directindustry

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directindustry

DIRECTINDUSTRY
Idnu4.sytr0 – Still Confused?
Industry 4.0: Scope, Vision, and Advantages
»AT FIRST, EVERYTHING IS COMPLETELY CONFUSING«
INTERVIEW WITH PROF. LINUS SCHLEUPNER
INTEGRATED MES
FOR GREATER PRODUCTIVITY AND EFFICIENCY
SMART DATA:
DIGITAL DOWN TO THE FINGERTIPS
INTEGRATING SYSTEM MODULES
IN LESS THAN 3 MINUTES
DIMA makes production processes versatile
• Essential Industry 4.0 component
• Standardized “Plug-and-Produce”
• Shortened engineering time
www.dima-process.de
EDITORIAL
Benefits and challenges
of digitization
Dear readers,
For all those who deal with Industry 4.0, particularly on the supply side, the issue may appear to be
old hat. However, many others – especially small
and medium enterprises – are new to its unique
challenges. This issue of WAGODirect is focused
on highlighting the benefits of Industry 4.0 while
addressing the technological aspects.
The fact is that digital zeros and ones are already a
large part of our lives today – and they will remain
influential in the future. The competitiveness of the
German industrial base depends largely on how
digitization is mastered. But what exactly does this
mean for business? Value chains and business
processes need to be fully networked. The ability
to collect and analyze relevant information and
implement actions will represent a significant
competitive advantage. In addition, business and
production processes must adjust to the surging
trend of individualized products. Addressing this
requires concepts that make plants so versatile
that they can vary functionality almost instantly.
Digitization brings opportunities and advantages,
but also poses new challenges. In particular, the
suppliers of automation technology have to face
these challenges if we hope to decisively design
and shape the path to Industry 4.0.
Enjoy reading!
Yours, Thomas Holm
COVER STORY
Idnu4.sytr0
It is clear that hardly anything is clear: While some
people do not really know where to start, others
have been implementing Industry 4.0 technology
in their production facilities for a long time. This
issues calls for vision because Industry 4.0 is not
very tangible and is sometimes difficult to understand. Nevertheless, the present and future benefits are undeniable – for businesses and consumers
alike.
CONTENTS OF THIS ISSUE
OPINIONS
Editorial
Benefits and challenges of digitization 3
COVER STORY: Idnu4.sytr0
Idnu4.sytr0
Although Industry 4.0 has dominated the specialist media for years, its presence
in the mainstream has received a mixed reception. However, it is not really that difficult…
10
»At first, everything is completely confusing«
Consumers and businesses may already benefit from Industry 4.0.
Prof. Linus Schleupner explains what rules must be followed.
18
Integrated MES for more productivity and efficiency
Ruch Novaplast records his production data in real time
using MPDV HYDRA and WAGO automation technology.
22
Digital down to the fingertips
Ordering and production processes are being increasingly digitized.
An integrated system provides transparency from the order to the finished product.
28
»Industry 4.0 is no mainstream solution«
WAGO sales manager Jürgen Schäfer reveals in an interview
why companies facing Industry 4.0 should not be afraid of possible risks.
34
En route to versatile production
DIMA: Plant engineering on the fly
38
APPLICATIONS
Pioneers plan in record time
As early adopters, MatriX developers rely on e!COCKPIT 6
TECHNOLOGIES
PFC speaks OPC UA
Industry 4.0 with firmware 06: With the current firmware version,
the PFC100 and PFC200 do more than just communicate via OPC UA. 15
Integrating machines via MTConnect
Implemented according to projects: WAGO’s PFC controllers
communicate machine data as per MTConnect.
16
Send the right signals: TOPJOB® S Sensor/Actuator Terminal Blocks
WAGO is adding new sensor/actuator terminal blocks to the TOPJOB® S line
of rail-mounted terminal blocks. 27
APPLICATIONS | PIONEERS PLAN IN RECORD TIME
MatriX R&D Manager Martin
Sokolowski relies on modular
plant and automation concepts: “This is the only way
that we can produce inspection machines with rapidly
proliferating options and still
meet the shortest possible
delivery times.”
As early adopters, MatriX developers rely on e!COCKPIT
PIONEERS
PLAN IN
RECORD TIME
They reminisce fondly about the
early days, when they brought their
first X-ray inspection systems to the
market. “At the time, we hardly knew
what ppm meant,” R&D manager
Martin Sokolowski says with a wink.
Today, the engineers at Nordson
MatriX focus on improving resolution
at higher cycle speeds, while simultaneously creating their machines in
record time, even though none are
identical. WAGO automation modules
have always supported a high degree
of customization, and lately – the
e!COCKPIT engineering software is
the latest contribution to the cause.
Greater accuracy, speed and flexibility: Manufacturers of high-value
and safety-related products place
stringent requirements on their X-ray
inspection systems. Nordson MatriX
meets these by employing a modular
concept that extends from the mechanical system up to control programming. MatriX systems are used
during quality control of electronic
6
WAGO DIRECTINDUSTRY | NO. 01 / 2016
components, medical implants, and
cast components. The roster of
customers ranges from well-known
firms in the automotive and medical
industries to famous names in the
consumer electronics industry.
Since 1998, the manufacturer, headquartered in Feldkirchen, has made
automated machines with around
100 employees worldwide. WAGO
technology played a role from the
beginning. Initially, the engineers
were merely interested in an I/O
system that could be connected via
ETHERNET. They hit pay dirt with
WAGO; however, shortly thereafter,
the team decided that they needed
a completely new fieldbus controller.
At first, the controllers were used
purely as remote I/Os, without a PLC
program. However, the developers
were already aware that they would
not be able to realize the future
real-time requirements placed on
control tasks using a PC application
and a TCP/IP-based remote I/O.
Therefore, the controller functionality
was also used and increased in the
following years. Each new generation
of WAGO controllers brought the
increased performance necessary
for greater machine development.
At the time, MatriX was still named
Macrotron Process Technologies;
it already viewed the automation of
its X-ray systems as one of its core
competencies. Under the name MatriX Technologies, the company really
took off in 2004 and demonstrated
convincing growth rates. MatriX has
been a part of the Nordson Group
since 2015.
The company’s automation experts are in high demand. Programming controllers, generating circuit
diagrams, providing integrated
automation that keeps up with the
ever-increasing miniaturization
of electronics, and addressing
other customer needs – their work
ensures the company’s competitiveness. Purchasers naturally
expect that the machines will support extremely short cycle times
to ensure quality and operate at
a high resolution. They also plan
on receiving the Automated Inline
X-ray Inspection systems (AXII), as
well as any other MatriX equipment
for non-destructive testing, shortly
after ordering them.
Modular for fast development
times
Such short delivery times for special-purpose machines place high
demands on the machine concept
and configuration. Christoph Bestle,
who has been responsible for
programming electrical systems,
creating circuit diagrams, and PLC
programming at MatriX since 2009,
uses the WAGO-I/O-PRO development environment for control
systems, based on CODESYS 2, to
program the WAGO-I/O SYSTEM
750. Using this system, it was easy
for him to manage the high levels
7
APPLICATIONS | PIONEERS PLAN IN RECORD TIME
of configuration effort that are
required for new application fields,
such as the final assembly tests on
packaged, high-value consumer
products, like smartphones, or for
medical devices. He views WAGO’s
I/O components and stepper controllers as modules to be combined
as needed for automation within the
framework of a modular machine in
a way that is similar to how he views
Pilz safety components.
