Embracing Industrie
This document introduces KUKA's engagement and innovations in Industrie 4.0, emphasizing connectivity and digital transformation in industrial settings.
Hello Industrie 4.0 �we connect you
The digital transformation is now. Let us connect you. The added value of integrated, globally interconnected value chains is acknowledged throughout the world. Companies are opening up to the digital transformation in order to successfully compete in the markets of the future. As a thought leader and trailblazer for Industrie 4.0, 阀阀 supplies intelligent solutions for maximizing the 昀氀exibility of the entire process chain – from consultancy and conceptual design through to the complete implementation of individual requirements. With the expertise to help you step successfully into the future world of production, 阀阀 is transforming the here and now.
Dr. Till Reuter Chief Executive O昀昀icer 阀阀 Aktiengesellschaft Hello Industrie 4.0�we connect you
» It is time for us to help business to fully exploit the potential of Industrie 4.0.« 04�05
A collaborative approach is required in order to leverage the entire potential of Industrie 4.0. One thing is for sure: Industrie 4.0 has arrived in industry worldwide. Transformation towards a globally networked and integrated economy is taking place at all levels. Almost half the German companies from the manufacturing sector are already employing Industrie 4.0 applications. Most of them are focusing on optimizing individual processes from an economic perspective and increasing output. Every second company is investing in digitization to make production more 昀氀exible. Another 20 percent of the companies are planning to implement digitization. The desire is for this to be achieved quickly and in accordance with individual customer requirements. The primary focus here is on the proven success factors of the economy: greater e昀昀iciency, greater productivity and higher speed. Some people still regard this development anxiously. However, the opportunities for digital transformation stem from us challenging traditional thinking. The digital world is not waiting for us. It is developing at a breathtaking pace – and anyone who wants to be on the winning side must clearly take a leading role. The integrated networking of production is an important and correct milestone on this road. But we must also make sure that our supply chains and our business models keep pace with this new era. Moreover, it is important that Industrie 4.0 does not remain the sole preserve of large corporations. Every company should have the opportunity to participate in this technological revolution. No matter Hello Industrie 4.0�we connect you
what sector they come from or how big they are. Industrie 4.0 solutions must therefore be tailored in a wide range of di昀昀erent dimensions and for varying goals and target groups. It is ultimately not about convincing industry of an abstract model of digital networking but rather about technology and tools that enable companies to generate quite speci昀椀c added value in their competitive environment. In this connection, we also consider the abstract search for “the one right Industrie 4.0 platform” to be of little value. 阀阀 has very deliberately opted for a di昀昀erent approach. An approach that focuses on the goal-driven analysis of our customers’ requirements. An integrative concept in which suppliers, partners and specialists for external expertise are actively incorporated in the digital strategy of our customers. 阀阀’s key added value lies in the capability of seamlessly uniting expertise from the digital and real worlds. The digital transformation necessitates a radical change in thinking on the part of all those involved. The world in which everything is interconnected will become not just more interactive and 昀氀exible but also more complex. Any action in the value chain will trigger a reaction at another point. And that will also permanently change the way we work and how we set about 昀椀nding solutions. For this reason, 阀阀 is setting a clear course by infusing the principal thematic areas of Industrie 4.0 with its own expertise. 06�07
�Customer Focus �Consulting �Digital Domains �Intelligent Machines �Progressivity �Technical Expertise Hello Industrie 4.0�we connect you
Our “Intelligent Machines” and “Digital Domains” make for a seamless connection between the real and digital worlds. And this can be scaled to any conceivable degree in the value chain between the shop 昀氀oor and the cloud. One speci昀椀c example might be the intelligent networking and 昀氀exibilization of individual production processes. It may also be a matter of connecting complex production systems and integrating them into an existing IT infrastructure or of implementing entirely new business models with comprehensive interfacing to the cloud, Big Data or predictive analytics tools. We know from countless projects that the full potential of Industrie 4.0 does not unfold until solution concepts holistically encompass the issues facing companies with a high level of competence in all customer-speci昀椀c topic clusters. We have pooled specialists from a broad range of 昀椀elds in a dynamic, interdisciplinary Industrie 4.0 accelerator unit. Our aim is to reveal to our customers at the outset of the planning phase all added value that they stand to gain from digitization. And then to accompany them with our project expertise. In this way, companies also obtain direct access to 阀阀’s global ecosystem. A network of highly quali昀椀ed partners, integrators and suppliers from all areas of the digitized value chain. 08�09
Global. Dynamic. Fast-growing. KUKA addresses the global growth markets with holistic solutions.
