TECHNOLOGIES FOR

INDUSTRY 4.0

TOTO SUHARTO
ROBERT BOSCH INDONESIA
INDUSTRY 4.0
Technologies for Industry 4.0

2 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Technologies for Industry 4.0
 Additive Manufacturing
 Internet of Things
 Simulation
 Augmented and visual reality
 Vertical and horizontal integration
 Cloud computing
 Cyber security
 Big data and analytics
 Collaborative robot

3 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Additive Manufacturing

4 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Additive Manufacturing
AM technologies offer a lot of benefits to meet future demands Today´s weaknesses of additive
for the development and production of technical components: technologies and systems regarding
industrial usage (selection):
• Design complexity “for free” • Energy & resource
efficiency Technological limits (in general)
• low accuracy
• low surface quality
• high manufacturing cost
AM of metals:
• limitations regarding processable alloys

• Flexibility: from batch size 1 • Agile prototyping / AM of thermoplastic polymers:

• insufficient mechanical properties
to high volumes manufacturing, lean logistics
• processing of fiber reinforced plastics

Chances / Benefit for RB

• USP: complex & function optimized parts
• Highly flexible low volume production
• New business models (digital, printable
data)
5 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Internet Of Things (IoT)

 All over the world, billions of objects are already

interacting and sharing information, such as
cars and smartphones. Things are increasingly
becoming an active part of the internet
 How is this possible? Every “thing” in the world
can transmit data to the web and communicate
with every other “thing” in order to perform a
variety of tasks for its owner
 On the internet of things (IoT), the physical and
virtual worlds are fused

6 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Simulation
Digital Twin Digital Twin
Product Production

< Verification <

Validation
Virtual Virtual Real
produc productio productio
t n n
Specification Commissioning
> >

7 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Simulation

MPP/Easy Plan Line Designer Process Simulation Plant Simulation

8 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Simulation

 Shop floor layout, Machines, Conveyors, Buffers…

 Process time, Availability

 Material: Storage, Commissioning, Transportation, Logistic

 Shift systems, Stuffing

 Production orders/Sequences, Schedules

 Plant control

 Energy consumption and control

9 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Augmented Reality

Increase Productivity

Changing the way

we interact with the Digital World

10 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Vertical and Horizontal Integration

11 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Vertical and Horizontal Integration

Incoming Machining Assembly Finished

From Testing Packing
Goods Stores Shop Lines Goods Stores
Suppliers To Customers

Engineering
Planning Supermarket Maintenance Quality

12 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Cloud Computing
Cloud Computing: NIST defines Cloud
Computing as:

On-demand self-service

“Cloud computing, often referred to as Resource pooling

simply ‘the cloud,’ is the delivery of
on-demand computing resources -
Broad network access
everything from applications to data
centers - over the Internet on a pay-
for-use basis.” Rapid elasticity

Measured service
Source: NIST

13 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Reasons for Cloud Computing
Experiment often Enter new markets quickly CAPEX to OPEX
(Pay for use)

Introduce new features Easily scale up/down Faster time to market

often, rapidly

14 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0

Technology Traditional Infrastructure as a Plattform as a Service Software as a Service

(On-Premises) Service (IaaS) (PaaS) (SaaS)

Operations Dining Table Dining Table Dining Table Dining Table

Application Wine Wine Wine Wine

Application Server Energy / Supplies Energy / Supplies Energy / Supplies Energy / Supplies

Operating System Oven Oven Oven Oven

Installation Chef Chef Chef Chef

IT Hardware Dough Dough Dough Dough

Infrastructure Topping Topping Topping Topping

IT Stack Home-brew Convenience Pizza Pizza delivered Eat-out

You manage Vendor manages

15 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Cloud Computing
Providers
Cloud
Private

Hybrid

Public
Solution Solution Solution Solution Solution

16 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Cyber Security

17 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Big Data

Defining “big data”

• New technologies for the processing of

very large data sets with respect to volume,
variety, velocity and (sometimes) veracity
• For instance, Hadoop, NoSQL data bases,
streaming platforms and many more …

Note: No exact thresholds or limits of big

data vs. enterprise data as technological
boundaries are continuously moving.

