INDUSTRY 4.0 The computerization of manufacturing
PROJECT Flexibility in the industry
SCIENCE, TECHNOLOGY AND KNOWLEDGE
LUBMAT 2016 IK4-TEKNIKER will host the LUBMAT conference
JANUARY 2016 | No. 103 ENGLISH EDITION
New paradigms, new opportunities
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INTRODUCTION
The fourth industrial revolution has given rise to what is known as Smart Factory or Industry 4.0. It is within the scope of this new paradigm for the industry, that IK4-TEKNIKER has proposed a reference model that features three levels. Level one is focused on trends or drivers (customisation, shorter life cycles, sustainability or other similar elements). Level two deals with the production model (exible, digital, reconďŹ gurable and smart). Level three addresses enabling technologies (cyber-physical systems and collaborative robotics). This edition of newtek describes the progress made at IK4-TEKNIKER with regard to Industry 4.0 among other current topics. 2 | NEWTEK JANUARY 2016
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INDEX
THE EXPERTS’ VIEW
C04 What is Industry 4.0?
INTERVIEW
C06 “Industry 4.0: the computerization of manufacturing”
NEWS
C08 IK4-TEKNIKER will participate in the upcoming 29th edition of BIEMH
PROJECTS
C12 Eliminating lead from large-sized machines
C14 Flexibility in the industry
C10 IK4-TEKNIKER will host the LUBMAT conference on industrial lubrication JANUARY 2016 NEWTEK | 3
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THE EXPERTS’ VIEW
What is Industry 4.0?
AITOR ALZAGA AND JON RREINA
The expert’s view: by Aitor Alzaga, Assistant Manager for Technology and Jon Larreina, Industry 4.0 Coordinator at IK4-TEKNIKER The term Industry 4.0 embraces the “so-called fourth industrial revolution arising from a technological evolution brought about by the development of embedded systems, by their connectivity and by a confluence between the physical and virtual worlds. It provides integration capabilities for objects, information and people that could eventually produce a qualitative leap in terms of production and the use of goods and services”. In order to set the context for this revolution, it would be appropriate to recall the different “waves” associated with the introduction of electronics and ICTs in terms of industrial production. The fi rst wave, dating back to the eighties and early nineties, focused on process efficiency. These were the days when CAD, CAM, CIM (Computer Integrated Manufacturing), FMS (Flexible Manufacturing System) and other similar systems were introduced. As occurs nowadays, the main objectives were geared towards incorporating and giving greater flexibility to manufacturing systems that were limited by the available technology.
devices with extensive connectivity capabilities grew substantially towards the end of the fi rst decade of the new century and eventually gave rise to the so-called third wave in terms of ICT utilization and can be rated as the precursor of what is currently called the 4th revolution. The term Industry 4.0, coined by Germany and whose debut coincided with the presentation of the document entitled “Recommendations for implementing the strategic initiative INDUSTRIE 4.0”, published by ACATECH in April 2013, falls under the dual German strategy of playing a leading role in terms of supplying equipment and solutions for industrial production at German manufacturing facilities to include them in value chains and digitize the entire production process.
The second wave, in the nineties, coincided with the onset of the Internet and other closely related technologies such as Internet portals and solutions that enhanced collaboration and integration along the entire the value chain based on a highly extensive concept (SCM, CRM, etc.).
Since then, many countries and regions (like the Basque Country, amongst others) have been making efforts for the purpose of making better use of the opportunities this new scenario offers. It must not be forgotten that whilst this movement was unfolding in the area of manufacturing, Europe was pushing for the so-called “Factories of the Future” concept via EFFRA (European Factories of the Future Research Association) in the guise of a public-private partnership that was implemented in 2008 to address innovative projects.
It was some time later, at the turn of the century, when connectivity reached machines and when concepts such as M2M (Machine to machine) were extensively implemented. This was later followed by another powerful concept, the Internet of things, linked to the development of IPv6. The proliferation of mobile
Businesses, in the meantime, have been giving thoughtful consideration to how this movement might affect them in order to react accordingly (using a defensive strategy) or have been pondering the opportunities this new scenario will offer (using a proactive strategy).
