Industry 4.0 Magazine by GB Media & Events Ltd.

THE MAGAZINE FOR THE FOURTH INDUSTRIAL REVOLUTION

issue no. 5 - October 2018

IN THIS ISSUE Industry 4.0 in Practice

Manchesterâ&#x20AC;&#x2122;s role in the Fourth Industrial Revolution

From CIM to 4IR

How software development is gathering momentum

Interview with Prof. Dr. Detlef Zuhlke Founder Smart Factory

Unlocking the Hidden Factory Keeping pace with industrial communications

Britain’s Manufacturing Future. We’re here to enable it The Factory of the Future is coming to Britain soon and we’re here to help make it happen. British businesses are already taking their first steps to remain competitive in a world where customers demand customised products, faster delivery and shorter lead times. As leaders in drive and control solutions, we offer the digital solutions you need to maximise the opportunity of Industry 4.0. The Factory of the Future is more than just a vision, so join us on our journey Now. Next. Beyond.

WE MOVE. YOU WIN. www.boschrexroth.co.uk/FOTF

Issue no 5 - october 2018

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WELCOME TO THE

Industry 4.0 magazine Thank you for reading the 5th edition of The Industry 4.0 Magazine. The official magazine of The Industry 4.0 Summit in Manchester. We are pleased to include an interview with Prof. Dr. Detlef Zuhlke, Founder of SmartFactoryKL in Germany. He talks about the game changing technologies of Industry 4.0, how SMEâ&#x20AC;&#x2122;S are adopting Industry 4.0 and the global industry 4.0 landscape. We are now six months away from our flagship event, The Industry 4.0 Summit 2019. In this issue we look at the role of our host city, Manchester in the Industrial revolution. We have spoken at length to the Chamber of Commerce and their initiatives for Industry 4.0 and the developments shaping the Northern powerhouse. Dr Carl Diver, the first reader in Industrial Digitalisation at a UK University, talks about the contribution of Manchester Metropolitan University to Industry 4.0 and the pioneering concept of PrintCity. In other features we look at the areas of Software development, retrofitting for Industry 4.0 and Industrial communications. We have now published 5 editions of The Industry 4.0 Magazine. We would like to thank our readers and contributors for supporting the publication and look forward to hearing from you with feedback on the articles in this issue and also any suggestions on future topics of interest.

THE INDUSTRY 4.0 MAGAZINE IS PUBLISHED MONTHLY BY GB MEDIA AND EVENTS - ORGANISERS OF THE INDUSTRY 4.0 SUMMIT PUBLISHER Gary Gilmour EDITOR Pav Baghla TEAM Matthew Pearsall Digital Manager Joe Illsley Designer All Editorial and advertising Enquiries to Digital@gbmediaevents.com +44 (0) 207 9932300 +44 (0)1642 438225 GB Media & Events, Wilton Centre, Redcar, North Yorkshire, TS10 4RF. GB MEDIA & EVENTS LIMITED GB Media and Events Limited is a company registered in England and Wales with company number 10114934

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Kind regards, Pav Baghla, Editor The content of this magazine does not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for the loss arising from information in this publication. All rights reserved. No part of this publication may be producted or stored in a retrieval system without the written consent of the publishers.

industry 4.0 Issue no 5 - october 2018 Interview With Prof. Dr. Detlef Zuhlke Founder - Smart Factory

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From CIM to 4IR How software development is gathering momentum

Retrofitting to Industry 4.0 How manufacturers can use their existing equipment to realise Industry 4.0

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Industry 4.0 in Practice Manchesterâ&#x20AC;&#x2122;s role in the Fourth Industrial Revolution

Unlocking the Hidden Factory Keeping pace with industrial communications

Industry 4.0 Summit & Expo 2019 Exhibitor Focus

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Interview with

Prof. Dr. Detlef Zuhlke Founder - Smart Factory

The World is Changing: Connectivity is Key Prof. Dr. Detlef Zühlke is the spiritual father of the Smart Factory idea. He is the founder of SmartFactoryKL in Kaiserslautern, an influential showcase for smart factory technologies and the birthplace of the Industrie 4.0 paradigm.

“The biggest risk is to do nothing,” Prof. Dr. Zühlke tells Industry 4.0 Magazine when we ask what the risks of Industry 4.0 are. “There will be no old world anymore. We will live in a connected world, so we all have to participate in all of this.” Prof. Dr. Zühlke has been working with smart factory technologies since studying Electrical and Computer Engineering at the Technical University at RWTH Aachen in the early 1980s and admits that many Industrie 4.0 ideas were talked about during the first wave of Computer Integrated Manufacturing in the 1980s.

