Steps to Industry 4.0
INDUSTRY 4.0 ?
Task to the production system – Order: 500pcs. in one week
I cant do Saturday
Magazine is empty! Please refill!
I refill the magazine.
Two hours overtime today!
Capacity's are overloaded till Friday
Turn me on! Your BBQ weekend is canceled I can work this Saturday.
I got to be at the goods issue in 2 hours
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What is Industrie 4.0? The fourth Industrial Revolution
First programmable logic controller (PLC), Modicon 084 1969
First mechanical weaving loom 1784
Third Industrial Revolution Through utilization of electronics and IT for further automization of the production
Degree of Complexity
First assembly line, Slaughterhouses of Cincinnati 1870
Fourth Industrial Revolution On the basis of Cyber Physical Systems
Second Industrial Revolution Through implementation of labor division in mass production utilizing electrical energy
First Industrial Revolution Through implementation of mechanical production-plants utilizing water- and wind power
End of the 18th Century
20th Century
Beginning of the `70s 20th Century
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Present
Time (Source: DFKI, 2011)
Phases of earlier 3 Industrial Revolutions 1. 2. 3.
1760 to 1840 - Penggunaan Mechanical production; railways and steam engine 1870 to 1940 - Mass production; electricity dan assembly line 1960 to 2010 - Computers; semi conductors, main frame computing, personal devices, internet
Definition „Industrie 4.0“ represents the “Fourth Industrial Revolution”, a new level of Organization und Control - concerning the whole value creation chain over the entire life cycle of products. The life cycle becomes orientated towards the increasing individualism of costumer requirements and encompasses: the idea, the order for development and production, the distribution of products plus recycling, and furthermore including all related Services. Industrie 4.0 is based on the availability of relevant data in real time through the interconnectedness of all instances related to the value creation process, and moreover on the ability of deriving an optimized value creation process from the available data. The interconnection of human beings, objects and systems leads to dynamic, real time optimized and self organized inter-company value creation systems which are evaluated and optimized using criteria such as costs, availability and resource efficiency Quelle: Plattform Industry 4.0 11
What is the Basic Idea of Industrie 4.0?
Characteristics:
Challenges:
Several autonomous Systems
M-2-M Communica tion
Complexity
Heterogeneous Networks
The Internet of Service - IOT
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Controlling and Monitoring
Actuality, Integrity and Propriety of Data
Integration of the physical Environment
How does Industrie 4.0 work?
As a Cyber-Physical Production System, connecting the material and virtual world Cyber Space Technologies:
Quality Sensors & Actuators Breakdown Cloud Services Energy Demand Time Limit Wireless & Mobile Com. Resource Real Space Self X (Standards)
Supplier
Engineering
Functions:
Availability Quantity
Energy supply
Production
Communicating & Negotiating Interpreting & Deciding Configuration & Adjusting Analyzing & Optimizing
Costumer
Lifecycle (Production und Production system) Development/ Construction Con
Process Planning
Production
Operation/ Utilization
Disposal/ Recycling
Logistics (Intra- und Inter-Logistics)
Visualization
Control real/concrete
virtual/abstract Source: TU Wien, Gerhard, 2014, TUWIn 4.0 13
How can weimagine Industrie 4.0 in Reality? Smart Factory Autonomous Organization in Real Time Cyber-physical Systems Order: 50 Engines until Monday
Empty Stocks, Please re-fill!
restocking the
Switch me off!
On-time delivery of goods
Capacity booked until Friday!