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Regardless of whatever applies, the resulting thinking process will take place at three levels:
1 2 3
First and foremost, and from a strategic perspective, we must be fully aware of how it is we want to improve our value proposition. Embodying new technologies that give greater value to my product is not the same thing as setting them up on machines to be used as tools to achieve operational efficiency. Nor is it like changing the value proposition and/or business model. Once the strategy and the associated challenges have been defi ned, it then becomes necessary to consider how this can be transferred to the production process or product, by taking action with the product, equipment or production system provided by the company. In other words, a production model capable of responding to the strategy has to be defined and then followed by the implementation of a suitable roadmap. It is important for this roadmap to pinpoint key supporting technologies and decide how they can be brought on board; either by acquiring or developing them and, if so, with whose assistance. If the base technology is to be a key element in the business, capabilities will be developed internally. This could also be done with external stakeholders to speed up the process. A reference model should be used when defining and deploying an Industry 4.0 strategy similar to the one shown, in a simplified manner, in the chart below (a model implemented and presented by the IK4 Research Alliance at the recent Basque Industry 2015) conference: Customisation
Shorter Time to market
Servitization
Sustainability
Ageing
Connected / Digital
Reconfigurable
Smart
EFFICIENT
HUMAN-CENTRED MANUFACTURING
• Flexibility understood as the capability to produce, in extreme cases, in a customised setting. • Re-configurability understood as the capability to adapt quickly and economically to any product changes. • Digitization of processes, connecting and integrating the different stages and units of the production process. • “Smartization” of processes and equipment to develop a smart response; amongst a host of other issues, this also entails learning from previous experiences and requires that unexpected situations be dealt with autonomously. The degree of significance allocated to each one of these features in terms of the production model will vary as a function of the nature of the trends we wish to address.
Transversal characteristics All production models feature another two very relevant transversal characteristics that are closely in line with the sustainability driver in its economic, social and environmental dimensions: • A focus on people, regardless of the level of automation. In a production system, people are fundamental to achieve good performance levels.
Enabling technologies
Flexible
Lastly, there are a number of enabling technologies that are usually associated with Industry 4.0 Advanced Manufacturing that have been grouped in two blocks: • Cyber-physical systems, Big Data – predictive analytics, Cloud Computing: Due to their essence as integrating elements, these technologies might eventually become the backbone of an Industry 4.0 initiative.
ENABLING TECHNOLOGIES
3D Simulation/ Cyber Physical Collaborative Additive Cloud computing/ Augmented reality Systems robotics manufacturing Virtualisation
There are three levels in this reference model: Level one covers trends or drivers; level two presents the production model and, lastly, level three addresses enabling technologies. In fact, it can be stated that these three levels are related to the other three mentioned above and offer guidance throughout the thought process:
The features of an advanced manufacturing Industry 4.0 production model are:
• Efficiency: the elimination of waste to ensure top value based on using a minimum amount of resources.
PRODUCTION MODEL | (USER / SUPPLIER)
Machine vision
Main features
Big data
SUCCESS 4.0 STRATEGY
POSITIONING BUSINESS MODEL MARKET
TECHNOLOGY
PRODUCTION MODEL PROCESSES SERVICES ROADMAP
PRODUCTION SYSTEMS ICTS
The strategic position of a company will be related to or in line with any drivers or trends that could have a significant impact on business in the form of customisation, shorter life cycles, sustainability, etc.
• Collaborative robotics, simulation – augmented reality, artificial vision, additive manufacturing: All of these technologies will be relevant to a greater or lesser extent as a function of each case and a number of specific attributes. Production models are always addressed from the point of view of users and suppliers of equipment, systems and solutions. It is therefore necessary to underscore the opportunities offered by smart and connected machines or systems as equipment suppliers will fi nd it easy to collaborate with users to optimise machine operation and maintenance. Although certain cultural barriers might hinder a massive degree of implementation, this collaboration will defi nitely be set into motion in those instances in which the advantages related to pursuing this option are evident. This will give rise to new ways of doing business such as, for instance, paying for using means that provide supporting actions that are not connected to any key activities or processes but that could be related, amongst other things, to issues such as material logistics.