The engineers at MatriX repeatedly
conclude that WAGO is a partner
with a comprehensive product portfolio, which they can always utilize
successfully. Martin Sokolowski,
Manager of R&D and Engineering
at MatriX, believes this is due to
small quantities, thus supporting our
development and growth.” Personal
contact with his suppliers over many
years is as important to him as that
with the MatriX customers.
The IEC 61131-compliant programming system provides the system
manufacturer with a great advantage
in the form of integrated visualization. Christoph Bestle explains, “We
install the engineering tool on every
machine. This makes us flexible
when small adjustments are needed
on location.”
Due to the targeted integration
of the latest WAGO controller
generation, which MatriX has been
consistently implementing for years,
»It makes it easier for our technicians, and
especially our end customers, to perform
diagnostics and troubleshooting, especially when it
comes to interface problems.«
WAGO’s focus on the numerous
medium-sized machine manufacturers in Germany. He opines that,
“WAGO also deals with orders in
the developers are simultaneously
able to pave the way for use of the
new engineering software. One of
WAGO’s next-generation PFCs, the
PFC200, is the migration product
for the change from the CODESYS
2-based WAGO-I/O-PRO to the
new e!COCKPIT system, which is
based on CODESYS 3. The PFC200
supports both software generations.
The lack of complex changes in the
hardware configuration or parts lists
makes the transition to e!COCKPIT
particularly easy.
e!COCKPIT – convenience for
programmers and end users
The important development step,
which WAGO completed by transitioning to the CODESYS 3-based
tool, directly benefits MatriX. “Much
more state-of-the-art,” Bestle calls
the new e!COCKPIT configuration
tool, “especially compared to the
old configuration tool” The lockand-feel alone of the all-new WAGO
development environment convinced him the first time he laid eyes
on it. The software, which supports
not only hardware configuration and
programming, but also simulation,
visualization, and commissioning, is
based on CODESYS 3.
Bestle commends the integrated
visualization, “It makes it easier for
our technicians, and especially our
The latest Nordson MatriX machine platform
for automatic X-ray inspection at the highest
speed: It guarantees reliable testing of double-sided circuit boards and is ideal for final
assembly tests.
8
»I really appreciated
the convenience when
configuring a CT inspection
machine for batteries.«
Christoph Bestle has already gained experience with the new e!COCKPIT engineering
software.
end customers, to perform diagnostics and troubleshooting, especially
when it comes to interface problems.” Of course, he also benefits
from the integrated tool, whose
configuration can be accessed
directly from the PLC program.
He has already successfully realized
his first major project with e!COCKPIT. “I really enjoyed the convenience
during configuration, such as input
assistance while programming,” he
says. This resulted in a computer
tomography inspection machine that
can be used to examine batteries for
consumer products.
The engineering software provides
support at many points so that
developers can cope with complex
projects in record time. The network view allows classic network
protocols, such as MODBUS, to be
configured and programmed easily.
Thanks to drag-and-drop and copyand-paste functions, this can be
done intuitively. Due to the ability to
create applications, Nordson Matrix
will continue to benefit in the future
from the high reusability of software
modules. In this way, the proven
modular concept of the mechanical
engineer is further supported.
Little training is necessary for
e!COCKPIT – especially for those
who, like Bestle, already have experience with IEC 61131. They will
quickly feel at home in the CODESYS
3-based software. The predefined
libraries and the design of the user
interface, with a clear menu ribbon,
provide convenience and speed.
Only the functions that are relevant
to the task at hand move to the
foreground, which increases comprehension and saves time.
Opportunities for early
adopters to exert
developmental influence
Bestle believes there is still room
for improvement. A revision of the
licensing model would be desirable
in order to maintain the proven
flexibility in the field. That would
remove any obstacles during the
generational changes to the development environment. MatriX R&D
Manager Sokolowski is also happy
to be among the early adopters. “We
are ready to take this step as soon as
possible. The service life of our products in the field is six to ten years.
The sooner that we can employ the
improved engineering software, the
longer we can provide support.” For
Sokolowski, it is very important to up
to date in the use of the latest technologies, as he understands that this
can sometimes require an effort. “In
this early phase of e!COCKPIT, we
can play an especially intense role,
thus setting standards and trends.”
Sokolowski had an immediate suggestion, stating that “We have not
found a perfect solution for the issue
of version control.” Archiving different
versions of a project, being able to
roll back to earlier versions – this
has been a common practice for a
long time in software development.
Sokolowski would also like something similar for quality assurance in
e!COCKPIT, as a plug-in for example.
He emphasizes, “This could also
significantly reduce effort in the field.
Once versioning works this easily,
that is, when it is no longer discipline
based, it is guaranteed to work.”
Together with Bestle, he continues
to focus on the successful long-term
partnership, in which WAGO expands
its product range with MatriX in mind.
There is no doubt that WAGO will
handle this request with the highest
priority and implement it as soon as
possible. After all, the automation
specialist listens very closely to early
adopters.
TEXT JÜRGEN PFEIFER
AND CHRISTIAN MÜHLEGGER | WAGO
PHOTO STEPHAN GÖRLICH | VOR-ORT-FOTO.DE,
NORDSON MATRIX
9
Idnu4.sytr0
Although Industry 4.0 has dominated the specialist media for years,
its presence in the mainstream has received a mixed reception.
However, it is not really that difficult…
It is clear that hardly anything is clear: While some people do not really know where to start,
others have been implementing Industry 4.0 technology in their production facilities for a
long time. This issue calls for vision because Industry 4.0 is not very tangible and is sometimes difficult to understand. Nevertheless, the present and future benefits are undeniable –
for businesses and consumers alike.
©Boggy/Fotolia.com
In communist East Germany, one car manufacturer was primarily known for assessing lengthy
delivery times for cars despite an extremely
limited list of options. Nowadays customers are
more demanding – and far less patient. There
is no question that it has not been easy to
combine to tremendously different economic
systems. However, Trabant’s example shows
how consumer behavior has altered after a few
decades of technological progress and social
change. When searching for small or even
large consumer projects, there are few who are
limited to regional, or even national markets and
borders. The purchase process begins and ends
on the internet.
12
E-commerce instead of the mall
An additional trend has followed globalization:
individualization. Tailor-made clothing is a part of it
just as much as a terrace house, breakfast cereal,
or a cell phone selected according to your own
preferences. In every case, the customer is able
to select from a number of options offered to him
or her. This is nice, but it is far from being the end
of the story. It is far more exciting when individualization can go one step farther: What should I do
when I want my new car painted in a custom hue
that is not offered in any brochure? What if the
treatment time for my arthritis could be noticeably
reduced by medicines customized to me?
The increasing desire for individualization impacts
consumer and investment goods of the most varied
types in the same way. Not surprisingly, these trends
represent an enormous challenge to industry, since
personalized products cannot be easily scheduled for
production like their mass-produced counterparts are.
Product life cycles are reduced further and further by
increasingly specific customer needs, and in return,
the need for speed and flexibility in production is
increasing.
Modular automation technology creates transparency into the processes, performance, and
quality of a company’s manufacturing. It forms
the technological foundation for comprehensive
data transparency, for example, from a manufacturing execution system.
Data transparency up to the upstream supplier
BMW is already accepting customer requests for
specific modifications. It has individualized car manu-
13
COVER STORY | IDNU4.SYTR0
German companies will invest
40 billion
euros
annually in Industry 4.0 through 2020.
80%
of businesses will digitize their value added
chains in the coming years.
18% of the efficiency increase by
2020
will be attributable to Industry 4.0.