�Electronics �Healthcare �Aerospace �Energy �Metal industry �Automotive �E-Commerce / Retail �Consumer goods
Automotive On the data superhighway to the future The automotive industry is undergoing an epochal change. In the age of e-mobility, intelligent vehicles and completely new mobility services, the industry is facing far-reaching changes – from development through to production and logistics. So, the time is ripe for decisive technical and entrepreneurial challenges to be faced. This is the only way that existing competitive advantages can be secured, or new ones established. As a world market leader, we have already been the strategic partner for all important manufacturers for decades. This is because even today, 阀阀 delivers scalable concepts and solutions for the smart factory of tomorrow. In the automotive industry, new market that is capable of coping with the fast- conditions are leading to structural paced change of time. Together with our changes of wide-reaching import. customers, we are already implementing The focus is on the need for vehicles agile, intelligent production solutions that customers all over the world 昀椀nd today, which will turn these dynamic and exciting, at the same time keeping pace reactive worlds of production into reality. with the growing trends and technical development in an extremely 昀氀exible way. Irrespective of whether we are Seamless integration into the existing talking about new powertrain concepts, ecosystem intelligent driver assist systems or totally innovative mobility solutions in the These solutions are providing a key im- �Now is the time to address the decisive individual case – what is crucial when petus for future-oriented production technical and entrepreneurial challenges it comes to sales success is that the concepts. As a driver and pioneer in in order to develop and establish new time between the initial concept and Industrie 4.0 and the Internet of Things, competitive advantages, expand existing market launch must be kept short, and we are developing hardware and soft- ones and maintain these in the long term. sustainably so. This is a requirement ware solutions that achieve maximum that can only be met in the long term variability, availability and greater with intelligently networked value chains. throughput. Intelligent components for Consequently, the market is demanding a fully digitized value chain can be 昀氀exible, robot-supported automation integrated seamlessly into existing ecosystems. Hello Industrie 4.0�we connect you
Maximum availability for greater throughput, plannable ROI Customer-speci昀椀c human-robot collaboration for the smart factory Agile, networked Industrie 4.0 solutions towards a fully digitized value chain 12�13
Greater e昀昀ectiveness and a lower error rate Optimal complement to and relief for skilled workers Development of holistic HRC solutions for customer- speci昀椀c applications Hello Industrie 4.0�we connect you
Metal industry In the crucible of the data revolution Trains pass safely through the transport systems of global cities. Modern agricultural machinery ensures that billions of people can be fed, while highly developed construction machinery forms the foundation of today’s infrastructure. The metal industry makes life as we know it possible. For our customers in these central processing sectors, it is important to manufacture large and complex machines that are processed to perfection down to the smallest detail. This is a challenge that robotic automation solutions were made for. And we supply intelligent, networked concepts for this. Our many years of experience mean we that work with pin-point accuracy are highly familiar with the challenging today. Innovative software technologies tasks faced by the metal industry. such as 阀阀.ArcTech, 阀阀.SeamTech We are familiar with the demanding or ROBOTstar System Software allow fast production conditions and have already con昀椀guration and evaluation of welds worked together with customers from and data. In this way, even during pro- the metal industry to implement numer- duction we ensure that the ultimate ous solutions enabling sustainable, quality check is carried out, and we are e昀昀icient production. With our broad already supplying the technologies to portfolio of industrial robots adapted to link this to the cloud today. the exacting requirements of the metal industry of tomorrow, we supply the Companies in the metal industry operate �Robot-based automation concepts from entire spectrum from robots right up to in a 昀椀ercely competitive environment. 阀阀 enable smooth, safe collaboration cells and complete systems. Many of our International competitors are creating between humans and machines. robot models are produced in special price pressure. An increasing shortage versions, such as for particularly hot or of skilled labor and demographic change wet environments. are leading to personnel bottlenecks. As a result, new robot-based automation In spite of the di昀昀icult production condi- solutions are needed to optimally tions and extreme time pressure, the support skilled workers in the workplace greatest possible freedom from defects and provide supplementary assistance is required. The customer wants to be at decisive points – even in cramped able to rely on the product 100%. 阀阀 or hazardous environments. We stand combines all of this expertise within beside our customers in developing the company in order to already supply tailormade and safe human-robot collab- groundbreaking Industrie 4.0 solutions oration solutions together. 1414�15�15
Energy On the side of the energy visionaries Automation partner for key technologies in e-mobility and renewable energy The latest battery manufacturing processes Climate change is one of the greatest global challenges. Notwithstanding whether the subject is e-mobility or the use of renewable energies – the mass availability of high- performance energy storage systems is the central element in the success of the shift in energy policy. As a key technology for the future, the energy market o昀昀ers gigantic growth and innovation potential, although it is also crucial for complex, technological and economical challenges to be resolved in the entire production process. Against this backdrop, we are acting as partners to manu- facturers and investors as well as other technology providers to jointly implement future-oriented automation concepts which will make the shift in energy policy a successful model in both ecological and commercial terms. Comprehensive documentation of production processes Hello Industrie 4.0�we connect you
Energy storage systems form the critical that are hard to connect, as well as in assembly, ensure comprehensive docu- interface between energy production and the development of intelligent, 昀氀exible mentation of the production processes. energy consumption. At present, the automation concepts that permit eco- This is an important factor in ensuring solutions available for this are still cost nomical mass production – even for safe operation of high-energy storage intensive to produce and subject to signi- a large number of variants and shapes. systems during everyday use. 昀椀cant technological change. Researchers are looking at a blend of in-situ energy storage systems, pumped storage systems A partner for individual and decentralized battery back-ups as automation solutions an appropriate solution for storing energy from solar installations. At the same As part of this, we combine the know- �Intelligent high-tech solutions from time, work is being carried out world- ledge and experience of various technical 阀阀 thus make an important wide on compact battery concepts with disciplines to search for and implement contribution towards making the energy high energy density in the e-mobility holistic solutions – whether for the transition a global success story. sector – which is decisive for the overall materials used, the module design, the concept of the shift in energy policy. connecting technology or 昀椀nal production. In this environment, 阀阀 is involved At the same time, our intelligent and with innovative joining techniques for networked automation processes, for materials such as copper and aluminum example in battery production and 16�17