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INTERVIEW
Professor Dr. Eng. Eberhard Abele is the Director of the Institute of Production Management, Technology and Machine Tools at the Technical University of Darmstadt (Germany) and leader of a team working on new production technologies. He is also an expert in terms of the new “Industry 4.0” paradigm. In this interview, Abele explains this new paradigm and the advantages it offers for the industry.
PROF. DR. ING. EBERHARD ABELE
You are the leader of a team of 70 engineers in Darmstadt exclusively devoted to research focused on new production technologies. Regarding the European Industrial sector, why is R&D&I a key effort? Industrial competitiveness refers to the ability of companies to compete in more and more global markets. R&D&I will be a key effort for all industrialised countries. The development of new production technologies which allow new products or an advance in quality and costs will be in future a main challenge for competiveness. By developing technological innovations and novel systems solutions for the industrial sector our institute will help to reinforce the competitive strength of the economy in our region, throughout Germany and in Europe. Our research activities are aiming at promoting the economic development of our industrial society, with particular regard for social welfare and environmental compatibility. In this particular context, one of the most outstanding concepts that you have pioneered is connected to Industry 4.0. But what is it exactly? What kind of a competitive edge can it provide for the European economy? And, finally, what challenges will it face in the future? The term “Industry 4.0” originates from a project in the high-tech strategy of the German government, which promotes the computerization of manufacturing.
“Industry 4.0 : the computerization of manufacturing” Prof. Dr. Ing. Eberhard Abele, Director of the Institute for Production Management, Technology and Machine Tools at the Technical University of Darmstadt (Germany)
The major basics in Industry 4.0 are: Interoperability: The ability of cyber-physical systems (i.e. workpiece carriers, assembly stations and products), humans and Smart Factories to connect and communicate with each other via the Internet of Things and the Internet of Services. Virtualization: A virtual copy of the Smart Factory which is created by linking sensor data (from monitoring physical processes) with virtual plant models and simulation models. Decentralization: The ability of cyber-physical systems within Smart Factories to make decisions on their own. Real-Time Capability: The capability to collect and analyse data and provide the derived insights immediately (Big Data). Until now, a lot of studies have been made by institutes or management consultants regarding the impact and visions of the Industry 4.0. But now the industrial side demands solutions! Which real effect Industry 4.0 may have to productivity, quality improvement or to a progress in flexibility? This challenge demands closer cooperation between informatics and production engineering but as well between academia and Industry. Some positive, already running examples for Industry 4.0 are machines which can predict failures and trigger maintenance processes autonomously or self-organized logistics which react to unexpected changes in production.
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A significant part of your career has been connected to research centres such as PTW or Fraunhofer, but you also have extensive industrial experience as you’ve worked for leading companies such as Bosch or Stihl. In your opinion, what kind of added value do technology centres produce for businesses and what will this relationship be like in the future?
Germany is, without a doubt, Europe’s main industrial driving force and a benchmark in terms of Industry 4.0. Based on this fact, how would you rate the contribution made by small companies with a long-standing industrial tradition such as the Basque Country as regards renovating its fabric via Industry 4.0?
Looking back to R&D&I- projects in general, the challenge is still to combine the creativity and innovative ideas of young researchers in research institutions with the process- and marketknowledge in industry.
Regarding the possible contribution to innovation in the industry 4.0 direction, you have to distinguish between users or system providers or solution providers. Regarding the solution provider area you will have as well, small and medium sized companies as of course international big players like Siemens and SAP.
Young researchers are often not aware of the complexity of a production system. They underestimate the speed in industry and the necessary robustness of a process or an innovation. From a prototype at a university level to a real innovative product is a big step!