90%
of companies believe that by 2020, the ability
to analyze data will be a deciding factor for
their business model.
German companies generate
30 billion
euros
annular through digitalized products and
services.
facturing to craft custom interiors and exteriors.
As long as no security or legal requirements or
typical brand attributes are adversely impacted,
every customer can explore the role of designers
and engineers and sample an almost infinite
variety of configurations. In order for production
companies like BMW to address the demands for
higher individuality, a company’s own processes
must be designed transparently, and this must extend to their manufacturing partner’s production
and supply chains. For example, in order to offer
unique exterior colors, the production department
requires data transparency up to the upstream
supplier of the paints. Instead of large orders,
small quantities are purchased, which are intended
for only one car.
This type of comprehensive access to data
outside of one’s own company has an additional
effect in that delivery times can be more precisely estimated. In an online retailer like Amazon has
comprehensive information about warehouse inventories, production capacities, and production
times, then their customers also know exactly
when their package will arrive. In addition, deliveries are also accelerated, because couriers and
logistics contractors can source the product and
send it at exactly the right time using the just-intime supply chain strategy. Interim warehousing,
even if it is already for short periods, can be
further reduced.
Customer-specific projections and production
are also a reality at WAGO today. Order processing and management of manufacturing and
logistic processes is carried out automatically.
Customers, regardless of where they are located, can use their web browsers to access the
systems in Minden with online tools like smartDESIGNER. This allows for a projection of DINrails with terminals, interface, and automation
components, which can be directly forwarded to
WAGO. As a direct reaction to this, a connected
and consistently digitized process operation is
implemented, during which the order is enriched
with important product and process data, and the
manufacturing location and completion data are
determined. This enables the machine and equipment manufacturer to optimize its engineering
and production, and simultaneously eliminates
the expense required for the individual ordering
and assembly of parts.
All data is found in “Industry 4.0 – the
fourth industrial revolution”, a study by
Strategy& and PwC.
14
Every component learns to speak
Complete transparency and consistency in data
communication is the essential component of
today’s Industry 4.0 concept. All components
participating in the value creation process,
including the final product, must do more than
just speak; they must master the ability to
converse between and with each other. Essentially, this means every participant, asset, and
process, from obtaining raw materials through
production and consumption to subsequent
recycling. The basic through behind total
interconnectedness is founded on vertical integration with access to that extends deep into
the product and also in the horizontal direction
along the value creation chain.
Modular automation technology, especially technology with an open system concept, can be employed
to obtain greater transparency into the processes,
performance, and quality of a company’s manufacturing. It forms the technological base for data
access further down to the field level, to the sensors
on the production systems. High-performing controllers process the recorded data at decentralized
points and then forward the processed data, for
example, to the cloud or to a manufacturing execution system, which reduces the load on higher-level
controllers and process systems.
PFC SPEAKS OPC UA
Industry 4.0 with firmware 06: With the current firmware version,
the PFC100 and PFC200 do more than just communicate via OPC UA.
New firmware, new functions: The performance
of the WAGO PFC100 and PFC200 controllers
continues to grow, this time due to updated device
firmware 06. The exchange of machine data is now
possible according to communication protocol
OPC UA, which reflects a substantial innovation.
Application variables, like the counter, are provided via the server integrated in the controller
with the aid of the e!COCKPIT engineering tool.
The OPC UA client, for example, a SCADA system,
accesses these variables for the data released to
it. WAGO is a member of the OPC Foundation and
strives for continuous development of Industry
4.0-compliant communication in its controllers.
OPC UA is anchored in the ZWEI reference architecture model RAMI 4.0 as a communication
standard.
The secure networking of devices is also of
considerable importance within the context of
Industry 4.0. An individual configuration interface
is provided on all PFC devices using Firmware 06
to configure OpenVPN, IPsec, and the firewall.
These considerably facilitates use. New libraries
for the e!COCKPIT development environment
are available, in addition to an update of the
Linux kernel (3.18.13) and an update of
e!RUNTIME (CODESYS 3.5.6.0).
Also new: the PFC100 and PFC200
controllers can communicate via OPC
UA with the current firmware version
06.
15
TECHNOLOGIES | INTEGRATING MACHINES VIA MTCONNECT
INTEGRATING MACHINES
VIA MTCONNECT
Implemented according to individual projects: WAGO’s PFC controllers
communicate machine data via MTConnect.
In Germany, OPC UA is the predominant means
of integrating machines, whereas in North America, the preference is for MTConnect within the
context of Industry 4.0. The protocol enables
unidirectional communication between devices
and superordinate command levels, for example,
within a manufacturing execution system. Data
transmission thereby follows an adapter-agent
principle: the adapter reads analog or digital data
from the machine or system via corresponding I/O
modules and transmits it in a proprietary way to the
agent, which conveys it to the control center via
MTConnect.
In the project-specific technical implementation that
WAGO uses, the CODESYS development environment – either WAGO-I/O-PRO running CODESYS
2 or e!COCKPIT running CODESYS 3 – and the
real-time-capable Linux® operating system of the
PFC controllers, play a decisive role. The MTConnect source code is freely available for Linux®, so
the agent function can be implemented directly
within the operating system. The communication
between agent and adapter is, however, realized as
a function block in CODESYS in a so-called “pipe
delimited text” format. Configuration is carried out
conveniently via the web-based management of the
WAGO controllers.
Using the security options is easier with the
updated firmware version 06: in addition, an
individual configuration interface is provided on
all PFC devices using Firmware 06 to configure
OpenVPN, IPsec, and the firewall. The MTConnect queries to the agent can also be transmitted in encrypted format via HTTPS.
Client
ETHERNET
Agent
with integrated adapter
Agent
Agent
In the project-specific variant,
WAGO has implemented the
MTConnect agent function directly in the Linux® operating
system of the PFC controller,
and the MTConnect adapter
function directly in CODESYS.
16
Designing versatile production systems
To satisfy the demands for individuality and to
address the associated small quantities, the very
structure of production must be changed; this
is in addition to requirements for transferring
data into and outside of production. The greatest
challenges are volatile production quantities,
which are increasingly difficult to predict. Moreover, a product alternative is always available for
the consumer due to globalization, so product
life cycles must become shorter. For these reasons, it is immensely important for businesses
to bring new products to the market as quickly
as possible. However, it is becoming increasingly
more difficult to satisfy these demands in a
cost-efficient manner using current production
facilities.
This is why production facilities based on modular
machines and systems capable of future change
are required. Admittedly, concepts that reflect
these modular notions and meet the technical
requirements are required to implement these
programs. The new DIMA automation architecture
approximately describes this type of methodology
for modular production systems. The concept, introduced by WAGO in late 2014, is useful for quickly
adapting production modules to higher-level
manufacturing computers. DIMA thus enables the
uncomplicated and accelerated conversion of production facilities without requiring reprogramming
of the primary processing computer. In this way,
DIMA solves a core challenge of Industry 4.0.
In order to satisfy demands
for individuality and the
associated small quantities,
production facilities based
on modular machines and
systems capable of future
change are required. With
DIMA, WAGO has introduced
a suitable concept.
Investments with success
Whether it’s a car, laptop, or one-off perfume, no
one today waits for the delivery of their order as
long as people waited for a Trabant in the sixties and
seventies. This forces industry to invest significantly
towards this goal. According to a study* by Strategy&
and PwC, German businesses will invest 40 billion euros annually through 2020 in new structures for converting their production facilities using aspects of
Industry 4.0. In the coming five years, around 80% of
the horizontal and vertical value-added chain will be
digitalized, and thus offer communicative transparency. The result is already visible today: production
and resource efficiencies have already noticeably
increased due to aspects of Industry 4.0.