Electronics Technical innovation setting the pace “Who is interested in yesterday’s technical highlights today?” This sentence sums up the electronics sector. The market is hungry for innovations and the immediate availability of the latest products. The Internet of Things will increase the pressure on companies many times over through a multitude of new product ideas. As a result, changes will form part of everyday survival training. Enormously shortened lifecycles accompanied by tough price wars present manufacturers with a herculean task, however: they will have to produce and deliver massive quantities of premium products within an extremely short time and with maximum reliability. 阀阀 knows where the crunch points of the industry are and is working with customers to develop automation solutions that are extremely 昀氀exible. More intensive media usage, individu- Thought leader and trailblazer As a thought leader and trailblazer for alization and fast product lifecycles lead for Industrie 4.0 Industrie 4.0, we enable our customers to greater performance and lower costs. to respond directly to market changes To enable smart products to be produced In our TechCenters, we are working and to match the requirements of quickly and successfully for this fast- globally on the latest technologies and consumers at any time. This is true, for paced world, 阀阀 is, among other future scenarios. As a result, we are example, with our KR 3 AGILUS – deve- things, developing “ready2�use” packages always capable of developing modular, loped specially for assembly and handling together with its customers speci昀椀cally robot-based automation solutions and of small parts. This lightweight robot for this area. These are innovative concepts together with the customer – has the agility and dynamism to accom- automation solutions that deliver developments that are increasingly plish an extremely wide range of tasks numerous commercial bene昀椀ts to the able to accomplish the speci昀椀c tasks in small, compact and cost-e昀昀ective customer. The precon昀椀gured robot right out of the box. Together with our production cells. The result: top perfor- packages simplify installation and partners and customers, we develop mance, maximum output and extreme commissioning, increase output, and concepts for automation and application precision with very short cycle times. make production more modular. solutions, carry out feasibility studies, work on demos and on-site product tests. �Our 昀氀exible automation solutions such as “ready2�use” enable our partners to meet the ever-changing requirements of the market optimally at all times. Hello Industrie 4.0�we connect you
The product cycle of electronics Consistent quality thanks products in the industry to high precision is less than 6 months Flexible automation solutions and High availability and thus ideal smart manufacturing for 24/7 production Forecast sales revenues in the smart entertainment segment in Germany from 2014 to 2020 500 442.02 400 375.33 288.72 os 300 eur 196.82 200 124.65 100 81.52 s in millions of 58.73 enue v e R 0 2014 2015s 2016p 2017p 2018p 2019p 2020p Source: Statista (Digital Market Outlook) *All forecast values are marked © Statista 2015 with a p. 18�19
Rapid integration of new technologies and materials Perfect documentation of all process steps Industrie 4.0-ready from the design phase Hello Industrie 4.0�we connect you
Aerospace Perfection at new heights Without question, aircraft are the backbone of our global, mobile society. The requirement pro昀椀le for a modern aircraft is the equivalent of “squaring the circle”: designed for a decades-long product lifecycle, it must be capable of adapting chameleon-like to the fast-paced changes of technological developments, ecological requirements, customer expectations and safety standards. Implementing this variability in production on a competitive basis creates extremely demanding requirements in terms of the 昀氀exibility, e昀昀iciency and transparency of all processes in the value chain. This is a challenge that can only be met economically in the long term by the comprehensive intelligent networking of all components over the entire lifecycle of an aircraft. Today, a modern transport aircraft down to the levels of subassembly, parts are relevant to production. Our joint comprises about 昀椀ve million individual or raw material suppliers will lead to work together with manufacturers starts components that are produced by remarkable improvements in knowledge right from the design and development thousands of supply companies and input about potential weak points in an phase so as to optimally design compo- in the production sequence at precisely aircraft. nents and assemblies for automation the right time. Thus, the aviation indus- over the entire production process. try generates products with a simply mind-boggling range of variants. At pres- From virtual simulation through to As a result, we make a decisive contri- ent, there are more than 1,500 airlines automated production bution to creating future-oriented that order speci昀椀cally adapted versions. products in the aviation industry. At the Adding the suppliers, sub-suppliers and Even though it may sound like science same time, we provide for a humane maintenance providers to this results in 昀椀ction – with digitized production working environment and support an extremely multi-faceted supply chain. processes, we will not only be able to companies in coping with the lack of This closely intermeshed sequence of produce with greater 昀氀exibility and skilled workers. working steps means the quality of e昀昀iciency, but also detect problems long every individual part and every process before they have e昀昀ects on the practical can determine the reliability and safety functional capability of an aircraft. of the produced aircraft. Within this complex sequence, knowledge of details, As a result, the path for the aviation no matter how small, is an important industry towards the uncompromising commodity. Today, it is a standard digitization of all processes is pre-or- feature of the aircraft industry for all dained. The development and design of components that are essential for aircraft has long since been veri昀椀ed �Our automation solutions with a wide operation, such as the jet engines and supported by virtual simulations in variety of specialized end e昀昀ectors and control systems, to be monitored almost every area. This applies to physi- can be seamlessly integrated into the by sensors. The increasing, digitized cal/technical properties just as much networked production lines of the networking of production processes as to the de昀椀nition of all processes that aviation industry. 2020�21�21
Flexible and scalable systems provide dependable responses to market volatility Data analysis tools and arti昀椀cial intelligence provide trans- parency and provide predictive calculations of supply chain events Intelligent and mobile robotics is revolutionizing intralogistics Hello Industrie 4.0�we connect you
E-Commerce / Retail Smart automation of unpredictable processes Electronic commerce is setting new standards and challenging brick-and- mortar retailers. Fast delivery, maximum variety of products and absolute price transparency combined with seamless logistics are convincing advantages for online consumers. Smooth logistics necessitates digiti- zation of the supply chain and the implementation of automation solutions in warehouses. Business models in e-commerce demand highly 昀氀exible supply chains with a holistic approach that permits the seamless integration of retail, 昀椀nance and logistics processes into one transparent entity. Against this backdrop, solutions in e-commerce have to meet many demands simultaneously. These range from the interests of exclusively online retailers through to classic retail outlets and the distribution service provider or brand-name manufacturer. Mobile end devices, internet research Digitization is creating on the goods-to-person principle. Human- with a purchase option and exchange via intelligent intralogistics machine collaborations such as the social media have now become part and AutoPiQ order picking technology from parcel of the buying process. As a result, In the future ever more powerful fore- Swisslog are capable of opening up areas it is almost certain that the commercial casting tools will be available to the to automation that were previously an signi昀椀cance of e-commerce will increase retail sector that will be capable of exclusively manual domain. Particularly further in coming years. Even conservative predicting consumer behavior more forward-looking: even today Swisslog can estimates for the year 2020 predict on- accurately and will allow targeted adver- already seamlessly depict the transitions line sales in excess of 4 trillion US dollars. tising. Smart purchasing may require between the requirements