In Germany, even small companies have embraced Industry 4.0 early, which has allowed to grow with it and gain a strong understanding of its workings and capabilities.
In this aspect, the research centres in Basque Country which are aiming at professional scientists, looking for a continuity in research fields and customer relations may have a big advantage.
Each company should be aware that Industry 4.0 is changing the rules of the game as automation merges with the IT world and what its benefits could mean for the own operations.
In my opinion, the Basque Country has an important network of technology centres that carry out excellence research and provide the industrial sector with valuable technological solutions and knowledge.
Integration has begun and will give a chance to each company, whether small or big, independent if you are tool manufacturer or supplier, equipment operator or factory integrator.
The efficiency of these research centres depends – like in all industrialised countries -upon their cooperation. How is synergy possible? How infrastructure can be shared? In this regard you will fi nd in the Basque Country a very positive example: the establishment of the Basque Network of Science, Technology and Innovation (RVCTI), with the aim of developing the infrastructure that would supply synergetical effects inside this region of Basque country. Another positive example which could be seen from an international aspect is the IK4 Research Alliance, a technology centre alliance where each centre is managed individually but they work together in the development of projects and share infrastructure.
In recent years you have been able to co-operate with IK4-TEKNIKER. Could you please elaborate on this co-operation and point out future trends? Yes indeed we often had the chance to get into contact with IK4-TEKNIKER and to share our ideas and to cooperate in projects. Since more than one decade we are organising jointly the High Speed Machining (HSM)- Conference. The strong point always has been the highly qualified staff and the technological excellence due to the specialization in IK4-TEKNIKER. Regarding the infrastructure in labs, it is competitive to the world’s prestigious research centres. One trend we can see in our contacts with companies; Customers asking for a so called “one stop solution” which means they are looking for one partner which will accompany him through the whole development and industrialisation process. In this regard the IK4 Research Alliance may have synergy effects. On the one hand, IK4 Research Alliance can offer the high level of specialization by centre and on the other hand, allows the high degree of cooperation between the research teams of the centres to offer solutions along the whole innovation process to customers.
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PHOTOGRAPHS:
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NEWS
BEC | BILBAO EXHIBITION CENTRE BARAKALDO | BIZKAIA | SPAIN MAY 30 > JUNE 4 | 2016
IK4-TEKNIKER will participate in the upcoming 29th edition of BIEMH Smart manufacturing and Industry 4.0 will provide the main focus for the 29th edition of BIEMH in 2016. BIEMH will hold its 29th edition in 2016. Hosted by the Bilbao Exhibition Centre and AFM (Advanced Manufacturing Technologies), this trade fair has an impeccable track record dating back to its origins. In terms of this particular speciality, it is Europe’s third most outstanding trade fair as well as a major benchmark in the country. “You make it big” is the motto chosen for this upcoming edition that will take place from May 30 – June 4 2016 at the Bilbao Exhibition Centre and focus on smart manufacturing and Industry 4.0.
On the occasion of the 29th edition where IK4-TEKNIKER will participate as an exhibitor, we will recall our presence at the previous edition of BIEMH held in 2014. During the previous edition, visitors had the opportunity of learning about the technology centre’s activities in the machine tool sector via demonstrators such as metrology: volumetric checking and compensation of machine tools and coordinate measuring machines, industrial and service robotics, selfstanding machine tools and additive manufacturing.
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NEWS
IK4-TEKNIKER will host the LUBMAT conference on industrial lubrication Among a number of other subjects, the fifth edition of LUBMAT 2016 will address issues related to lubrication management. Sector experts will attend plenary sessions and an international committee made up of industrial lubrication professionals and academics will review abstracts submitted during the event.