© SmartFactoryKL / A.Sell At that time, he agrees, the technologies were not mature and the market wasn’t ready to talk about solutions. It took until 2002 before his ideas started to coalesce around a smart factory concept. Data management is the sum of all parts, and for each part, Industry 4.0 technology is exceptionally promising.

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SmartFactoryKL and Industry 4.0: From Vision to Reality

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SmartFactoryKL at Hannover Messe 2017

“I was touring Smart Homes in the US, and I thought ‘why not have a Smart Factory?’ Now we have all the pieces of the puzzle,” explains Professor Zühlke. The technologies had matured, and huge advances in computing and networking were being made: the time was ripe for the birth of the Industry 4.0 concept.

“There will be no old world anymore. We will live in a connected world, so we all have to participate in all of this.”

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International Cooperation: the World View While the German Government was quick to learn from the experimental facility in Kaiserslautern, the rest of Europe was slow to take up the ideas in play there. Instead, Professor Zühlke says the second nation to really interact with SmartFactoryKL was South Korea. From around 2008, the South Korean Government invested heavily in the concepts of Industrie 4.0 and, in the process, leapfrogged Japan as the leader of automation in Asia. However, interest around the world is now catching up with the Smart Factory concept. Japan is recovering from its financial crisis and the aftermath of the tsunami and is now hot on Korea’s heels. And, in the last couple of years, China has recognised its business model of offering cheap labour to the world will no longer work and is currently pushing forward with Industrie 4.0 very deeply and very quickly. Meanwhile, since 2012, the USA has been advancing the Industry 4.0 agenda through its national network for manufacturing innovation under the Manufacturing USA banner, using a similar model to Germany’s Fraunhofer Institutes. Its focus is heavily on the supply chain and a “top down” approach as well as a much-needed investment in workforce education. Here in Europe, the approach is less “top down”. The European Commission is now focused on the Industry 4. 0 concept with a “ground up” approach and millions of euros of investment over the last couple of years with more planned. While much of Europe, including Britain, was late to the Industry 4.0 concept, many exciting projects are underway.

Countries across the EU are cooperating, and this is being pushed forward by the Commission. “We are very involved, participating in many working groups on a European level; trying to bring our European partners up to the network and be active as well,” explains Professor Zühlke. “We are now talking to an inner circle of partners to really cooperate – in the sense of having compatible test-beds for example.” Professor Zühlke has praise for the educational networks here in the UK as well as programmes such as Digital Catapult and Innovate UK. “You have the right research centres and research institutes,” he says, “But since the Brexit decision, our contacts and cooperation with British people has really slowed down and I am very sorry about this.” “In the next year there will be a big programme of enabling existing centres around Europe to cooperate in a network of Digital Innovation Hubs. We will have to see with the British side how this will work after Brexit.”

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Engaging with SMEs The UK’s research and university education combine with a well-educated factory workforce to place us in a good position to exploit Industry 4.0 technologies, but more work needs to be done across Europe to bring the same opportunities to small and medium-sized enterprises, especially in terms of education, says Professor Zühlke. In Germany, this is being tackled by the government through the creation of 24 Competence Centres which will, between them, provide national coverage to support SMEs. SmartFactoryKL is involved in this national project and is thus also increasingly working with SMEs. “The first step is always that you have to convince the management of a company of the need to be prepared for these changes,” advises Professor Zühlke. “If the management is not really convinced and pushing it forward, the rest of the company will not follow. We undertake a Readiness Check to identify low-hanging fruits. The first projects are very simple sometimes, but it means they can start with something.” Typically, digitalising paperwork-heavy processes or improving tracking through RFID tags are an easy quick-win, but Professor Zühlke is keen to point out the process isn’t proscriptive.

“We will not directly give solutions; we want them to find the solution for themselves, so they develop their own solutions and are convinced of the solution. Once you have the big picture in the background, you can identify the small pieces you want to start with.” Experience with a small initial project builds confidence and momentum and demonstrates to employees and stakeholders that Industry 4.0 is important. “You will go step-wise into the new world,” says Professor Zühlke. “We will guide them on the way to create projects that are a little bit bigger and finally to build up their own puzzle of the things that they need to be very active in this new world. We have very good examples here with medium-sized companies of how effective this approach is. Today, they are very happy they started with some pieces of the bigger puzzle and they have a much clearer view of what is coming in the future.”