18 RBIY/GM | 2019-10-15 http://www.ibmbigdatahub.com/sites/default/files/infographic_file/4-Vs-of-big-data.jpg

© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Data Analytics
Defining “data analytics”
Big Data
Predictive Broader sense
Analytics • Analysis of data for decision support and
Analytics
knowledge extraction.
• Then, business intelligence refers to the
Deep
Data Learning use of data analytics in enterprises.
Analytics
Business Narrower sense
Intelligence • Synonym for “advanced analytics”
• Collective term for all analysis
techniques beyond classical reporting
Artificial
Intelligence and OLAP, especially data mining,
visual analytics, text analytics and
Data
Visual Mining more…
Analytics
Note: Data analytics are applied across
both enterprise data and big data.
19 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Big Data in Manufacturing Lean Logistics
• Inventory management
Connectivi • Milk run optimization
ty and
digitization Adaptive Manufacturing
Smart • Demand forecasting
Logistics • Production planning
• Smart root cause analysis

Smart Manufacturing IPN IPN Connectivity

Platform • Ease of data access
Conecti
• Agile problem solving
Data
factory Storage
vity
• 360° data view.
Mining and
and processing Big Data
AI
architect Smart Testing
• Test time reduction
Visualization • Lower warranty costs
expert
Preventive Maintenance
• Lower downtimes
20 RBIY/GM | 2019-10-15
•
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Higher OEE
INDUSTRY 4.0
Continuous Data-Driven Improvement

Adaptation Knowledge
Optimization

Enterprise
Control Level

ERP CRM …
Continuous
Process Control Level Data-Driven
Improvement Analysis
MES BPM

Process Level

Real-World
Data Data Integration Data

21 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Types of Data Analytics
How can we
increase FPY?
Business Value

What will be Prescriptive Analytics

FPY in the next Action
quarter? (How can we make it
happen?)
Why has FPY Predictive Analytics
decreased in Forecast
certain regions? (What will happen?)

What is the Diagnostic Analytics

current first pass Root Cause
yield (FPY)? (Why has it happened?)

Descriptive Analytics
Transparency
(What has happened?)

Data Mining with IBM SPSS Modeler, R, Python…

Exploration and Visualization with Tableau and MS PowerBI
Technical Complexity
22 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Data Analytics: Use Cases
1 2
Product & Line Test
performance Performance
Analysis metric

3 4
Root Cause
Issue Rate Daily
Recommender

5
ETL for self
service
dashboards
Descriptive
Data sources ETL Master Table
23 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0

Provide automated early warning on warranty claims by predicting trends in the Global Warranty
Business Objective
Analysis database; reduce Bosch warranty costs

Data Sources & PRODUCT & DATA METHODOLOGY RESULTS

Analytics Approach

Trend Detection Approach Automated Alerting System

• wavelets on high-dimensional time series • multi-resolution approach
• input: global warranty database • time series hierarchies • trend monitoring on different scales
• product: web-based QM tool • smoothed and weighted differences (short-, mid-, long-term)

• automated nightly analysis of warranty claims trends

Result • tool rolled-out across BBM, has become mandatory alert system for all QM engineers
• tool reduced detection lead time

Value $ Potential annual savings in automotive warranty costs

24 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Collaborative Robot: Case study
+
Fast Integration
Easy Programing
Collaboration with operator
Low total investment
Flexibility

-
Limited speed
Unknown Reliability

25 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
INDUSTRY 4.0
Collaborative Robot: Case study
Production Cost Savings
0.65 € 30,000.00 €
UR3
25,000.00 €
0.60 € Without
Robot 20,000.00 €
Production cost [€/unit]

0.55 € 15,000.00 €

Cumulated Profit
10,000.00 €
0.50 €
5,000.00 €

0.45 € 0.00 €
1 2 3 4 5 6 7 8 9 10 11 12
-5,000.00 € Breakeven point
Breakeven point
0.40 €
-10,000.00 €

0.35 € -15,000.00 €
1 2 3 4 5 6 8 9 10 11 12
7
Months -20,000.00 €

26 RBIY/GM | 2019-10-15
© Robert Bosch GmbH 2019. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
THANK
YOU