As lubrication is a key element for machines to operate efficiently and durably, the fi fth edition of the LUBMAT conference on lubrication, maintenance and tribology will take place at the Euskalduna Conference Centre in Bilbao on June 7 and 8. LUBMAT is the outcome of a collaboration agreement signed by the Jost Institute for Tribotechnology of the United Kingdom and IK4-TEKNIKER. The event has gradually become a key European gathering where sector experts can debate the most recent developments in terms of products and services. In the course of this fi fth edition, discussions will address a range of issues such as the management of lubrication, lubricants and special fluids, reliability and asset management, oil condition monitoring and tribology.
Keynotes Furthermore, the conference has programmed six plenary sessions directly related to key conference subject areas to be attended by experts in lubrication, maintenance and reliability.
Several courses will be given by a number of outstanding experts to round off this highly attractive event the day before the conference opens (on June 6).
24 professionals on the international committee It is a committee with 24 professionals from different countries and organisations specialised in lubrication, maintenance and tribology together with experts from the industry, technology centres and universities. It has been set up to review abstracts submitted during the conference. Conference organisers will provide exhibition space and stands for any companies interested in this option.
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LUBMAT 2012 IMAGES EUSKALDUNA CONFERENCE CENTER BILBAO | BIZKAIA | SPAIN JUNE 7 & 8 | 2016
International committee Listed here are the names of some of the Committee members:
Jo Ameye
FLUITEC
Greg Livingstone
FLUITEC
Wilfried Bartz
TRIBO-LUBRI
Ichiro Minami
LULEA UNIVERSITY
Udey Dhir
VAS TRIBOLOGY SOLUTIONS
Terrence O’Halon
RELIABILITY WEB
Luis Fernández Ruiz-Morón
REPSOL
Anu Ritson
INLUBE
Antonio José Fernández Pérez IBERDROLA
Neil Robinson
WEARCHECK AFRICA
Jim Fitch
NORIA
Ian Sherrington
JOST
Francisco Javier González
AEM
Andy Sitton
FOCUSLAB
Robert M. Gresham
STLE
Jason Tranter
MOBIUS
Suzy Hitcock
ICML
Gerardo Trujillo
NORIA LATIN AMERICA
Kenneth Holmberg
VTT
David Zhou
RUNNINGLAND
Rüdiger Krethe
OILDOC
Jesús Terradillos
IK4-TEKNIKER
Esteban Lantos
LANTOS
Ana Aranzabe
IK4-TEKNIKER
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PROJECTS This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement nº 691503.
Eliminating
lead
from large-sized engines
Lead-free bearings for large-sized, high-performance engines
With the aim of continuing to drive forward the structuring of more efficient and less polluting industry, the Basque R&D centre IK4-TEKNIKER is participating in a European project focussing on the development of a new range of lead-free bearings for largesized, high-performance engines. The Th initiative, i ii i known k as BeLeadFree, B L dF is i being b i coordinated di d by b the h British manufacturer of automobile bearings Daido Metal and has the participation of the Belgian company Elsyca and the University of Coventry (United Kingdom). The project, which kicked off recently and is set to run for two years, has funding of nearly 3 million euros approved within the programme designed to encourage innovation within the European Commission’s Horizon 2020 programme. The project is seeking to develop multilayer engine bearings that are highly friction- and wearresistant and manufactured using alloys free of lead, the material most widely used today to manufacture these components. Bearings are parts used by engines to minimize the wear of the elements that perform rotatory movements. Until now, lead has been used to manufacture these parts but its high polluting level and toxicity make it necessary to seek alternative alloys free of this element.
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IK4-TEKNIKER will be carrying out the advanced characterisation of the materials of the new lead-free bearings, the composition analysis, the microstructure, and the supervision of the surface characteristics, etc.
The IK4-TEKNIKER R&D centre is working on the BeLeadFree project, which is aiming to eliminate lead from the bearings built into the engines of heavy diesel vehicles used in road transport, electrical power generation and maritime transport.
The iniciative is seeking to develop multilayer engine bearings that are highly friction- and wear-resistant and manufactured using alloys free of lead.