in brick-and- The boundaries between online shopping only two clicks by the consumer, but it mortar retailing and e-commerce in and brick-and-mortar retailers are is based on extremely complex and hybrid systems. They are capable of both becoming more blurred and entering heterogeneous logistics networks – order picking for pallets and single-item into a long-term symbiosis. Whereas we characterized by a large number of data shipments from a warehouse. are currently still busy mapping the interfaces and an interchange between intermeshing of internal and external automated and manual activities, for logistics processes in real time, the trend example in the storage and picking of is moving towards predictive analytics goods. The latest automation technol- of the available mass of data. This means ogies from Swisslog are already provi- that we are using digital information ding the e-commerce and retail sectors �Industrie 4.0 solutions from 阀阀 intelligently enough to allow the next with networked software and robot- optimize the throughput of goods, consumer action to be predicted based logistics concepts that precisely minimize downtime and ensure both accurately. serve the nerve centers of the logistics transparency and high-speed responses chain – for instance, technologies based throughout the entire supply chain. 22�23
Consumer goods Customization requires production expertise. In actual fact, there is no such thing as “the” consumer goods market. Rather, there are dozens of them. No other market segment is as fragmented as the consumer goods segment. And scarcely any other market is facing such diverse challenges in coping with the future. However, they all have one thing in common: modern production concepts and logistics should support them in making their o昀昀erings even more 昀氀exible and suitable for customers, through to complete customization of mass-market products. Any company that intends to survive in this challenging sector in the long term really has no other choice: only consistently digitized processes and highly 昀氀exible, automated production and logistic systems are capable of e昀昀iciently bringing these customer-driven business models to a position of economic success. Solutions from 阀阀 take account of the entire value chain from manufacture through to packaging, logistics, sales and distribution. A look at the large shopping malls and Using digitization to mass-produce supermarkets leaves no room for doubt: unique products there is a massive variety of products in the consumer goods industry. In view of the enormous dynamics in the Foodstu昀昀s, clothing, personal hygiene consumer goods market, every future products, cleaning products – in each strategy for automation solutions must segment, the o昀昀ering is characterized by be capable of responding to new con- a large number of categories, sub- ditions e昀昀iciently and functionally. Here, categories, packaging sizes and types 阀阀 o昀昀ers digital concepts and techno- as well as di昀昀erent brands. In addition logies for agile control of integrated to the variety of items available, volatile value chains. Intelligent analysis pro- parameters in the business models are cedures use real-time data to precisely key factors in the success of the con- predict customer behavior and market sumer goods industry – for example, movements. It is not an exaggeration to global and regional trends, political say: any company that does not digitize in昀氀uences, new technological drivers, will be punished by the market. 阀阀 social taste and changes in values o昀昀ers customers a tailored solution for through to economic crises and natural each sector – in the area of Industrie 4.0 events. At the same time, it is apparent automation, this is achieved through that the number of product variants is the networking of the shop 昀氀oor with �Digital production permits business continuing to increase because of the data analytics tools, which enable us models that are individually adapted trend towards increasingly customized to better gauge the end users and their to customers and optimum control of products. responses. the entire process sequence. Hello Industrie 4.0�we connect you
Digitization and automation open up decisive potential for efficiency gains and cost reductions Transparency of all production and supply processes Establishment of planning and analysis instruments 24�25
Intelligent robots support treatments Optimization of material 昀氀ows and safe medication management Development of future technology for a digitized healthcare system Hello Industrie 4.0�we connect you
Healthcare Digital intelligence for perfect patient care Healthcare systems are coming under pressure from two sides: 昀椀rst, there is an obligation to keep costs down for running clinics, patient care and medication. Secondly, the quality demands for healthcare are rising in parallel to the aging of society. However, quite apart from the 昀椀nancial challenges and necessary e昀昀iciency increases in processes, what is ultimately important is the ongoing treatment success and patient welfare. With this goal in mind, we are creating modern automation systems for our customers which, for example, permit material 昀氀ow, 100 % traceability and safe medication management during and after hospital stays. The challenge of allowing everyone to With networked systems towards enjoy the best possible healthcare into proactive healthcare old age is reaching its limits in existing systems. This is because the costs of Beyond this, a comprehensive view of healthcare systems are rising at the same healthcare provision is crucial. This is why time as demand on them is growing due 阀阀 is working together with custom- to the ever aging population. In China, ers to produce integrated solutions Japan and Germany, the number of beginning with prevention and contin- people over the age of 67 will increase by uing to hospital stays, rehabilitation almost 50% in the coming decades. As and the sector of ambient assisted living. age increases, so does the intensity of Health data continuously gathered care – and thus the cost for healthcare from people by means of sensors as well systems. as the networking of medical databases will make it possible to establish a pro- �The healthcare system will bene昀椀t A whole series of technologies and active healthcare system. This means, from automation solutions in the concepts from the environment of for example, that routine examinations form of increased, logistical e昀昀iciency Industrie 4.0 can make a decisive and hospital stays for observation can and treatment methods improved contribution to breaking the “ever more be avoided. by robotics. expensive” trend and reducing the load placed on our healthcare systems. This includes the use of robot-supported automation solutions as assistants during treatment and aftercare as well as digital process optimization and intelligent monitoring technologies. 26�27
Holistic. Intelligent. Interconnected. KUKA identifies three key areas that open the door to tomorrow’s production.
�Consulting �Digital Domains �Intelligent Machines
Dr. Christian Schlögel Chief Technology O昀昀icer 阀阀 Aktiengesellschaft Hello Industrie 4.0�we connect you
» Those who act quickly and with foresight will have a handle on the future.« 30�31