Additional shift necessary
do have an identity
are communicating with each other and with the environment
are configuring themselves (Plug and Produce)
are storing information
Required at Outgoing goods department in 2h
De-centralized selforganization in real-time
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Focus: Organiszation
Organization
Focus: Human
Organization
Focus: Technology
Organization
Implementation of the design aspects in Cyber-Physical Production Systems
Industrie 4.0 - What should we pay attention? 15
Design aspects of Cyber-Physical Production Systems
Internet of things
Industry 4.0
Smart products
Product innovation
Process innovation
…
Smart factory
Autonomous agents
industry 4.0
Digitized services
Digital networking
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Building blocks of Industry 4.0 Autonomous Robots Big data analytics
Augmented reality
Simulation
Industry 4.0
Horizontal and vertical system integration
Industrial Internet of Things
Additive Mfg Cyber Security
Examples of Product evolution: Connected and smart products
Steps to Industry 4.0
Transformation of work structures at the automotive auto body manufacture
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Manufacturing • replacing human work • man-machine collaboration • 3D - Printing • Augmented Reality (training / support / advice through dataglasses) • Shift/working hours-coordination over the internet • Remote control of production equipment Engineering • Computer based simulation • extended usage of cloud-computing and crowd-sourcing
Maintenance • Remote controlled maintenance • Data-glasses, computer based support for decision making • Exensive use of sensors to monitor the state of production equipment Production control • paperless logistics • traceability of products and parts (realtime information of inventory) • RFID • digital memory of the product • optimisation of production with BIG DATA
Challenges for the workforce Rapid change of necessary qualification Ergonomical improvement through the use of robots Creation of new jobs for high skilled workers in thea areas of planning, configuration and maintenance of the new technologies Expansion of low-skilled work through the use of robots and assisting systems Extensive control and monitoring of workers behavior and performance Increased expections regarding individual flexibility
Challenges for the society
Increase of precarious work (agency work, outsourcing, crouwdsourcing, solo-self-employed) Race to the bottom on social standards Where are the jobs for low-skilled workers and the non-digital-natives
Indonesia menyongsong Era Industry 4.0
Business Enviroment
People skills and availability
India
3,22
China
2,55
2,28
Malasya
1,59
3,23
1,54
3,04
Philippines
1,9 1,25
2,99
0,94
2,79
Sri Lanka
2,88
1,22 1,66
1,16
3,37 0,52
1,88
1,37 3,19
Romania
1,61
1,26
2,41
Bulgaria
1,29
1,56
2,58
Vietnam
1,44
1,43
2,71
Poland
1,22
1,44
3,17
Chile
1,89
2,07
Indonesia
Mexico
1,51
1,42
2,34
Thailand
1,19
2,71
2,75
Brazil
United State
Financial Atractiveness
1,64 1,03
1,14 2,11
Menteri Perindustrian Bapak Airlangga Hartarto di World Economic Forum on ASEAN 2017 di Phnom Penh, Kamboja : Sektor manufaktur nasional harus siap menuju perubahan besar dalam menghadapi revolusi industri keempat atau Industry 4.0. Konsekuensinya, pendekatan dan kemampuan baru diperlukan untuk membangun sistem produksi yang inovatif dan berkelanjutan.
Dimana Posisi Industri di Indonesia ?
4. Industrial revolution Based on cyber-physicalsystems
3. Industrial revolution
Through the use of electronics and IT further progression in autonomous production
2. Industrial revolution
Level of complexity
Introducing mass production lines powered by electric energy
1. Industrial revolution
Introducing mechanical production machines powered by water and steam
Industry 1.0
End of the 18th century.
Industry 2.0 Beginning of the 20th century
Industry 3.0 Beginning of the 70th
Industry 4.0 Today Source: DFKI/Bauer IAO
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KEBIJAKAN PEMERINTAH INDONESIA 1. Mendorong agar angkatan kerja di Indonesia meningkatkan keterampilannya untuk memahami penggunaan teknologi IOT atau mengintegrasikan kemampuan internet dengan lini produksi di industri. 2. Pemanfaatan teknologi digital untuk memacu produktivitas dan daya saing bagi industri kecil dan menengah (IKM) (program e-smart IKM). 3. Penggunaan teknologi digital seperti Big Data atau otomatisasi industri yang digunakan untuk mengoptimalkan jadwal produksi 4. Inovasi teknologi melalui pengembangan startup dengan memfasilitasi tempat inkubasi bisnis.
Sektor industri nasional memasuki era Industry 4.0 : 1. Industri semen, 2. Petrokimia, 3. Otomotif, serta 4. Makanan dan minuman.
Faktor penggerak Industri 4.0 didasarkan pada empat faktor penggerak, yaitu: (1)Peningkatan volume data, daya komputasi dan konektivitas; (2)Kemampuan analitis dan bisnis intelijen; (3)Bentuk baru dari interaksi human-machine, seperti touch interface dan Sistem augmented-reality; serta (4)Pengembangan transfer instruksi digital ke dalam bentuk fisik, seperti robotik dan cetak 3D.
Implementasi Kemenperin mendorong kesiapan industri nasional menghadapi babak Industri 4.0 dengan berbagai upaya : (1)Pemberian insentif kepada pelaku usaha padat karya berupa infrastruktur industri (2)Kolaborasi dengan Kementerian Komunikasi dan Informatika dalam optimalisasi bandwidth (3)Penyediaan Sistem Informasi Industri Nasional (SIINAS) yang memudahkan integrasi data untuk membangun industri elektronik (4)Penyiapan SDM industri melalui pendidikan vokasi yang mengarah pada high skill (engineer) (5)Meningkatkan keterampilan SDM industri yang dominan low/middle ke level high skill.
Thank you