All the products being developed in this project are geared towards medium heavy-duty and heavy-duty diesel engines used in heavy commercial vehicles, ranging from large two-stroke or fourstroke medium-speed engines used in seagoing vessels right up to submarines or generating sets. IK4-TEKNIKER’s Tribology unit will be responsible for carrying out the laboratory simulation of the wear mechanism of the new bearings developed and of the current ones by means of short tests and in conditions of extreme precision; all this is designed to predict the useful service life of these bearings. IK4-TEKNIKER will be carrying out the advanced characterisation of the materials of the new lead-free bearings, the composition analysis, the microstructure, the supervision of the surface characteristics such as morphology, hardness, roughness or the contact angle as well as the study of residual stresses and mechanical and tribological properties.
The specialists will be testing the various lead-free alternatives, selecting the ones that offer better mechanical and tribological performance, less friction, wear and greater resistance to extreme pressure, and will also be verifying that these new alloys are environmentally friendly. To achieve this second objective, the wear particles produced in the tribological test and in the engine tests will be gathered and they will be subjected to ecotoxicity tests in order to confi rm that they are not toxic. “It is essential to guarantee that the new alloys generate low friction so that fuel consumption can be cut, that they have a duration similar to the lead ones currently in use, and that they withstand high pressures and speeds to guarantee that the industry can safely replace them, but also that they are less toxic and contaminating and more environmentally friendly than the solutions used until now,” stressed the head of IK4-TEKNIKER’s Tribology Unit Amaya Igartua. The bearings developed within the framework of this project will be useful in industrial sectors such as electrical power generation, engines for seagoing vessels and heavy vehicles in the automotive sector.
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PROJECTS
Flexibility in the industry
A new generation of robots integrated with people in manufacturing environments
A new concept of robotics featuring collaborative robots is now reaching the industry; a new generation of robots that work with people in industrial environments and deliver a high degree of flexibility in the automation of a number of tasks. C Collaborative robotics, a new co concept that has been develo loped in recent years, is here to meet growing demands as re regards achieving greater flexi xibility for the robot-based soluti tions used nowadays. At a time w when many processes are chara racterised by production runs th that are not only short but also ex extremely variable and increasi singly complex and when tradi ditional robotics can no longer offer reasonably priced soluti tions capable of delivering prope per returns on an investment. Th These new robots provide a m much more accessible robotic au automation technology, particu cularly for SMEs, the greatest co consumers of automation solu lutions whose main goal is to re reduce costs and enhance proce cess quality.
In this regard, collaborative robotics matches the strengths of people and robots and offers solutions for processes in which, if otherwise, it would not be an affordable automation option for tasks such as part assembling in manufacturing or the inspection of complex components. Safety is one the key issues behind collaborative robotics. Conventional robots guarantee safety by resorting to barriers and sensors that separate people and robots. This precludes any type of collaboration. To avoid these barriers, new products have been developed in recent years in the field of robotics in compliance with safety regulations. There are, however, major challenges to be addressed if a safe collaboration is to be established: the introduction of safety elements removing risks inherent to each application, the incorporation of sensors to be adjusted accordingly in order to confer smart adaptation capabilities to robots and, fi nally, planning strategies that can offer collaborative solutions and enable tasksharing between people and robots. It is along these lines that IK4-TEKNIKER has decided to develop a number of technologies associated with robotics geared towards ensuring safety and flexibility by installing state-ofthe-art sensors and developing control systems applied both to industrial and collaborative robots. These advances have allowed the technology centre to offer applications in diverse sectors such as logistics for product packaging or manufacturing for the assembly of complex parts in the aeronautical business.
IK4-TEKNIKER has decided to develop a number of technologies associated with robotics geared towards ensuring safety and flexibility by installing state-of-the-art sensors and developing control systems.
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Collaborative robotics matches the strengths of people and robots and offers solutions for processes in which, if otherwise, it would not be an affordable automation option.
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PARKE TEKNOLOGIKOA CALLE IÑAKI GOENAGA, 5 20600 EIBAR · GIPUZKOA · SPAIN TEL: +34 943 206 744
www.tekniker.es
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