* You can read the complete
study at www.strategyand.
pwc.com/media/file/Industrie-4-0.pdf
TEXT ULRICH HEMPEN AND STEFAN KEGGENHOFF | WAGO
PHOTO FOTOLIA, WAGO
17
»AT FIRST, EVERYTHING IS COMPLETELY
CONFUSING«
Greater individuality, speed, economic value – according to Linus Schleupner, Professor in Strategic
Management at the Cologne University of Applied Sciences, consumers, like businesses, could
soon take advantage of Industry 4.0. However, all players have to follow the rules of the game.
Prof. Schleupner, everyone is talking about
Industry 4.0. But what has it done for me?
Schleupner: At first, everything is very confusing.
Industry 4.0 refers to global digitalization and
networking, beginning in the production phase.
However, keywords like ‘batch size 1’ or ‘individualization of products’ have not yet become
reality. However, in the next ten years or so, the
implementation could be completed. The first
tendrils of digitalization are already affecting us;
for example, insurers use our data to understand
our behavioral patterns and to use them in calculating their premiums. Another example would
affect people who wear glasses. They will soon
be able to have information projected onto their
lenses. The new smart glasses for the Galaxy
phone from Samsung already provide a taste of
this. The display produces digital images which
the user sees through a dual lens system. The
glasses provide of feeling of immersion in a completely new world.
That sounds either superfluous or frightening.
Is there anything else?
Schleupner: The vision is that Industry 4.0 will
make life easier and better. End users expect
individualized solutions: Industry 4.0 facilitates
them. Soon I will be able to design my sport
shoes online according to my own color preferences. However, it’s not just about luxury items.
Digitalization will help us to save food and pro-
18
vide it to people, who previously had no access
to it. Businesses have been producing globally
for a long time; however, intelligent networking
of their production lines is still very much in its
infancy. Industry 4.0 will be able to stem both
overproduction and food shortages when we find
algorithms that enable optimal distribution and
resource investment into all areas through global
value added chains.
Will products by more expensive due to Industry 4.0? Will mass production stop?
Schleupner: You should consider instead that
products will resemble their value more closely.
The effects of scaling will no longer result from
the current methods of increases in quantity,
but through the ability to produce intelligently.
Smart productions processes bring savings
because fewer resources are wasted due to
targeted production. Businesses naturally benefit from digitalization because it enables real
increases in efficiency during production. And
not only there. Let’s use a retailer as an example. Thanks to digitalization, our retailer can
precisely record our purchasing behavior and
thus optimize the goods for sale. The result is a
range tailored to customer preferences and thus
less waste. Production companies also benefit
from the customer information provided by the
retailers, because it allows them to optimize the
products that they offer.
Prof. Dr.-Ing. Linus Schleupner
studied electrical engineering
and business management at the
Cologne University of Applied
Sciences, and information and
communication technology in
the distance learning program
at the University in Hagen. He
has lectured as professor for
market-oriented corporate
management at the Cologne
UAS since October 2014.
He is co-author of the book,
“Industry 4.0 in the international context – core concepts,
results, trends”, published by
VDE publishing house.
»If we abide
by certain rules and adopt
the right measures,
we can all benefit from it.«
20
But doesn’t Industry 4.0 lead to massive stress
on the value-added chain? Customers want
individualized products, and they want them
now. Won’t manufacturers in turn demand a
high level of flexibility from their suppliers?
will have to accommodate this; however, they
may also choose not to follow certain trends. This
means that companies should build up their core
competencies. This will be easier due to digitalization and increased information.
Schleupner: I really don’t think so. Granted, the
supplier has to react more quickly. On the other
hand, customers will also have to accept that their
desires cannot be satisfied all the time. Things
are no different today: if you order a car, you
can combine certain colors and features, but not
all of them. Thus, in the future, a company will
not have to fulfill 100% of a customer’s desires,
rather 80% will probably suffice. From my point
of view, things will tend to average out. Suppliers
That sounds easy, but it is often medium-sized
companies that lack the expertise and financial
strength to become drivers of digitalization.
How can they be convinced?
Schleupner: This is where we are, indeed, coming
slowly off the starting blocks. Medium-sized companies do not have the resources to continuously
follow the topic, and it is difficult for them to recruit the necessary people. They have technicians
data, then I should be able to enforce that decision. However, we, as users, also have to be more
responsible in the way we handle our data. We
simply click agree with regard to cookies or terms
and conditions, and are then astonished by targeted advertising. We have to pay more attention in
this case.
Shouldn’t the law makers hurry up and pass
suitable data protection guidelines? Industry
4.0 is already here.
and engineers, but they don’t yet have any engineers trained in Industry 4.0 who they can rely on.
The Industry 4.0 platform, which was launched
by the Federal Government and is supposed to
enable the relevant participants to exchange
information, has not had any noticeable effect. At
the moment, it would appear that medium-sized
companies are cut off from essential information
and are stranded between the ivory towers of the
universities and the visions of technicians. This
is why we urgently need a platform that provides
access to Industry 4.0 to medium-sized companies. Without access to advice, the uncertainty
will remain, and when people have doubts, they
do not invest in change.
If businesses themselves are so unsure about
digitalization, how secure is my data with
them?
Schleupner: That’s a difficult question. We have
to acknowledge that we leave a digital trail
behind, and that we cannot always control what
happens with our information. There will be no
magic bullet protecting us from misuse. The
problem, however, can be contained. Legislatures
have already ensured that our personal data trail
cannot be evaluated in its entirety. However, internet users should also receive greater flexibility
and more options for opting out. If I don’t want
Facebook or Google to have access to certain
Schleupner: They should at least adapt the
current Data Protection Act to present needs. In
principle, it is well structured and requires companies to have data protection officers, who are
responsible for data security from a legal, informal, and technical point of view. However, when
we consider the sheer speed of the digitalization
process and the advancements in systems in all
areas, many criteria are either already obsolete or
have not yet been introduced. Consider the digital
factory or the digital house, in which the electrical
supply is controlled through automation. This is
happening now, which is why we need guidelines
as quickly as possible.
What if we forego the revolution and choose
evolution instead.
Schleupner: That will hardly be possible, as
digitalization cannot be slowed down, let along
stopped. Look at the services and products
offered on the internet: current generations have
to accept this path because certain things can’t
function any other way. This means that we have
to rise to the challenges posed by digitalization.
This doesn’t imply dramatics. In my opinion,
there are more opportunities than risks. If we
abide by certain rules and adopt the right measures, we can all benefit from it.
Professor Schleupner, thank you very much for
sharing your insights.
21
Ruch Novaplast records his production data in real time
using MPDV HYDRA and WAGO automation technology.
INTEGRATED MES
FOR GREATER PRODUCTIVITY
AND EFFICIENCY
Almost nothing runs today without electricity. Plastics processor Ruch
Novaplast has demonstrated that electricity can do more than just run the
machines; it can optimize manufacturing using an integrated manufacturing
execution system (MES).
The fog has begun to dissipate for
Mathias Schmälze, Comptroller
at Ruch Novaplast and the man
responsible for the introduction of
the HYDRA manufacturing execution
system from MPDV. The recording
of real-time data in manufacturing
has enabled calculation of key data,
such as OEE (overall equipment
effectiveness) and ensures greater
transparency and efficiency at the
production facilities in Germany
and in the Czech Republic. Ruch
Novaplast, a mid-sized plastics com-
22
pany, has produced molded parts
from EPS and EPP particle foams
since 1960; with its 180 employees,
it is one of the market leaders in this
sector in Europe.