The digitized world is incredibly fast. At times, products that were all the rage their 昀椀nger on the pulse will succeed, Production and logistics at the center just yesterday are considered boring or and those who miss the boat will lose of the storm old-fashioned at the blink of an eye. For out. Hyperconnectivity will enable new gadgets this may be the case within days, forms of production, spur many new The trend towards personal or individu- for clothing it may be weeks, for a car business models such as the shared alized products is already clearly notice- perhaps months or years. And of course economy, and the data will allow us to able in many manufacturing sectors. we expect products that highlight our make clear predictions. No matter It is highly likely that the variants of particular style and status, not just o昀昀- whether we are talking about consumer industrially manufactured products will the-shelf products. It is no surprise that behavior or the failure of a component proliferate explosively in the coming years. we can con昀椀gure our cereal online, and in a machine. And quantities will remain constant or we expect this high level of personaliza- increase slightly at the same time. But it tion and customization in virtually every Prosumers, consumers with more pro- would be wrong to think that optimiz- aspect of our personal and professional fessional demands on the product or who ing production and logistics processes life. may even directly impact the added and making them more 昀氀exible will value of a product as co-designers, will su昀昀ice. In the course of digitization, all For how long do people deem products challenge manufacturing and logistics communication within the value chain or services exciting? At what point do we in a completely new way. Many analysts will be restructured. Customer contact, become ambivalent to them, bored or even go so far as to predict that, in communication channels, distribution even get annoyed by them? There are the end, the best business model will channels – everything will change. In probably no generalized answers to win, and not the best technology. Even order to remain successful and address these questions. But they reveal the factor though we do not entirely agree with all of these aspects, companies must that is key to sustainable economic this opinion, it certainly points out that, take a holistic look at the possibilities, success: empathy for the market, adapt- in essence, it is about bringing products opportunities and challenges of ability and speed in implementation. and services to market maturity as Industrie 4.0. When implemented In the coming years, it is estimated that quickly and simply as possible. Speed in properly, Industrie 4.0 is a tremendous about 50 billion devices and 4 billion all of its forms is the decisive argument opportunity. For example, it is entirely people will be networked. Even today it of our time. realistic to assume that the combination is clear that this provides the foundation of a fast time-to-customer and the high for numerous new services and products demand for personalization renders it that will dramatically change the world necessary to produce closer to the con- as we know it today. And just like in sumer, or even to include the consumer all previous revolutions, the fourth in the product design as a co-producer. industrial revolution will be a blessing Intelligent automation with reduced and a curse at the same time. Those with manual e昀昀ort presents an opportunity to reshore outsourced or relocated production. Hello Industrie 4.0�we connect you
Holistic. Intelligent. Interconnected. Programmed for dynamism – Focus 4.0 First, we started using networked and Industrie 4.0 and IoT taken a more 昀氀exible production in our own fac- step further 阀阀 recognized the importance of the tories and our own robot production. fourth industrial revolution many years Next, we recognized early on that our The digital revolution is here. The com- ago and has strategically aligned itself concept of approaching Industrie 4.0 in bination of Industrie 4.0 and the Internet systematically to these new challenges a holisitic manner can only be imple- of Things probably o昀昀ers the greatest and topics. As a result, it is of no sur- mented with proprietary expertise in edge opportunity for the economy to realign prise that 阀阀 is amongst the world’s computing, our own IT hubs and our for a stronger future. In our opinion, the leading companies in this future-oriented own cloud platforms. For this reason, we existing consultancy sector is not capa- segment as one of the drivers of moved quickly and decisively to enhance ble of addressing this complex issue Industrie 4.0. We 昀椀rmly believe that our OT (operation technology) portfolio holistically. Contradictory statements or digitization will sustainably and irrevo- with IT expertise. We call this new isolated viewpoints from the individual cably transform the global economy. overall competence of OT and IT simply disciplines reinforce the uncertainty in Even if the technological cycles shorten, “Digital Domains”. Hidden behind this companies and inhibit the investment this topic will be the decisive factor for humble name is a core competence for propensity necessary for Industrie 4.0. industry over the next decades. And seamless and integrated digital net- But the technical groundwork has long that has consequences for the direction working of industrial production environ- been established. Today, 阀阀 is imple- of our own business as well. The world ments. A marriage between the real (OT) menting complex Industrie 4.0 scenarios is fast-paced, and this is sure to only and digital (IT) worlds. This involves in virtually every industry and to vastly increase in the future. To be successful, basic knowledge that gives us a decisive di昀昀erent degrees. In our opinion, the it is important to adapt swiftly. That edge even when seamlessly integrating actual risk is that companies will miss applies both to our customers and to our OT systems in existing or third-party their window of opportunity for trans- 阀阀 itself. This is why we have been IT infrastructures. We are now making formation and that they will eventually making changes over the past years and this accumulated in-house expertise be outdone by more agile competitors. will continue to do so in the future. available to our customers within the 阀阀 manufacturing ecosystem. 阀阀 has therefore asked the question of how we can use our own knowledge and our advanced global ecosystem, which includes relationships with research institutions, specialists, industry experts and much more, to signi昀椀cantly facili- Forecast global sales revenues with networked devices tate access to Industrie 4.0 for our cus- by sector in 2020 tomers. To make it safer, more needs- 950 driven and above all easier. Our answer 1,000 is very simple – we o昀昀er our customers direct access to our network of exper- 800 tise. No matter whether you require validation for new digital business models, 600 532.2 seek an exchange of experience in your US dollars industry, are looking to consult with Big Data specialists or if you require 400 expertise for a speci昀椀c manufacturing or 208.9 logistics process – the 阀阀 ecosystem s in billions of 200 o昀昀ers competent answers to all your enue questions. v e R 0 Smart Smart Smart mobility electronics M2M* Source: University of Jyväskylä *M2M stands for “Machine to Machine” © St atista 2016 (excluding PCs, laptops and smartphones). 32�33
Demographic change Home assisted living Robofactoring n=1 Ergonomic work Desire for customization Customized production within industrial manufacturing Hello Industrie 4.0�we connect you
Intelligent machines Interoperable systems for tomorrow’s production Unimaginable only a few years ago, but this knowledge with processes and few years back. Wherever the journey already entirely normal today: devices of systems in an intelligent way. These are takes us – in the future too, intelligent all kinds – whether autonomous lawn- parameters that are required for suc- robots will form the sturdy backbone mowers, thermostats, lamps, cars or cess in the networked world of IoT and of industrial production. They will not simply kitchen appliances – nowadays, Industrie 4.0. At the same time, they only be tethered within cells as we knew almost everything is capable of contact- take on a range of di昀昀erent guises. We them in the past, but provided with new ing other gadgets or data sources via know them as 3D printers, CNC machines intelligence, apps that are simple to inte- the Internet. Now, it is time to make or indeed as robots – probably the grate and give them new capabilities industrial production more agile, more most generic and versatile machine that at a click, or cloud-based functions that intelligent and more e昀昀icient along the human beings have ever thought up. turn them into active players in the same lines. This is done by endowing 昀氀exible, autonomously operating smart machines with the ability to develop factory. In contrast to Isaac Asimov’s themselves in an evolutionary way in a The backbone of the fourth industrial visions, this is not science 昀椀ction, but diverse range of forms and con昀椀gurations. revolution – intelligent robots actual, progressive reality. Among other things, they possess the capability of communicating with other 阀阀 recognized the potential of net- systems via the cloud – with production, worked and open automation systems workpieces or other machines. back in the 1990s. For example, in 1998 we introduced the world’s 昀椀rst inter- Intelligent machines that support operable, web-capable industrial robot humans cleverly, powerfully and safely onto the market. Possibly, it was those during their everyday work are a reality. machines that provided the impulse for Not in the humanlike form as Isaac Asimov the evolution which we currently know forecast in the 1950s: this is where as Industrie 4.0, or the fourth industrial reality departs from 昀椀ction. Machines revolution. It is a fact that no robot that join, assemble, transport and so today has any future unless it is capable on do not have to look like people. For of being integrated into complex, net- all intents and purposes, they only have worked production systems on the basis to accomplish three things: they must of standardized mainstream technologies. carry out their task as e昀昀iciently as And robots are continuing to develop possible, be able to adapt to new frame- further. In a variety of forms and con昀椀- work conditions as quickly as possible gurations, they are conquering areas and, in the future, be capable of sharing which were still closed to them only a 34�35