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Game-Changing Technologies The test-bed model used in SmartFactoryKL is another key element for successful, practical collaboration. It is constantly evolving to take in new ideas and technologies. Recently, the one long production line was broken into three smaller lines to explore the role of robotics in enabling greater agility. An autonomous robot now runs between the line sections to deliver parts – offering opportunities to explore mobility, location-based systems and machine vision.

“We have to identify these game changing technologies,” calls Professor Zühlke, “and deeply work on them so they can be used very successfully.”

What are the most exciting emerging technologies? Fifth Generation Mobile Networks “5G will be a game changer for industry again. We will have the opportunity to have microcells in the machines in our factories and this will give us completely new opportunities for setting up the automated and highly flexible systems that are needed.” Additive Manufacturing “For me, 3D Printing is really the only disruptive technology. Whereas many of the other technologies of Industrie 4.0 are following a more evolutionary path, 3D Printing can really disrupt what we do today.” Internationally Accepted Standards “There is a real need for collaboration to create “plug and play” solutions.”

As well as demonstrating what is possible with the technologies, SmartFactoryKL performs a vital role in allowing companies throughout the supply chain to collaborate on new ideas and solutions. “Today we have about six or seven products which you can already buy on the market,” enthuses Professor Zühlke. “The companies were only able to produce these solutions because they were operating and talking in a network with us. They can see what is missing to set up such a demonstration line, for example, and they see the opportunities. I think this is a wonderful example of what you can achieve when you push people into cooperation: learning from each other, identifying what is needed in the future.” It is through networks such as SmartFactoryKL that suppliers are working together to produce compatible products and also the standards required to create compatible products.

Ultimately, a “plug and play” paradigm is desirable says Professor Zühlke. “We already have this with computer parts today, so why not also with parts for industry?” he asks. However, he acknowledges that the theory doesn’t match exactly with the reality: “This is also why I am absolutely convinced we need international cooperation. Otherwise a country that is not participating will lose. As well as the exciting technologies and research, we have to recognise that there are different opinions emerging around the world right now that are about building fences around countries.”

“We have to identify these game changing technologies, and deeply work on them so they can be used very successfully.” 9

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Building Bridges, Not Fences Disruptive technologies and the new expectations of consumers are bringing change to systems and international trade. 3D Printing technologies combined with sensors, information and communication technology will not only enable greater customisation of products, it means that we will be able to produce anywhere in the world. “We can send over the data in microseconds,” says Professor Zühlke, “and produce on the other side of the world.” However, he acknowledges this will require difficult conversations about standards, laws and intellectual property. Ultimately, he thinks this will lead to the creation of regional groupings of supply chains, rather than the global supply chain we have today. “A customer sitting in front of his computer can order a part in a mouse click. But then he does not want to wait another six weeks until the part is delivered from production in China. So, in the end, we will have production closer to the customer and this will lead to more regional markets; there will be a European market, a North American market, and Asian market. And production will come closer to these customer markets again. “Therefore, it may be that a fence, let’s say to China, will not have such a deep effect as it does today.” These changes to world markets and trade give Professor Zühlke further concern over Britain’s decision to leave the EU.

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SmartFactoryKL Industrie 4.0

“If we are going to do more in regional markets, this will also be one of the deep questions Great Britain has to answer when it leaves the European market. Britain may find itself alone in the world market and I think that’s going to be a very bad development.” It will be a particular challenge for SMEs since they will need to change their business model to operate in such agile markets. “For the UK, the key question is whether you can participate in Europe-wide networks. Because the technologies being developed are network technologies – not only network in the technological sense, but also network in the cooperation sense. We will all need to work with partners in education, universities, and industry partners. Therefore, I think it would be much better to be part of the European Union to really participate in all of these things. I don’t know whether Great Britain can really withdraw from all of this. I think it is a big threat for all of us.” It is clear that collaboration – internationally, across the supply chain, across disciplines, and between industry, government and education – has been key to the success of the Industrie 4.0 concept and much of what has been achieved at SmartFactoryKL. It seems, at the moment, that we could all learn much from its example. Find out more: www.smartfactory.de/en

Issue no 5 - october 2018

Industry 4.0 in Practice

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Manchester’s Role in the Fourth Industrial Revolution

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Why manufacturers should transform into Connected digital enterprises in Industry 4.0?