Range of functions in the
integrated MES solution
The basic manufacturing process
is simple: particle foam granulate
is blown into the hollow cavity of a
closed tool using compressed air
and injector fillers. Hot water steam
flows across the steam chambers
and the tool to weld the raw material.
The beads expand and fuse at their
surfaces to form a homogeneous
foamed part. This is followed by
additional steps for stabilizing the
molded part until the finished part is
ultimately demolded, using ejection,
compressed air, or handling systems.
The HYDRA MES supports Ruch
Novaplast along the entire value
added chain: the incoming raw material is inspected and provided with
Production of molded parts of
all types at Ruch Novaplast.
a unique batch number in receiving.
The data generated here is available
during later process steps due to the
central production database. Order
planning is carried out in the ERP
system, which is linked to the MES via
a bidirectional interface. Using this
interface, the orders are downloaded,
while data recorded on the shop
floor is reported back in compressed
format. The operators use MES module functions, operating data, and
machine data for this purpose.
Like all suppliers to the automotive
industry, Ruch Novaplast is obligated
to document the complete manufacturing process, including the material
batches, machines, and tools used.
The tracking & tracing module in
the MES supports them in this. An
automated inspection is also useful:
it carries out inspections during
production and files the results from
the linked scale system in the MES.
Faulty parts are immediately dealt
with in a standardized way by the integrated complaint management. To
minimize the number of IT systems
on the shop floor, the parts manufacturer also uses HYDRA functions for
staff work time logging, time management, and access control.
When asked about his experiences
over the last few years, Schmälze
explains, “Using the MES is as natural
and indispensable for our colleagues
in manufacturing as the ERP system
is for management. The HYDRA MES
offers all the functions we need in
order to monitor and control our pro-
23
»The transparency
gained this way
increases employee
awareness about
their own work
and provides extra
motivation.«
Everything from just one system: data entry at the shop floor
terminal and information for everyone on the large flat screens
around the production hall.
duction. The key productivity data
are automatically generated by the
MES. In just the first 24 months after
introducing the MES, we were able to
significantly improve our OEE index.
This corresponds to a savings potential in the high six-figure euro range.
The investment in HYDRA has already
paid for itself several times over.”
Easily capture data in the field
Extending the existing MES installation by adding the energy
management module was a quantum
leap forward. Ruch Novaplast
requires both compressed air and
steam during production. While
compressed air is generated using a
compressor, as in most factories, the
steam results from water heated by
a gas burner. The amount of steam
and compressed consumed varies
according to the shape of the item to
be manufactured. In total, the energy
costs account for up to 15% of total
expenditures. Using numerous evaluations and operating figures, the
Automation technology from WAGO records the energy consumption at every machine and forwards it to the HYDRA MES
from MPDV.
HYDRA energy management system
provides the conditions for recording
and optimizing energy consumption.
The less time that the employees on
the shop floor have to spend learning
a new software solution, the more
willing they are to accept it. Therefore,
a system that records energy consumption in a highly automated fashion is recommended. Ruch Novaplast
met these challenges using WAGO
automation technology. To record
the use of steam in kilograms and
compressed air in cubic meters, an
I/O module with signal inputs is linked
to an ETHERNET controller at each
machine. In addition, gas consumed
during steam generation and electrical
consumption to generate compressed
air are recorded centrally. To simplify
things, all parameters are also assessed as euro amounts.
The use of steam and compressed air
varies depending on the item; however,
a consistent level develops over several consecutive cycles, which enables
detection of a fault in the system when
excess consumption occurs. Thus, for
example, a leaky valve or a crack in a
line in not just visually detected, but it
is also recorded in the MES so that service can occur in a timely fashion.
Compare, optimize, visualize
HYDRA uses evaluations to correlate
specific energy consumption with
the machines, the job registered to
the machine, and the machine status. Conclusions can then be drawn
as to which machine manufactures
an item most efficiently and when
a machine should be switched off
instead. The energy consumption
during stand-by operation held
significant savings potential. Evaluations of this type are, however, only
possible because Ruch Novaplast
records their energy consumption
in the integrated MES. Connections
between the data obtained, which
enable a subsequent visualization
and evaluation, are already produced
during the recording process.
25
Ruch Novaplast: the facility in Oberkirch in the
Black Forest is one of the largest producers of
molded parts in the sector.
As in other sectors, key performance
indicators simplify the overview of
complex connections. For example,
»The HYDRA MES
offers all the functions we
need in order to monitor
and control our production.«
the energy consumption per part
provides information about the efficiency of a manufacturing step, provided that there is a target setting.
The consumption per machine hour
or in stand-by operations allows
machines to be compared. However,
even meaningful operating data are
useless if no one knows them. This is
why Ruch Novaplast visualizes them
26
for context directly at the machine
on the shop floor terminal, and also
on large flat screens placed around
the production hall where they are
easily visible. The transparency
gained this way increases employee
awareness about their own work and
provides extra motivation. Ultimately,
it comes down to improving a little
bit every day, recognizing errors a
little earlier, and introducing counter
measures a little faster.
Electrical energy – more than
just a consumable resource
In the end, electrical energy is not
merely a necessity for a business
like Ruch Novaplast, or even just
a very expensive consumable
resource, it is a means to an end for
optimizing production processes.
As Schmälze confirms, “HYDRA
energy management has brought a
fresh outlook to our production halls
and enables us to continue offering
function solutions with added value
to our customers. In addition, we
are not only increasing our savings
potentials, we are expanding our environmental management abilities.”
Therefore, energy management
now has three relevant optimization
aspects: economical, ecological, and
organizational.
TEXT MARKUS DIESNER | MPDV MIKROLAB
FOTO RUCH NOVAPLAST
TECHNOLOGY | SEND THE RIGHT SIGNALS: TOPJOB® S SENSOR/ACTUATOR TERMINAL BLOCKS
SEND THE RIGHT SIGNALS:
TOPJOB® S SENSOR/ACTUATOR TERMINAL BLOCKS
WAGO is adding new sensor/actuator terminal blocks to the TOPJOB® S line of rail-mounted terminal
blocks. Machine control systems can now be wired safely and in a space-saving manner thanks to low
space requirements per sensor connection and integrated Push-in CAGE CLAMP® technology.
WAGO’s new 2000 Series TOPJOB® S Sensor/
Actuator Terminal Blocks allow several sensors to
be packed into the smallest possible space using
only 3.5 mm per sensor. These terminal blocks are
perfectly adapted to the conductor cross sections
(0.34 to 0.75 mm²) commonly used for sensors
and actuators. They are also ideally suited for both
small terminal boxes, within a system’s decentralized periphery, and for centralized switch cabinet
installation.
Doubled Current Bar for Continuous
Commoning
Quickly Label Terminal Block Functions
via Marking Strips
WAGO’s new TOPJOB® S Sensor/Actuator Terminal Blocks can be marked quickly and clearly
using multi-line marking strips that don’t cover the
jumper slot. Optionally, WMB markers can also be
used. The terminal blocks have two marker slots:
one on the top and one on the side. This makes
the marking easy to read, regardless of the angle
in which the terminal strip was installed.
Key Features at a Glance
WAGO’s TOPJOB® S Sensor/Actuator Terminal
Blocks feature several potential levels and one
signal level. The potential levels are for power supply and, if necessary, sensor grounding; the signal
level enables switching signal transmission from
sensors to actuators.