Cobots in industry Your robot colleague shares the work. In 1978, the cult band Kraftwerk re- Human beings remain at the leased a legendary piece of music under center of production the visionary-sounding title “The Man- Machine”. Today, this vision has become The crucial point is to achieve open com- reality. With sensitive robot colleagues, munication and simple integration. “cobots” for short, KUKA is demonstra- This makes cobots virtuosos for modern, ting that human-robot collaboration can networked production and logistics which be implemented today. will link together automation solutions with services and databases within the Sensitive cobots have the sense of touch foreseeable future. However, a factory required for the cyber-physical world staffed by robots alone will remain an of tomorrow’s production, in which IoT illusion, even in the smart factory. People and Industrie 4.0 will replace familiar will remain the central focus. However, structures. With their integrated sensors, robots will make people’s jobs less they make it possible to automate deli- arduous, will support people and give cate assembly tasks in the first place – them entirely new capabilities. ranging from assembling automotive transmissions through to inserting rubber This means the workers and logistics plugs or handling flexible parts. If unex- experts will be able to carry out their pected contact is made, cobots for jobs even more efficiently, with greater example reduce their speed and thus concentration and, above all, more the kinetic energy to an extent that ergonomically. This aspect is becoming prevents injury. When people and increasingly important, especially in a robots can work safely together, many society that is aging to an ever increasing conventional safety precautions become extent – worldwide. An ever smaller superfluous. Additional costs that number of people in employment will would normally be required for safety have to generate the entire productive technology and protective fences can output for the social systems. It will be dispensed with. Workers and robots only be possible to meet this challenge can share the same workspace without by employing the available workforce any concerns. In this way, expensive feed in a much more productive way than in systems and production floor space can all previous generations. With cobots be saved. in different payload categories, KUKA already offers central, key technologies Without doubt, cobots will play a key for a wide variety of tasks involving role in Industrie 4.0 – not only directly cooperation between humans and as part of modern production, but as machines: collaborative robots, mobile data gatherers that can communicate assistance systems, autonomously all relevant information to IT systems in controlled vehicles and intelligent, real time if required. Information that digitized automation solutions which can be processed immediately and sent reduce the burden on humans in a back to production. Knowledge that can variety of ways. be used for optimizing production suc- cessively or autonomously. At present, no other component in the production process is capable of carrying out this supporting role as well as modern robotic systems. Hello Industrie 4.0�we connect you
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KMP omniMove Maneuvering huge components simple and safely on site: the KMP omniMove at the Airbus plant in Hamburg KMR QUANTEC KMP 1500 Intelligent robotics Maximum 昀氀exibility, right where it is unlimited mobility, needed: the mobile autonomous navigation: industrial robot the omnidirectional KMR QUANTEC stands mobile transport plat- for precision transport form KMP 1500 makes of even the heaviest for smart production components. environments. Hello Industrie 4.0�we connect you
Mobile robotics The path is the goal. Future production and logistics will have Maximum autonomy for in the most cramped conditions. This to expand like a spring. This means flexi- mobile robots and platforms means the logistics area can be reduced bility is called for, not only for accelerated by up to 50 %, allowing more space to manufacturing but also for customized KUKA Navigation Solution knows the be used for production. In addition, products. Guaranteeing this flexibility destination and the best way to get there. KMP omniMove vehicles effortlessly cope will require significantly greater mobility – This navigation solution responds spon- with loads of up to 100 metric tons. irrespective of whether the mobility taneously to obstacles and modifications, It could not be more mobile. concepts involved are episodic, periodic and coordinates all known vehicles in or permanent. For this reason, KUKA is the system. Fully in line with Industrie 4.0, laying the groundwork for this techno- its software ensures planning and logy – with platforms that move auto- implementation of orders in a coordi- nomously and intelligently to transport nated way – even in conjunction with items or process workpieces. Or with higher-level control systems. It registers platforms that find their own way if data from safety laser scanners and radar required, align themselves with work- sensors, and uses the SLAM method pieces with millimeter precision or (simultaneous localization and mapping) respond adaptively to changing conditions to create a detailed map of the sur- in demanding logistics and production roundings. By means of this map, the Infallible sense of orientation: sequences through autonomous behavior. platform can respond to changes in mobile automation solutions the surroundings, which are a matter from 阀阀 昀椀nd the way to their destination with unerring Our mobile automation solutions of course in a flexible logistics system. certainty even within highly provide the basis for the highly flexible It’s good to know that the software, complex production environments. production world of Industrie 4.0, in which is not dependent on a hardware With or without heavy loads. which rigid, assembly line concepts are platform, can be used for different kine- consigned to history, and the future matic systems. It enables any motion belongs to productivity spaces that principles to be handled – and of course can be continuously optimized. Even also holonomic vehicles with Mecanum complete production units can be wheels, such as the KMP omniMove. repositioned somewhere else on an ad hoc basis. This new type of mobility These vehicles offer unrestricted maneu- sounds like science fiction. But at KUKA, verability in every direction, including it is scientific fact. This means we are rotating the robot about its own axis. providing the blueprint for mobile auto- As a freely scalable modular system, it mation solutions with which every can be precisely adapted to the specific industrial company can gear up for the requirements in terms of size, length flexible, digitally networked world of and width. With its omnidirectional production. wheels, the vehicle can be used even 阀阀 昀氀exMOVER CarryPick Automated guided Designed to be modular vehicle for the and multifunctional, smart factory: CarryPick from Swisslog the 阀阀 昀氀exMOVER consists of mobile racks is the 昀氀exible helper and automated guided for all requirements, vehicles for goods-to- from the distribution person picking. of materials through to integration in complex assembly systems. 38�39