How is Industry 4.0 being adopted by small businesses in the Greater Manchester region? Are SMEs really tuning in to the change that digitalisation will bring? And how are the potential of Industry 4.0 technologies and approaches really being felt on the ground in the North West? The Industry 4.0 Summit takes place annually each spring in Manchester – a reflection of the city’s proud contribution to the first Industrial Revolution. That’s why, in this issue, we are exploring what is happening in our host city and across Greater Manchester to develop the Industry 4.0 agenda in the North West region.

A leading light in the development of the Industrie 4.0 concept, Professor Detlef Zühlke, has told Industry 4.0 magazine that collaboration is key to developing and applying Industry 4.0 technologies successfully and that more needs to be done to involve SMEs. We investigate whether this is happening on the ground here in the North West. 11

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The Future of Skills For the past couple of years, Greater Manchester Chamber of Commerce has been focussed on looking at what challenges its Engineering and Manufacturing members and the wider sector face, as well as ways to tackle these challenges in a way that maintains productivity and growth. “It became obvious early on that there is already a series of huge changes taking place in production, technology and the way the sector operates. Much of this is what is recognised as Industry 4.0,” admits Chris Fletcher, Marketing and Campaigns Director and Greater Manchester Chamber of Commerce. Through some of the early stage work the chamber has completed through it’s regular forum meetings, it became clear that many businesses are already engaged in Industry 4.0 activity but may not actually be aware they are. Others have made specific plans and changes already and others are unaware or unsure of what it is and what they should be doing. Fletcher explains, “We are coming at this from an information angle about what Industry 4.0 is and what it can do. We constantly hear about lack of skilled workers available now and a looming shortage over the coming decade – something picked up in our Future of Skills 2028 campaign. So, as well as working on skillsspecific activity and encouraging more young people into the sector, we are also looking for great examples of where immediate roll out of technology can help make a positive impact now. However, it is crucial that there is a supply of workers with the right skills available now to make the transition successfully.”

He highlights some of the immediate issues as inadequate career advice, and lack of clarity over what the future of work will look like a decade from now. “We already have some employers a bit unsure of what makes younger employees tick these days – it’s not always money, so there’s a bit of a race on to get this part right as well as the actual skills. We will shortly be launching our first report and doing some roundtable follow ups,” Fletcher says. Brexit adds a further complication to the picture of recruitment and skills, he admits: “We’ve already had a few members say that EU workers have started leaving and they are struggling to replace them. It’s very worrying.” The Chamber of Commerce is also encouraging collaboration across sectors, which it believes is essential if the full potential of Industry 4.0 is to be grasped. Fletcher says, “We have also started to look at cross sector work with our Property and Construction members as this isn’t just confined to engineering or manufacturing, it genuinely is cross sector and methods and thinking in one sector can and should be transferred to others.”

“It became obvious early on that there is already a series of huge changes taking place in production, technology and the way the sector operates. Much of this is what is recognised as Industry 4.0”

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SMEs Are Grappling with Change The Greater Manchester Chamber of Commerce is keen to bring Industry 4.0 concepts to life for small and medium-sized businesses in the Greater Manchester region. Ian Trow, UK and Ireland Business Head at Automation company QuadPlus UK, Raam Shanker, Founder of Equitus Engineering, and Mike Morris of business change consultancy Maestro Business are three members of the Forum who have been working together to push the Industry 4.0 agenda. Together, they make the point that a lot of the discussion around Industry 4.0 is happening at too high a level. As a system integrator, QuadPlus works with technology suppliers in the automation and process industry sectors.

The Leap of Faith “The tier 2, 3, 4, 5s in the supply chain aren’t engaged with Industry 4.0. They are so busy keeping their business afloat, it is difficult to take the leap of faith Industry 4.0 requires,” says Trow. “The Northern Powerhouse and the Made Smarter review, this kind of industrial strategy, are sitting up there at 30,000 feet. We want to bring some of it down to earth – for the SME on the ground. We see ourselves as ambassadors of these heady concepts.” “We feel, as SMEs ourselves, we speak the same language,” agrees Raam Shanker. “And we come at prices they can afford. Industry 4.0 doesn’t have to be expensive; it’s a new encouragement to start a conversation. It has opened people’s mind to change.”

Based on this experience, Mike Trow argues, “There is quite a divide between the complete digitalisation of the supply chain as imagined by the large technology corporates and the reality of the SME manufacturers fuelling the supply chain. The key issue is how to bring bitesize chunks of Industry 4.0 technologies and understanding to the consciousness of SMEs.” While musing over this problem at a local Chamber meeting, the three began looking at ways they could work together to harness the complimentary skills of their organisations in a way that could begin the Industry 4.0 conversation with SME manufacturing businesses in the North West.