The colored conductor entries of WAGO’s new
terminal blocks simplify clamping point assignment. Furthermore, indicator LEDs, jumpers and
markers are always visible – even when wired. This
streamlined design provides a quick wiring overview and simplifies circuit control layout.
A special feature of the new sensor/actuator
terminal blocks is the 7 mm wide terminal block
housing that accommodates two connection
points. On the potential levels, the housing also
accommodates a doubled current bar with two
connected clamping units, and thus two connected jumper slots. This allows the positive and
negative potentials to be endlessly expanded
using standard push-in type jumper bars with even
pole numbers – there is no pole number limitation.
The use of color-coded, push-in type jumper bars
simplifies potential assignment. On the signal
level, the two current bars for signal transmission
are electrically isolated from each other, resulting
in spacing of just 3.5 mm per sensor.
WAGO’s new 2000 Series TOPJOB® S Sensor/
Actuator Terminal Blocks will be available in May
2016 in several different versions.
WAGO’s new TOPJOB® S Sensor/Actuator Terminal Blocks allow several sensors to be
packed into the smallest possible space using only 3.5 mm per sensor. Furthermore, a
special design allows the positive and negative potentials to be commoned without pole
number limitation.
27
28
©Cybrain/Fotolia.com
©Sebastian Kaulitzki/Fotolia.com
DIGITAL DOWN TO
THE FINGERTIPS
Ordering and production processes are being increasingly digitized.
An integrated system provides transparency from the order to
the finished product.
PLM, ERP, MES – In the industries of the future,
software technologies like these will be increasingly used to digitize and automate ordering and
production processes. No business headed for
smart factory technology can afford to be without
them. The people at WAGO, based in Minden, have
realized this, too. As early as 2000, the company
began to comprehensively digitize its value added
chain. Today, the manufacturer of electrical interconnections and automation technology not only
saves on paper, it also decides when and where orders will be processed in a fully automated manner.
This is especially relevant, not only when shipping
in-stock items, but also when producing custom
products for customers.
When systems manufacturer Andreas Muth designs
the circuits for his packaging machines, he relies
on smartDESIGNER from WAGO. He can start
configuring them immediately after launching the
software on the WAGO website or from EPLAN. Muth
finds that the most current product information is
always available online including: specific items, data
sheets and product pictures, as well as downloads
of CAE and CAD data. With just a few mouse clicks,
the designer can put transfer terminal strips and I/O
modules, when he can then assemble later in a way
that is affordable, space-saving, and functional. An
automated plausibility check guarantees that the
design of Muth’s support rails is error-free. He then
exports his design, including the parts lists, photos
of the products used, and a 3D model, and sends the
order to WAGO.
29
Smart Design for the Smart
1
2
Production has not yet started. I have to equip
the switch cabinet quickly with rail-mounted
terminal blocks and I/O modules. I can do that
with smartDESIGNER!
CAE data
START CAE DESIGN
Before the modular production line
can produce anything, the switch
cabinet has to be connected.
MODULAR MACHINE
4
5
Here are the CAD data
for reuse in the construction schedule.
I just placed the order!
That was fast!
Thanks!
GREAT!
Already COMPLETELY
ASSEMBLED and MARKED!
A SHORT TIME LATER
Additionally, all data sets can be
downloaded and saved, conveniently and easily, from smartDESIGNER in order to document
the design or to reuse the data
for mechanical designing.
30
Factory
WOW! My design in 3D!
3
OF COURSE!
The WAGO data are already in
the CAE system.
ORDERING
START smartDESIGNER
For example, the EPLAN database already contains
all WAGO data sets for electrical designs. The best
feature: configuration can start immediately after
launching the software on the WAGO website or
from EPLAN.
* https://configurator.wago.com
CLICK
+ Configure your system directly online without installing it
+ Precise designs in 3D
+ Item data is always current
+ Configurator automatically checks for errors
6
After the switch cabinet is equipped, production can start. The injection molding
machine is currently spitting out the designed modules.
IT
WORKS!
Fast design process
Automatic testing
Free WAGO software
A FEW HOURS LATER
POP
POP
MODULAR MACHINE
31
©C
yb
n
rai
/Fo
i
tol
om
a.c
Transparency instead of a black box
From Muth’s point of view, once his order arrives
at WAGO, it enters a so-called black box. However,
where his view is obscured, the people at Minden
can see everything clearly. Production processes
are completely software-based and transparent
from start to finish, at least, for every employee
who needs access to the ordering and production
processes.
Computer-based systems were introduced early
into the product development process at WAGO;
they are used in manufacturing and for product data
management because the rapidly increasing product
range, the competitive market, and the company’s
global presence place huge demands on the development and production departments. In addition, the
company’s high quality standards have led to a large
vertical manufacturing range and the need to develop and produce their own equipment and tools. The
Teamcenter product lifecycle management system
(PLM) was introduced when the company entered
the new century. It enabled integral control and
management of product data and processes across
the entire product lifecycle. “We made optimizing the
complete process chain a priority – from development to manufacturing,” explains Michael Burmester,
who heads the process and product data management division at WAGO. He adds, “It was important
32
to us to lay a good foundation so that the production
processes could be designed to be viable into the
future. Even back then, it was clear that we would
have to digitize all of our processes and information
in order to do this.”
Digital, fast, and flexible
Once WAGO has received Muth’s order, the data is
sent to the PLM system for processing. This adds
relevant information to the configured product – for
example, ETIM and eCl@ss classification data, and
information on the packaging type and unit. This
step also determines when and where Muth’s order
will be processed. This decision is based no only on
the requested delivery date, but also, naturally, on
logistical data, like delivery routes, shipping times,
and the capacities of the production equipment at
the facility in question. As Muth needs the finished
terminal strips at his factory in Berlin within a week,
they will be manufactured by WAGO in Sondershausen in Thuringia.
The order is subsequently further processed by
the enterprise resource planning system (ERP).
WAGO uses SAP for this purpose. This generates
a manufacturing order and triggers the production
and logistics processes. SAP and the manufacturing
execution system (MES) enable control and monitoring of production in real time. All relevant operating
Save valuable engineering
time: read external data, configure rail-mounted terminal
blocks, automatically check,
document and mark them all
– with just one software tool.
and machine data as well as staffing information is
collected for this purpose, and any additional data
that would have a real-time impact on the manufacturing process, are also input.
WAGO’s completely digitized process chain and
the real-time capabilities of the system allow for
subsequent changes to an order until just prior to
the point of manufacture. This is a great advantage
for Muth, the system designer, who realizes the
following day that he selected the wrong internal system supply module. To correct this, he simply revises
his configuration in smartDESIGNER and re-submits
the data to WAGO.
Well positioned for the future
WAGO has continuously expanded and improved its
ordering and production processes since launching
them in 2000. One milestone on the road to the
smart factory was the introduction of SAP in 2015 at
all German production sites. “We are really pleased
with what we have achieved thus far,” states Burmester, and adds, “we have already come close to
our vision. However, there are still a number of small
tweaks that we have to make to streamline the processes and become digital down to our fingertips.”
On the international level, WAGO is poised to take
another big step; they are about to switch to SAP as
their global ERP system.
»We are really pleaded with what we have
achieved thus far.
However, there are still a number of
small tweaks that we have to make to
streamline the processes and become
digital down to our fingertips.«
Even with the cutting edge, automated processing system, Muth’s carrier rails are, in the end, a
mixture of machine production and traditional,
manual labor. While the terminal blocks and I/O
modules are manufactured on modern production lines, the individual assembly of the components and application of the marking remains
complex due to the number of possible configuration options. Therefore, these steps are deliberately carried out manually. Yet even this manufacturing area has eliminated paper dockets.