Humans and machines together Unlocking scope for flexibility Robots are establishing themselves in more and more 昀椀elds. According to the International Federation of Robotics (IFR), the number of industrial robots used worldwide will increase to about 2.6 million units by 2019. One of the driving factors is human-robot collabo- ration (HRC) made possible through innovative technology. 阀阀 is laying the groundwork for this with the LBR iiwa, the 昀椀rst industrially applicable, HRC- capable robot. Its sensitive sensors 阀阀 Navigation Solution permit seamless integration – without Intelligent orientation, any safety fence – and a division of Industry requirements occupy a central positioning, response. 阀阀 Navigation Solution labor between human and machine. role in the strategic orientation and knows the destination The human being controls and monitors de昀椀nition of these solution packages. and the best way to get production, the robot supplements the As a result, these packages have been there – every time. human’s capabilities and carries out developed jointly with customers and an extremely wide range of tasks as an specialists, and are tailor-made to the “Intelligent Industrial Work Assistent speci昀椀c tasks. (iiwa)”. The option of interacting with people, machines or workpieces ready2�use packages are combinations irrespective of location means that of 阀阀 software and hardware there is a practically unlimited range components which can be put into use of applications for this new generation immediately. In this way, the appropriate of mobile robotics. With its numerous package can be assembled by 阀阀 possible applications, the LBR iiwa is and the integrator to precisely match symbolic of the reality of Industrie 4.0. the customer’s automation experience. Added value through individual “ready2�use” solutions However, sometimes even maximum 昀氀exibility alone is not enough. Fast-paced branches of industry such as electronics or plastics require solutions and appli- cations that are ready for immediate use and easy to integrate. To meet the need for fast availability, 阀阀 has cooperated with some system partners to develop ready2�use solutions that can be im ple- 阀阀 昀氀exFELLOW mented by customers “out-of-the-box”. From manual to auto- mated in 10 minutes: the 阀阀 昀氀exFELLOW assists the operator 昀氀exibly and adaptably with a wide variety of tools that can be changed in a minute. Hello Industrie 4.0�we connect you
Safe and troublefree: 阀阀 HRC technologies make for relaxed interaction between humans and machines KMR iiwa An intelligent lightweight: the KMR iiwa combines the strengths of the sensitive lightweight robot LBR iiwa with a mobile, autonomously navigating platform. 40�41
KUKA Digital Domains Smart transformation to the digital world UI & Apps User Interface Cloud e Edg Shop 昀氀oor Hello Industrie 4.0�we connect you
KUKA exercises a major influence on a key aspect of Industrie 4.0 by converging the necessary competencies from the digital and real worlds of machinery and system engineering. Aside from its role as proactive driver of manufacturer and industry-independent standards, KUKA is particularly engaged in creating essen- User tial platforms as a link between real Interface production and the relevant digital structures. In doing so, we create the prerequisites for an open, comprehensive architecture and a structure that provides constant user access on any end device to the customer’s own production data. This structure will allow components and processes to be analyzed, managed and, if necessary, even reconfigured with virtually unlimited computing power – a platform that scales know-how and unlocks access to whole new markets and regions over the Internet. Today, KUKA can master the key challen- ges arising from the integration of exis- ting industrial automation systems into a smart and consistently networked production chain. KUKA lets customers focus on their core competencies because the platform technology is available for every component, in every sector and market, thanks to open standardized interfaces. 4242�43�43
阀阀 Digital Domains Technical concept Shop floor / edge A trend can be identified across all cloud These services are directly integrated providers in which typical cloud func- into compact and, more importantly, As a first mover, KUKA has developed tions, like event processing, are shifted securely embedded computer systems open, interoperable and modular to the edge to increase closeness to the in the production environment for architecture layers and platforms for process and enable a more direct and cross-cell and cross-component tomorrow’s smart factory that ensure faster reaction in real time. Ultimately availability. efficient convergence of traditional this will lead to increasing centralization automation engineering with cloud of control and regulation tasks in the For end consumers and thus cell and technologies. cloud, instead of distributing them to system operators, it is important that various automation devices in decentral- data accessibility to their processes is Accordingly, every data transfer begins ized locations. enabled through minimally invasive with a production component or pro- edge integration. KUKA therefore cess, whose control and sensor system The edge is thus the crucial layer for strongly advocates the standardization communicates with peripheral equip- connecting real “things” on the shop floor and openness of interfaces to allow all ment via specific protocols and bus to the virtually infinite computing and production “things” to communicate systems. The edge provides the commu- storage capacity in the cloud. They can with the cloud via the same edge. nication interface between the cell also be incorporated into the new digital To this end, KUKA sits on established network (operation technology, OT) and world of Industrie 4.0 via the integration committees and promotes OPC UA as a overarching IT (information technology) of edge gateways in existing “brownfield” standardized communication protocol. network. Data are already consolidated, production plants. By contrast, when compressed, and encrypted in the local planning new “greenfield” plants, the Deep dive: the company is also pushing edge hardware before being transferred edge permits completely new control ahead with TSN (Time Sensitive Net- to the cloud. architectures in which an edge with working) expansion for deterministic high computing and real-time powers real-time communication via OPC UA acts as the central cell controller. and AMQP (Advanced Message Queue Protocol) for OPC UA cloud communica- As the edge layer interacts between tion. And, of course, KUKA draws on its things and the cloud, components are many years’ experience in remote main- relieved of requirements placed on cloud tenance of products at the edge and has communication, such as security, comput- recently extended its expertise through ing power, memory requirements, etc., participation in the Silicon Valley while at the same time being enhanced startup, Nebbiolo. by previously lacking cloud-compatible communication protocols. Hello Industrie 4.0�we connect you
Business cloud IT ERP / CRM Cloud MES / SCADA Production cloud y Edge e operabilit Edg er Int OT Shop 昀氀oor Brown昀椀eld Green昀椀eld 4444�45�45
The cloud layer – KUKA tailors its IoT platform develop- Business cloud – public, private, on the Internet ments to the requirements of MSEs in the production meets business intelligence. or on premises mechanical and systems engineering industry. After all, the platform is avail- The IoT platform manages thing-related The Internet of Things platform (IoT plat- able to enterprises from all sectors and data processing and evaluation. However, form) – included in the term “cloud” – can be used across all markets. Partners modern production systems also need is the next station for data sets after the can thus focus entirely on their core a uniform, structured approach to com- edge. But what is it actually all about? competencies and can access established prehensive value chain and maintenance micro services via KUKA’s IoT platform. processes. Since all things in production will be In addition, our partners and third-party communicating with the edge via stan- providers of services for programming And that is exactly what the business dardized protocols in the future, these and optimizing individual components cloud makes possible. It provides access, data are now sent to the cloud. In this or processes can also be integrated. for example, to all historically captured context, the cloud is a computer infra- A community based on partnership thus data for process and component analy- structure made available by providers evolves, driving the optimization of sis – such as the lifecycle or maintenance such as Microsoft or Amazon in the form components, processes and production information of individual robots. As a of “Infrastructure as a Service” (IaaS). operations via a shared technical result, processes can be launched and The IoT platform in turn describes a plat- platform. run digitally. form on one of these cloud infrastruc- tures – “Platform as a Service” (PaaS). Good to know: KUKA subsidiary connyun’s IoT platform is cloud-agnostic and can therefore run on any infrastructure. The customer can therefore freely choose whether this should be a private cloud, a public cloud (“anywhere” on the Internet) or on the customer’s premises. So-called micro services run on this plat- form, like for instance authentication, role concepts, Big Data storage and processing, etc. It also enables features such as artificial intelligence, predictive maintenance and event analytics. The IoT platform allows system operators to process the data from their producing things and to adapt processes on the basis of insights derived from the results. Hello Industrie 4.0�we connect you