Shanker admits the change isn’t necessarily new, but the Industry 4.0 is helpful in the way it is focusing attention on the possibilities. Plus, Trow points out, the enabling technologies are now much more affordable. “We’ve all delivered projects successfully in the past. And what we’re trying to do now is come together and pool our collective resources as three SMEs in the region and deliver similar successes under the banner of ‘everything Industry 4.0’.”

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Practical Results This collaborative approach has already seen the three organisations working together with a manufacturer in Rochdale that wanted to expand into China but was having problems with capacity. The collective developed some tools which revealed a further 25 percent additional capacity – enabling the China expansion. At the same time, Equitus investigated the reengineering of one of its products – enabling a more efficient design that could be sold at a higher price.

Shanker continues, “It is about collaboration more than anything else. We’d like to see engineering companies not being in silos, but coming together, collaborating, sharing best practice, helping each other out and becoming prosperous together as a collective.”

It is this type of holistic approach to the opportunities that Industry 4.0 technologies offer that the collective is keen to advance.

“In the post-Brexit world this is what people will have to do,” agrees Mike Morris. “We’ll all have to be more creative and think more. Industry 4.0 gives us more encouragement and impetus to think outside the box.”

The Brexit Effect Shanker is already feeling the effects of the Brexit decision. As a business that is involved in both European Space Agency projects though UK Research and Innovation and SCFC, and with three Horizon 20:20 projects, the announcement that a no deal or hard Brexit scenario will mean UK firms are excluded from European research projects is deeply worrying.

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Digital Factories

He is upbeat about the future, however; saying while Brexit is not desirable through necessity opportunities will arise. “Necessity is the mother of opportunity,” agrees Morris. “The industrial revolution started right here in Manchester. So let’s go back to our roots – let’s do the Fourth Industrial Revolution right here in the North West.”

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“One of our goals is to engage strategically with industry and authorities; it has to be very much collaborative.”

Manchester Metropolitan University Carl Diver is the Academic Lead on Industry 4.0 at the Manchester Metropolitan University and the first Reader in Industrial Digitalisation at a UK University. He is very enthusiastic about the future here in the North West due to the capabilities and the desire to succeed.

Dr. Diver moved across to Manchester Metropolitan University from the University of Manchester earlier this year and is already planning and engaging with groups such as the Northern Powerhouse and Manchester’s Combined Authority to discuss how the University can support industry and society in adopting Industry 4.0 concepts and technologies.

“Historically the collaboration between the University and industry has always been good and we do have aspirations to lead the way on this. One of our goals is to engage strategically with industry and authorities; it has to be very much collaborative. It’s also about listening to ensure we are implementing what people are looking for,” Dr Diver explains.

There are four key areas in which the University is working: Teaching – bringing digital industrialisation into the University’s MSc courses under an Industry 4.0 umbrella and offering digital apprenticeships in conjunction with industry partners. Knowledge Exchange – engaging with SMEs in the North West who are interested in the Industry 4.0 agenda, whether that’s knowledge transfer partnerships, education or direct involvement with projects and research. Research – supporting research in critical areas; matching research students with local businesses who have a research requirement; and securing funding from funding bodies, such as the Engineering and Physical Sciences Research Council (EPSRC). Wider Engagement – linking with the Smart City initiatives, such as CityVerve and Triangulum, the €25 million Horizon 2020 project funded by the EU in which Manchester is one of three participating cities alongside Eindhoven (Netherlands) and Stavanger (Norway); connecting with society at large to start a wider conversation and understand the human impact of technological change.

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In terms of what is happening in the region, Dr Diver emphasises the media power of the Northern Powerhouse and the pivotal role the North West will play in the digital pilot recommended in the Made Smarter review. “The Northern Powerhouse is a really important initiative, especially in terms of the visibility it brings to the region. It is important to tap into it and to collaborate with them to support what is happening in the North.” Dr Diver thinks the Northern Powerhouse indirectly played an important role in the industrial strategy challenge of the Made Smarter review and the decision to focus the digital pilot in the North West. “This brings more focus on the region and helps us get the message out about what kind of investment and training is required,” says Dr Diver. Investing in skills to help small and medium sized businesses make the transition is vital, he says, and especially for existing workers in industry. 16

This is why building close relationships for collaboration with industry across the region will be vital if the University’s Industry 4.0 programme is to have optimal impact. “Collaboration isn’t only needed between education and industry,” continues Dr Diver, “I’m very keen to capture everything that is happening in the University where we have digital industrialisation capabilities. Industry 4.0 isn’t just engineering – it’s digital arts, it’s HR, it’s healthcare, it’s economics… from a teaching and research point of view we need to take a multi-disciplinary approach to understanding where the opportunities are for the UK as a whole and what we need to be doing.” One such multi-disciplinary initiative already being pursued by Manchester Metropolitan University is its new PrintCity education and innovation centre, which specialises in 3D printing.