Instead, the staff always see the most up-to-date
version of the order on their workstation screens,
so that know how to populate the specific carrier
rail. Incidentally, the 3D graphic that they see now
is the same one that Muth modeled while working
in smartDESIGNER earlier.
TEXT SIMONE BRINKMANN-TEWES AND JULIA OCKENGA | WAGO
PHOTO FOTOLIA, WAGO
33
»INDUSTRY 4.0
IS NO MAINSTREAM
SOLUTION«
A salesman through and through: Jürgen Schäfer
has been with WAGO for more than 16 years; for
the last 14, he has been responsible for General
Sales, and a year and a half ago, he achieved a
management position. Now 55, the industrial
engineer has shaped the company in major ways:
through his unconditional focus on the customer,
34
the expansion of the global sales network, and
the establishment of an effective sales division
for automation solutions. In an interview, Schäfer
discusses the dimensions, aspects, and color
associations related to Industry 4.0, and reveals
why companies should not be afraid of possible
risks.
Mr. Schäfer, many people see Industry 4.0 as
a black box, while others view it as a red flag.
Where do you place the topic in the color
spectrum?
In my opinion, Industry 4.0 has many facets.
Actually, I should say that Industry 4.0 has many
dimensions. This gives all industry stakeholders interested in Industry 4.0 an extremely broad range of
design options. The trick is to break down the wide
variety of possibilities into comprehensible, manageable components. However, it’s important not to
lose sight of the overall context during this analysis
step. This is why we view Industry 4.0 as having
so many layers and colors. So, instead of being one
single color, it is a bright bouquet of flowers, and
we try to define the right color combination from
the spectrum as both providers and users.
So it’s a bright bouquet full of opportunities
and risks. Which one is more likely, in your
opinion?
Actually, I see a lot of opportunities in Industry
4.0, and hardly any risks. The reason is simple,
really. There is simply no alternative because we
can’t stop technology from advancing. If anything,
the question we should be asking is about how
fast we are moving, not “Will we or won’t we.”
The necessary conclusion is that, when processing designs and technologies, the focus lies on
where the most opportunities are. The challenge
is to control the bandwidth of all possible effects
and consider them from the start.
Industry 4.0 has broader implications beyond
technological effects ...
... It naturally also affects people and the way
they work for companies. It is precisely from this
social perspective that it is seen as a threat, and
this may actually be the greatest danger of all. If
Industry 4.0 is really here to stay, we will need
corresponding qualification measurement systems. Naturally, employees will have to deal with
reorientation; they will have to adopt changes and
learn to work in new ways. But this has always
been the case: progress and change have always
been a part of business. The important factor
here is to recognize if from the outset, include it
in your calculations, get your staff on board, and
then the opportunities will far exceed the risks.
Are your customers similarly optimistic? Or
has the mood swung in the opposite direction?
To exaggerate a bit, we get four different opinions
from three customers. This is most likely due
to the complex and multifaceted nature of the
material. What I’m saying is that every company
has to consider and then decide for itself, which
Industry 4.0 potentials it can leverage. This is
quite individual and depends on the role of the
customers, on its revenues, its products, and
processes, among others. So there is no single
answer to this question. What is certain is that
Industry 4.0 is not a simple mainstream solution,
but instead a subject that requires decidedly
differentiated consideration.
That may be the reason why WAGO has
pressed for clear positioning in Industry 4.0.
Why the change of heart?
WAGO is definitely not one of those firms that follows every hyped up trend, screaming, “We can do
that, too.” We also aren’t the type to immediately
adopt every idea, even superficially, that comes
down the pike. Instead, we consider what the consequences will be for us and how we can contribute in a meaningful way. For example, I can clearly
remember when the first articles were published
about plug-in connectors that were aligned with
Industry 4.0. We looked at them and asked: does
this make sense? is this what we want? or is this
a desperate move to jump on a bandwagon that
has already past? Different trends have developed
since then and there are naturally also connection
technology solutions within the concept of Industry 4.0. The important point for us, however, was to
find a plausible foundation that would enable us to
contribute in a relevant way.
If WAGO is not offering the Industry 4.0 plug-in
connector, what are they offering?
We are moving on different levels here. On the
one hand, we are creating a virtual link in the
horizontal value added chain that allows our
customers to completely design their products
35
online, in the comfort of their own offices and
using their own web browsers. Our customers’
interaction with WAGO thus begins on their own
computers. On the other hand, WAGO automation
technology also forms the basis for introducing
the necessary transparency into the manufacturing process in the vertical direction by providing
open-ended systems and standardized interfaces.
Our automation technology acts both as a data
collector for management execution systems, and
also plays the role of basic facilitator for Industry
4.0 architecture. After all, Industry 4.0 cannot
function without intelligent automation technology. Another consideration is DIMA, a concept
we have developed that – to put it simply – allows
production plants to be set up in modules, which
can then be easily linked. This type of modularity
is a basic requirement for flexible, easily convertible production systems.
We have thus defined four approaches in which
WAGO has established a position in the context
of Industry 4.0: online designing, manufacturing
execution systems, automation facilitation, and
DIMA.
Comprehensive engineering design, horizontal
and vertical integration – which of the Industry
4.0 works in progress is causing the most difficulty on the market?
That is hard for us to asses, because we have
not settled into all Industry 4.0 areas with our
products. When I consider the value added chain
and wonder what role WAGO plays there, it
occurs to me that for someone who manufactures
something, this role is just a tiny cog, a minor
element in the development from raw materials
to a finished product. So we can never have more
than a very selective view of a sub-segment of a
whole, for example, we focus on one machine, or
one process.
Which once again demonstrates its basic complexity.
Exactly. And that is why it is interesting or us to
adopt the role of Industry 4.0 user, i.e., to put on
our manufacturer’s hat. What does Industry 4.0
mean for WAGO? As a manufacturing firm, we
naturally integrate Industry 4.0 considerations
and perspectives into our production environment
and into our own value added chain. The thorough integration of our processes is a particularly
36
»The reason is simple, really.
There is simply no alternative
because we can’t stop
technology from advancing.«
important to us. In this case, we are focusing on
the whole. Our Industry 4.0 processes and those
of our customers naturally overlap, for example,
when our customers launch our production
process with their online projects. We derive
tangible, operationally-proven Industry 4.0 contributions for our customers from our own designs,
experiences, and solutions.
Some say that Industry 4.0 will not be implemented for a number of years, while others are
already thinking in terms of the fifth generation. How do you assess the current situation?
Industry 4.0 is analog, not digital, so there is not
completely clear On or Off. Instead, it is an iterative process of technological progress. As such,
certain components of Industry 4.0 existed as far
back as five years ago, and there are others that
will not be implemented for another five years. In
my opinion, therefore, there are no clearly defined
starting and end points. At the moment, we are
at a point in the evolution that cannot be clearly
defined.
Mr. Schäfer, thank you for the conversation.
37
Entire system modules can
be exchanged in less than
three minutes: In cooperation
with the Dresden University
of Technology and the
Helmut-Schmidt University
in Hamburg, WAGO has
implemented a prototype
to demonstrate the basic
practicality of DIMA.
DIMA: Plant engineering on the fly
EN ROUTE TO VERSATILE
PRODUCTION
With DIMA, WAGO presents a new, manufacturer-independent solution for automating modular systems
which significantly reduces plant engineering and facilitates future system modifications. DIMA links
modularity and Industry 4.0 approaches into a winning value added process over the entire lifecycle of a
facility, from design up to recycling.
