Digitizing dynamic manufacturing systems without waste. D r. - I n g. M a r t i n L a n d h e r r F e s t o o l G m b H

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1 Digitizing dynamic manufacturing systems without waste D r. - I n g. M a r t i n L a n d h e r r F e s t o o l G m b H

2 Navigation through a typical day in a volume production of customized products Material Information Staff Products Information Energy Equipment Process Waste / emission Missing or wrong material Human mistakes Technical errors Low utilization of staff and machinery Poor quality Waste High reactivity as the key to efficiency in dynamic manufacturing systems Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

3 Physical Domain Cyber Domain The Digital Shadow of Production a new name for an old goal. Services Digital Factory Digital Shadow of Production Based on historical data, experiences and knowledge Based on realtime data and information of the current PS Operation: Control, organization Planning: New planning, redesign time Optimization, (Re-)Configuration Historical PS Current PS Future PS PS: Production System M. Landherr Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

4 Benefit Digitisation Strategy of Production in a Nutshell: Think big start small scale fast Autonomous Factory Preventive avoidance of downtimes in production control and operation Automatic reaction to failures Smart Factory Dynamic forecast of bottlenecks Self-optimizing production Transparent Factory Availability of relevant data in near real time Comprehensive process and control data Reactive Factory Automatic escalation management Decision support for planning, control and operation Effort Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

5 Now we can start! right? Money Meaning Organization Technology Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

6 Technology All data available anytime, anywhere Sensors, MES, ERP, IIoT, Digital Shadow of Production Information retrieval Sensor integration, semantics, rules, pattern recognition, M2M-communication The right information at the right time Complexity management, context, decision support, HMI Become better and better Learning system (human & machine), self-optimizing production Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

7 Organization Source: 1. Scott Beale: Organizational Charts for Tech Companies, 2011, Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

8 DEPARTMENT Sustainability Structure Meaning TOP DOWN Power Big Picture Sustainability INTERNAL Sustainability Flexibility Less expensive PROJECT Efficiency Flexibility Transparency BOTTOM UP Efficiency Tangibility Motivation EXTERNAL Lower risk Expertise Experience Organization Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

9 EU: 110 bn. per year Germany: 30,7 bn. per year Increase in sales Money EU: 140 bn. per year Germany: 40,1 bn. per year Investment Sources: 1. PricewaterhouseCoopers: Industrie 4.0 Chancen und Herausforderungen der vierten industriellen Revolution, PricewaterhouseCoopers: Industriy 4.0 Opportunities and challenges of the industrial internet, Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

10 Corporate investments can only be made against proven economic viability.? What s the economic benefit of Outlook in your company? Money Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

11 Costs The companies surveyed [ ] expect annual savings of 2.6% with respect to cost reduction. 1 Meaning Customer We have to think today about the generation that will make the decisions in ten years. 2 Existence Companies have no real choice when it comes to digitisation. 3 Sources: 1. PricewaterhouseCoopers: Industriy 4.0 Opportunities and challenges of the industrial internet, Bauernhansl, Thomas; Dick, Peer-Michael (HRSG.): Digitalisierung im Mittelstand, Baltes, Guido: Interview, Badische Zeitung, Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

12 Meaning Customer benefits up Usage of resources down Skills up Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

13 CONCLUSION Every generation has its Darwinian failures but every individual is descended only from previous generations successful minorities. (Richard Dawkins) ADAPT LEARN MOTIVATE Dr.- I n g. M a r t i n L a n d h e r r m a r t i n. l a n d h e r f e s t o o l. c o m I n d u s t r y o f T h i n g s W o r l d S e p t e m b e r ,

14 Thank you. Dr.-Ing. Martin Landherr Head of Industrial Engineering Festool GmbH