“The Northern Powerhouse is a really important initiative, especially in terms of the visibility it brings to the region.”

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The centre is headed up by Professor Craig Banks, who works closely with Dr Diver. “It’s a great facility,” Dr Diver says, “From an Industry 4.0 point of view, 3D printing is a really important technology. And it’s a shining light of what is possible with a multi-disciplinary approach. It brings together engineers, computer scientists and industry with artists, digital designers, people who think outside the box, to work on some interesting and innovative projects. It’s a showcase of Industry 4.0 tech in action.” Showing local businesses around the centre is a great way of highlighting and demonstrating the different interests of Industry 4.0, he says.

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“One of the issues of Industry 4.0 is that people aren’t really sure what it is,” empathises Dr Diver. “Industry 4.0 has a wide remit and we want to show people it isn’t just about robotics and automation. Our doors are open for SMEs to come in and have a look at the different projects we have going on. We can help them with who are the right people to speak with, to build relationships, maybe to work on a digital pilot. We want to build these relationships and, as a result, I hope the region as a whole will benefit.” “It’s about starting conversations and asking questions, but it needs to be a collaborative process.

Small and medium-sized businesses that are interested in starting an Industry 4.0 conversation with Dr Diver and the Industry 4.0 team at Manchester Metropolitan University can reach Dr Diver by e-mail: c.diver@mmu.ac.uk or twitter: @carldiver Find out more: www2.mmu.ac.uk/print-city

industry 4.0 Issue no 5 - october 2018

From CIM to 4IR

How software development is gathering momentum

We are told that we live in a digital age of technological advance and integration. It is also assumed that the dizzy momentum and direction of new technology will be maintained. We do not know for sure what will come next, but industry feeds itself through science. Research is guided by need, such as the need for efficiency, quality, cost-effectiveness and competitive advantage. As a result, we have a good idea of where we are going in the short to medium term at least. Plus we know the momentum will be maintained because it is vital that individual companies, countries and the global economy be sustained in a post-carbon age. The tool of this progress is software and its ability to answer and adapt to evolving requirements.

Software is intrinsic to 4IR and key to increased productivity, safety and reliability in manufacturing. The complexities of the modern factory floor are immense. Every part of the manufacturing process and its related economic systems can be monitored, mimicked, guided and maintained with all data fed back along the nervous system of the virtual factory to the guiding brain of its head office. In this way, big (and small data) data can not only be stored and processed, but integrated to provide information to and from the entire body in real time. Computer control of the production process provides competitive and quality advantages with few, if any downsides. Software and its resulting efficiencies magnify the effects and extend the reach of the workforce, who remain at the heart of the process. In 1979 Dr Joseph Harrington introduced the term Computer Integrated Manufacturing (CIM) from the book of the same name. The integration of systems and process evolved as planning evolved. So, software was not to be an adjunct, or ancillary, to manufacturing, but as important as the physical tools it controlled and monitored. Roy Clarke, IoT Presales at PTC says that without software, 4IR wouldn’t exist. 18

He explains that 4IR is essentially about taking automation to the next level – orchestrating information exchange throughout manufacturing technologies – including cyber-physical systems, IoT and cloud computing. “4IR creates a ‘smart factory’ which involves the integration of people, sensors, industrial assets, control systems and enterprise systems such as ERP & MES in production, as well as the service sector.” However, we are not there yet. Sam Walton, Marketing Manager, Iconics UK, believes it could be another 10 years plus before the full potential of interconnected devices, protocols and embedded analytics is realised. “There are just as many barriers as features to expect, in both cyber security and change management. Digitisation is bringing about changes in the way manufacturers operate. For over 20 years, the ‘Purdue model’ of Computer Integrated Manufacturing has reigned as the foundation of how manufacturing systems are architected. Its hierarchical nature is slowly shifting as a peer-to-peer model as the IIoT opens up.” IIoT is more of an evolution of the industrial technology landscape than a revolution. He believes that it will not replace SCADA (supervisory control and data acquisition) as such, but the two concepts can be integrated.