At the Annual General Meeting of NAMUR in
November 2014, WAGO presented the Industry
4.0-leading DIMA (Decentralized Intelligence for
Modular Applications) concept. Developed in
collaboration with Germany’s Dresden University
of Technology and Helmut Schmidt University of
Hamburg, DIMA is an approach for the automation
of modular process applications to significantly
shorten an application’s integration engineering.
Beyond upfront engineering, DIMA simplifies
future application upgrades. MTP (Module Type
Package) is the centerpiece of the DIMA ap-
38
proach: a new way of defining the description for
process technology application modules. In this
module description model, information is stored
that is necessary for user-independent integration
of an application module into the process control
system of an application.
In the spring of 2015, the NAMUR interest group
commissioned the development of a standardized
integration solution based on WAGO’s DIMA concept. The goal was to specify the MTP presented
by WAGO in the areas of process management,
A “module type package”
is imported using a graphic
user interface into the Zenon
process control system.
visualization, alarm management and diagnostics.
WAGO, and their university partners, had implemented the DIMA concept as a prototype in parallel with this. The system demonstrator enabled
WAGO to prove that the method was not only
practical, but that the exchange of entire system
modules was possible in as little as three minutes.
DIMA networks
DIMA thus provides an enormous contribution to
versatile production – and is in greater demand
than ever in an environment of increasingly
dynamic market change. The desire for individualized goods leads to an ever increasing variety –
up to and including the production of customized
products. The global availability of good also
cause fluctuations in incoming orders and displacements in regional markets. Business should
therefore have production processes which are
universal, mobile, scalable, modular, and compatible. This, in turn, requires processes which can
be adapted to quickly changing needs, and which
deliver transparent, relevant production data,
for example, those that provide information on
delivery capacity.
This need to record, evaluate, store, and provide
operating data and lifecycle information assumes
that the facility is modular, that each system
modules is equipped with its own intelligence,
40
and that they system modules are able to communicate with each other and with the process
control system. Only then can the control level
penetrate to every parameter of the system, and
only then can the collected data be definitively
assigned and analyzed, without being lost in an
information overload. The automation components used for this must have a standardized
interface, such as the MTP interface provided
by DIMA. Only then can all components be networked and integrated across the entire lifecycle
on the path to Industry 4.0.
DIMA changes the value adding processes
Due to this type of modularity – of the physical
plant as well as the automation system – the information technology communication changes within
the system, the plant engineering, and the system
operation, and also the added value linked to this.
A modular system can thus consist of a number of
different modules in various configurations over
the lifecycle of the system. A module can, in turn,
be used in several different systems. The lifecycle
of the system thus differs substantially from that
of a system module. By using DIMA, this situation
can be exploited to increase yields across the
entire value added chain of a production system,
which affects the module manufacturers, the system designers, and the operators.
Key data at a glance: each application module has its own e!DISPLAY
control panel, so that the modules
can be independently parameterized and diagnosed.
Advantages for module manufacturers
and system operators
DIMA divides the process of plant engineering
into two phases: the design of the module and
the integration of the module into a system.
Designing the individual system modules is
the responsibility of the module manufacturer.
The manufacturer has expert knowledge of the
module and the corresponding processes within
the module. DIMA provides a neutral interface
between the system and the module so that
module manufacturers can protect their proprietary information, and system operators can
maintain confidentiality about their production
procedures. Due to DIMA, the module manufacturer gains economic independence from the
system designer. Therefore, the manufacturer
is no longer compelled to develop customized
or project-based system modules, and can
turn instead to series product manufacturing,
which leads to independence from the system
designer, both in terms of finances and time.
This allows the module manufacturer to develop
a sound, “standardized” module, subject it to
extensive testing, improve it over the long term,
and provide it on short notice. This is far more
economical than having to provide customized
system modules that match the proprietary
environment of the system designer.
41
Each module of the prototype
DIMA system is equipped
with a PFC200, which controls all processes within the
module, including: communication to the field devices,
monitoring locks, and calculating control circuits.
Using DIMA, the module manufacturer can deliver
modules for the system using the just in time
approach. This reduces capital commitment on
the part of the system designer. No proprietary
expertise is required to carry out maintenance on
individual modules, which lead to a further reduction in costs. The system designer is also exposed
to fewer risks, as the warranty and expertise for
the module are now tied to the manufacturer.
The integration of individual modules into a
system is carried out by the system engineer or
operator. Due to DIMA, the system designer can
assemble the best modules available from different manufacturers without having to consider
their process technology characteristics. By using
DIMA, the user interface maintains a uniform look
and feel, even though the system modules were
produced and delivered by different suppliers.
DIMA functions using a reference to operating
libraries for this purpose.
During system engineering, the system designer
merely loads the MTP into the process control
system and physically links the module to the
system backbone. The process control system
of the complete system and the module can then
42
communicate directly with one another using
plug-and-produce. This engineering procedure
requires less than three minutes per module; in
contrast to the days, weeks, or months that were
necessary for designing a system without DIMA.
Once the system is set up, the production line can
be quickly converted or retrofitted using DIMA by
exchanging individual modules or by integrating
them multiple times into the overall system architecture as part of a “numbering up” approach.
This allows system operators to flexibly react to
changing market requirements.
Finally, individual system modules can be retired
with no impact on the overall system because they
are recycled at the module level. The exchange
can be appropriately contracted with the module
manufacturers and carried out by their experts.
In this context, leasing modules becomes a real
possibility.
Horizontal and vertical integration
according to Industry 4.0
The business processes of module manufacturers and system operators are horizontally
linked at a much greater level with DIMA than
»Due to DIMA, the system
designer can assemble the best
modules available from
different manufacturers without
having to consider their process
technology characteristics.«
previously, because the selection and use of
modules requires close collaboration. Within
this context, the system operator merely defines
a process technical functionality, while the
module manufacturer offers a service bundle
included availability, service, and maintenance
of this functionality, which is encapsulated with
each module, for example, on the basis of a
service level agreement. System operators can
outsource the complexity to the suppliers and
can thus focus on their core competencies. This
new form of collaboration benefits the module
manufacturers, in that they have continuous
access to the operating and usage information
about their modules, and can then consistently
improve the modules on the basis of this data.
The vertical integration of information technology
into the value added chain of module manufacturers,
system operators, and system designers is carried
out using “module type packages”, which are the
digital description of the system modules. This is
automatically generated by the module manufacturer’s software tool, and then automatically imported
into the system operator’s process control system
in order to identify the modules and their services to
the process control system.
DIMA – Essential Industry 4.0 component
Regardless of how Industry 4.0 is implemented
in the future, it will require the use of “cyberphysical systems”, which are characterized
by the linking of components, e.g. a machine,
controller, or sensor, with a corresponding
virtual representative. The virtual representative
reproduces the physical component, manages
and controls it as a resource on a virtual market
place, and thus enables interaction between
different “cyber-physical systems”.
When projected onto DIMA, the autonomous
system module represents the physical object,
while the “module type package” provides a path
for implementing the virtual representative in the
information network. The MTP already represents
the functions of the system modules and manages them in the architecture of the overall system.
It is thus a facilitator for Industry 4.0 and DIMA,
and therefore functions as a first actual module in
solving the challenges posed by Industry 4.0.
TEXT THOMAS HOLM AND EVA BANHOLZER | WAGO
PHOTO WAGO
43
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WAGOdirect Industry, April 2016
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