OPC) unified structure (UA) to both reinforce movement keep watch over, or analytics on a PC or within the cloud. The trade of the batches is finished by means of SAP ME/order control, however within the device an RFID tag this is fastened to each and every paintings piece triggers all parameters/recipes according to station.

Because of the knowledge transparency with this setup, we had been ready to accomplish detailed information analyses that recognized some commonplace patterns, in addition to the most important bottlenecks. We then outlined an idea to conquer those bottlenecks, thereby optimising new device cycle time by means of 15% – from 13 to 11 seconds. The adjustments we made come with changes within the take a look at cells and their procedures. The workpieces, for instance, now cause the cellular upfront and thereby save time for booting the take a look at routing and its connectors. Different bottlenecks required a more potent central processing unit (CPU). With out information transparency such an optimisation shouldn’t have been conceivable.

It must be identified that this situation would possibly glance remarkable to a few, exceptionally just right and a success – and needless to say it’s, because the payback is underneath twelve months. However despite the fact that any other case would possibly display a way smaller impact and paying again in two-to-three and even 5 years: that may nonetheless be a pleasing and treasured one for plenty of industries.

KLL: What about your 2nd instance? Did it additionally reach a payback underneath twelve months?

EK: The second one instance I want to percentage is our cellular upkeep idea. Each and every upkeep employee on the new Festo era manufacturing facility in Scharnhausen is provided with a pill that comprises the common upkeep duties, manuals and service directions of all machines, together with 15 years of digitised ancient upkeep information. The drugs hook up with each and every device in addition to the endeavor useful resource making plans (ERP) and production execution techniques (MES). Fundamental purposes akin to e-mail or chats are to be had as neatly. It lets in the technician to have fast direct verbal exchange with a professional/colleague, busy at any other device. Greater than 200 machines can now be maintained the use of this era.

We straight away realised that the technicians didn’t have to stroll again to the central upkeep place of business all time and had been thus extra productive. The opposite impact is that the restore time according to device is considerably decreased as all data is to be had in an instant. Because of the era, we had been ready to bridge a 30% enlargement in manufacturing facility measurement and equipment, with out converting the staff measurement. This all in combination considerably greater OEE figures and confirmed a sensational payback underneath six months.

Now, in a 2nd step, further options can be built-in: A sensor that is hooked up to an CPX/MPA valve terminal from Festo, can now immediately convert error messages into a job within the job listing. The gadget additionally robotically re-orders the damaged section, after double-checking inventory ranges.

In keeping with those stories, we’ve got now evolved ‘Smartenance’ – a virtual upkeep supervisor for manufacturing supervisors and plant operators around the globe. Smartenance combines the learnings we generated in our personal vegetation and permits paperless upkeep with transparent scheduling and analysis of required upkeep duties.

KLL: That may be a nice innovation tale for a brand new product. Let’s speak about your legacy merchandise, despite the fact that. You love to check with your self as an innovation chief in automation. How are you making the prevailing automation merchandise you be offering smarter?

EK: Festo is handing over numerous automation era merchandise which are wanted for the fourth business revolution. They come with built-in power applications, modular valve terminals that come with OPC UA reinforce and IoT gateways, in addition to decentralised CODESYS controllers and self reliant mechatronic subsystems with IP20 or IP65. As well as, we offer IoT pushed programs and products and services, treasured dashboards for some merchandise and whole subsystems. Festo could also be ready to offer constant connectivity, for instance with the Festo Cloud, Siemens MindSphere, or Rockwell Manufacturing unit Communicate.

KLL: Are you able to give some examples of ways your consumers have applied those answers?

EK: Some consumers, like DMG Mori, have built-in our power transparency ideas into their machines and productions websites. Others have followed the Festo Movement Terminal for extra versatile and virtual pneumatics, MediaMation did so for a brand new technology of cinema chairs. Others upload further sensors and imaginative and prescient techniques, in addition to radio frequency identity (RFID) monitoring with a view to carry out higher procedure optimisation. A number of car authentic apparatus producers (OEMs) are piloting our machineto- cloud ideas in addition to our synthetic intelligence (AI) device with a view to beef up upkeep and OEE. One massive end-user is totally redefining their production competencies in response to our applied sciences. The corporate is lowering their manufacturing knowhow and delegating complete duty to the device developers. It is a radical shift that calls for threeto- 5 years of dialogue, making plans and trade procedure reengineering. It isn’t one thing that occurs in a single day because it calls for complete information transparency and the willingness to delegate duty to providers, together with device availability and marketplace possibility.

KLL: How can the talents hole be solved this is more and more turning into obvious round information science and analytics in small and mid-sized production vegetation?

EK: Certainly, those necessary competencies are underrepresented in SMEs as of late. Festo Didactic will goal those qualification gaps by means of 2019 inside of its seminar portfolio. We additionally actively paintings with executive representatives which are chargeable for schooling. One key task is to lead them to conscious about the portfolio hole in instructional establishments. Inside of our personal production websites, Festo is now qualifying device experts on information science and analytics talents, most commonly supported by means of our IT division.

HR could also be getting ingenious to find new tactics to recruit information science ability. They now seek in particular communities and employ analytics device for ability recruiting. We additionally co-operate with IT-focused universities around the globe and reinforce hackathon occasions. An interior information science lab supported by means of the IT division is helping qualifying interior abilities, for instance from the manufacturing and logistics staff.

KLL: What’s your technique for 2019 and past?

EK: Festo as an organization is converting so much, to not say totally: We introduced with a large bang on digitalisation at this 12 months’s Hannover truthful, and can upload a 2nd giant bang on electrical automation on the upcoming SPS/IPC Drives display. We see our corporate because the chief within the Trade four.zero transformation procedure – which underneath many facets raises the worth and contribution of device to a degree of 50% in the end. With our fresh takeover of the AI specialist Resolto, Festo obviously opens the path against added worth thru information, wisdom and device. What we use as a luck consider our personal manufacturing atmosphere we additionally percentage with our consumers. Strolling our communicate, we’re the engineers of productiveness.


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