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There has also been a lot of hype about 4IR which could potentially put people off; companies have been automating their factories for years of course, and this is just another extension to that – but now it’s getting easier and cheaper to implement.

Three co-dependent technical principles identified by Walton as essential to IIoT include the following: Smart Technology Integration: “Breaking down data silos and system segregation”. Anticipate better integration between production, resource, customer and supply chain systems as open communication protocols come online and technologies are forced to start integrating or be left behind. Augmented Display: “Cutting the operators ties to the control room”. Support personnel will begin to alleviate their ties to the control room by accessing production data at the right time through technologies like Augmented Reality and HTML5. Mobile Human Machine Interfaces (HMIs), wearable devices and IP-access to data will enhance our ability to discern, troubleshoot and act away from our conventional spaces. Cost-effective Data Architecture Driven Asset Innovation: “Efficient data storage and connectivity will cause an uptake in asset performance technology adoption.” Wireless connectivity, cloud-based architecture, and low cost IoT sensors will break down barriers to investment and incentivise asset monitoring innovation.

Clarke believes that software in 4IR is about automation and being able to extend the scope of what we can do. “If you look at a typical factory setting, with a wide range of industrial assets from different manufacturers, and then think about the different disciplines such as logistics, quality control, production etc, with the implementation of Industrial IOT solutions you are now gaining a full insight across the whole of the factory in a scalable and affordable way. A device can be changed from its original use into a whole new business model, which generates return on investment to the customer. He observes that in Factory settings, it starts with visibility.

The world of operational technology (OT) is very different from what we see within information technology (IT), he says. “The OT landscape is typically running a variety of automation protocols and does not necessarily have the unified connectivity we get to our data centres in IT. So visibility requires connectivity and protocol translation, such that assets speak to a unifying OT environment – an Industrial IoT platform - and get a consistent view across everything. There has also been a lot of hype about 4IR which could potentially put people off; companies have been automating their factories for years of course, and this is just another extension to that – but now it’s getting easier and cheaper to implement.” 19

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PTC IoT Manufacturing - Solutions Demonstrator

Clarke says 4IR requires integration at the various layers of the ‘ISA-95 stack’ – sensors, PLCs, SCADA, ERP/MES etc. “We see the role of PTC’s ThingWorx Industrial Innovation platform as ‘wrapping and extending’ what customers have already in place rather than ‘rip and replace’. This is where we see the value is – unlocking the ‘hidden factory’ and achieving better automation, better productivity, better quality etc. There is no value in replacing a SCADA system for the sake of it for example. With respect to integrating business systems, the necessary ‘plumbing’ of such integrations has become a lot easier over the years with the adoption of web services for integration tasks (e.g. SOAP, REST) – but still the process needs to be considered, and an understanding of how those business systems are being used – that has never really changed.

“At PTC we turn Industry 4.0 into reality with an organic suite of solutions that are specifically made for 4IR. Customers need deep, real time understanding of operations and PTC has solutions for every stage of that journey – design, manufacture and service of products. Through our software, engineers can now receive instant feedback on costs and performance predictions, factory assets can automatically assign factory processes, parts and processes can now be compared and performance optimised. We enable our customers to transform their operational systems and release value.” “We see the role of PTC’s ThingWorx Industrial Innovation platform as ‘wrapping and extending’ what customers have already in place rather than ‘rip and replace’”

The Way Ahead Software is the glue that pulls the various real-world elements of the smart factory together as a coherent whole. Are we there yet? No. Is there more to discover and develop? Of course there is. The key to progress is interaction – not only of technology and mechanics, but of people and ideas. This interaction takes place within and between companies and with academics, legislators and industry associations. The technology is moving forward, but not in a vacuum. We share to learn. 20

For further information on interviewees: www.iconics.com /iconics www.ptc.com/en /PTC

Issue no 5 - october 2018

industry 4.0

Unlocking the hidden factory

Keeping pace with industrial communications

Humans have developed numerous technologies to make communication easier, faster and, most importantly, cost effective. For industrial automation, effective communication is the real strategic tool for improving a companyâ&#x20AC;&#x2122;s productivity. Here, Steve Hughes, Managing Director of power quality specialist REO UK, explains why businesses need to keep pace with developments in the Industrial Internet of Things (IIoT).

Traditionally, factories operated with a labyrinth of mechanical and electronic devices. Now, more and more manufacturers are adopting IoT because of the growing need to transmit copious amounts of data, in realtime, between different automation systems to control machines, as well as monitor and synchronise production lines. As you might expect, connecting a plethora of devices, systems and machinery from across a manufacturing facility is no simple task. This becomes even more complicated when plant engineers must ensure that all equipment is able to communicate properly, which can be difficult if systems are provided by different equipment manufacturers, each of which may use a different communication protocol or connection.

A common characteristic of the industrial sector is that much of the equipment is under pressure to operate under harsh conditions without jeopardising its connectivity. As a result, many companies incorporate a series of industrial communication methods like Ethernet and Fieldbus to ensure their products meet requirements. According to the president of the OPC Foundation, Tom Burke, the majority of manufacturing operations segregate their communications systems this way. Burke says that manufacturers often have â&#x20AC;&#x153;their standard Ethernet devices running on commercial offthe-shelf Ethernet and then their fieldbus networking devices running on the fieldbus network, sometimes having a simple bridge or gateway between the two network connections.â&#x20AC;?

industry 4.0 Issue no 5 - october 2018

Video:

Introduction to OPC for Factory Automation and plant process control

This has put significant pressure on information technology (IT) and operations technology (OT) departments to unify their processes so that manufacturers can gain the greatest value. Given that industrial protocols (IP) can be required to connect everything from wind turbines to electric grids, the easier a communications system is to integrate the more appealing it is to business managers to install.

Having been widely adopted by the process, electronics and automotive industries, the Fieldbus protocol presents an extensive number of opportunities to increase the level of efficiency and output for manufacturers. This is because industrial communications that feature Fieldbus offer a fast and secure method of transferring data that works even over significant communication distances.

At REO UK, we have come to see complex automated industrial systems like a manufacturerâ&#x20AC;&#x2122;s assembly line be commonly operated under a hierarchy of controller systems. Often, this includes communication protocols based on wired connectivity technologies such as Fieldbus, which is commonly used in emerging economies like India, Japan and China.

REODATA is one example of a communications system that offers a customised interface for compatibility with a range of industrial control products. This meansthat communication is always possible, whether the required fieldbus technology is Profibus, CANBus or ProfiNet.

Fieldbus refers to a group of industrial computer network protocols meant for distributed control in real-time. Placed at the bottom of the hierarchy or the control chain, the Fieldbus links the programmable logic controllers (PLCs) to the electric motors, sensors, switches, actuators or any other components.

In fact, to take that one step further, many manufacturers are now implementing a hybrid Fieldbus approach with Ethernet and Fieldbus networks to interconnect even more devices. This can range from assembly robots, PLCs to central operation control centres.

About REO: REO manufactures resistive and inductive wound components for use with static frequency converter drives in lift and HVAC applications. The company is becoming increasingly involved in renewable energy technology, where power quality is of overriding importance. REO has manufacturing operations in Germany, the US, China and India. 22

Issue no 5 - october 2018

industry 4.0

Video:

Fieldbus Modules from Pepperl+Fuchs â&#x20AC;&#x201C; The Perfect Interface to Industrial Fieldbus Systems

This type of high-performing industrial communication technology can utilise more wireless devices. This is especially important to the future of Fieldbus protocols in industrial settings. While the Fieldbus market grows around seven per cent each year and occupies 66 per cent of the total industrial communications segment, wireless connectivity has been positioned as a potential option for reducing network costs. This is because sensor-fitted devices are becoming more easily accessible in terms of cost, but also wireless applications operate through widely used technologies like Wi-Fi and Bluetooth. â&#x20AC;&#x153;Having been widely adopted by the process, electronics and automotive industries, the Fieldbus protocol presents an extensive number of opportunities to increase the level of efficiency and output for manufacturers.

Although forecasters are expecting a surge of companies to apply wireless connectivity to their processes, there is a large legacy system of wellsuited Fieldbus applications. It is therefore very unlikely that this technology will be replaced, but instead will co-exist alongside wireless applications. Being able to connect different types of devices to a centralised control system is essential for real-time insights and forecasting. With the IoT trend not looking to slow down anytime soon, enhanced levels of factory automation and process information makes the integration of Fieldbus communications even more important. Effective and reliable industrial communication is pivotal to increasing productivity and output levels. With the ability to easily control and monitor the entire production line, industrial communications technologies like Fieldbus make it easier for companies to track any issues along the line, which can then be quickly addressed. Fieldbus is at the centre of a more modern and efficient method of manufacturing control and itâ&#x20AC;&#x2122;s inevitable that businesses that fail to integrate such technologies are likely to be left behind.

Submission by Steve Hughes, Managing Director, REO UK www.reo.co.uk michelle@reo.co.uk /REO_UK 23

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