Simple Updates Programming Process Analysis New Revenue User Interface Streams Intuitive Operation Complex Individual Analyses Community Dashboards Thanks to the standardized IoT platform UI, HMI & app layer – KUKA already possesses wide-ranging link to the customer’s business cloud, the basis for intelligent applications expertise and specialized staff in the all databases – of KUKA and its partners and human-machine interfaces field of app development, as has already alike – can be incorporated into the anal- been required for many years for the yses and quality assurance processes Human-machine interfaces (HMIs) allow local operation of components such as via this interface. customers to access IoT platform data robots. This is reflected, for example, and analysis results and to take the in the style guide for programming user Like many other customers, KUKA also required operator control actions. The interfaces, which supports the intuitive operates its own business cloud. The interface between the cloud and HMI operation of all HMIs. The so-called system offers customers an integral ex- end devices is also implemented by RESTful APIs allow our partners in the perience with KUKA across all points of means of open and documented APIs – KUKA Manufacturing Ecosystem to contact. In the future, our robot, cell and known in this case as RESTful APIs. implement the apps they need, designed system-specific data will additionally Community partners and other custom- exactly in accordance with their own be available to our community partners ers can thus program their own appli- ideas. Companies can thus not only on the IoT platform for improving cations for any end devices and evaluate access their own production data, but production efficiency. data supplied via the edge in line with also have them analyzed and evaluated their requirements. via the established micro services from The KUKA Marketplace including the KUKA and other third-party providers. App Store will also be operated via the Applications may have a very compact system. In practical terms, this means design and be used for highly specialized In the future, companies from all sectors, that the growing number of apps and and possibly component-specific tasks. such as system integrators, process, generated know-how can be marketed However, it is equally possible for complex hardware and software manufacturers, worldwide through this store – by a applications with a wide-ranging scope OEMs and start-ups will enhance their simple mouse-click. The benefit for cus- of functions to be implemented. In products, and especially their services, tomers: KUKA takes on the responsibility practice, requirements vary enormously with relevant apps. This scenario is for developing and operating the infra- depending on the sector, individual made possible by the KUKA Marketplace structure and places the process expertise production solutions and corporate with its App Store: programmed best available on the market at the commu- structures. Virtually no bounds are set – practice solutions can be bought and nity’s disposal in the form of applications. everything is covered from recording downloaded here, thereby giving the operating hours to optimizing the energy creators the opportunity to market their consumption of process sequences. know-how on a global scale. KUKA provides customers with a structured platform and broad community that offers all the relevant tools for quickly and efficiently integrating Industrie 4.0 solutions into the value chain in a dynamically growing ecosystem. 4646�47�47
KUKA Connect The smart KUKA robot Full transparency of in-production data By incorporating the data, KUKA also These services substantially reduce the through the intelligent connection of offers practical services for the robots. management requirements for operating various layers. KUKA has not only intro- For example, if a number of robots are the robots. Thanks to KUKA Connect, duced this model, but also puts it into deployed in a system, KUKA Connect laboriously compiled, redundant or even practice. The company has created and automatically calculates optimized main- contradictory documentation is now a launched the product KUKA Connect tenance cycles for them. The responsible thing of the past. Customers can access fully in keeping with the slogan “Practice technicians are immediately notified of long-term analyses of their robot systems what you preach”. Today, it already allows any service work required and the entire and can draw conclusions as to their customers to access and evaluate the history of each individual robot is saved incorporation in the process. usage and consumption-related data and made accessible. of their robots – from any end device, For this purpose, KUKA provides the anywhere and at any time. The award-winning knowledge database necessary infrastructure for its products “KUKA Xpert” is also integrated into and customers. For enterprises such as KUKA Connect is based on the layer the user interface – without the need system suppliers or line operators, model already described. If the for any complicated installation work. KUKA Connect opens up wide-ranging Nebbiolo box (edge) is integrated into This makes the many years of expertise possibilities for integrating KUKA robots a production cell, it automatically acquired by our service specialists into their concepts and operating them identifies the connected robots. The accessible worldwide and at all times. in their systems even more easily. harvested data are evaluated in the Up-to-date documentation and speci- cloud via the existing micro services fications, work instructions and demo in accordance with the customer’s videos, help in locating the right spare requirements. This enables system parts and troubleshooting based on operators to directly view the status qualified solution proposals – after and condition of their robots. more than ten years in field operation, KUKA Xpert has become a valuable companion for its users. Hello Industrie 4.0�we connect you
• Operation: production optimization • Maintenance: robot condition and monitoring, maintenance planning and schedule, anomaly detection and predictive maintenance • Service: remote management, 昀椀eld services, spare parts management and knowledge-based services • Resources: energy optimization and management • Data: static robot data and dynamic operating data
KUKA SmartProduction For seamless transparency across all processes Production lines consist of numerous KUKA SmartProduction enables all enter- sensors, actuators, network components, prises to consistently digitize whole and lots more. Virtually all these inte- cells and production lines. It creates an grated “things” are potentially valuable interoperable network, in which micro information providers, since processes services and Big Data analyses can be depend on the interaction of various used to analyze and lastingly improve components and peripheral properties. manufacturing efficiency, quality, and If the aim is to use data not only to opti- flexibility. With our open platform we mize individual components, but also offer component manufacturers, system to increase process quality, they must integrators, and machine operators be intelligently processed and visualized an additional channel for value-added together. KUKA SmartProduction gives services and applications for the system operators access to the information manufacturing industry. of process-relevant machines for eva- luation – in compliance, of course, with At the end of the day, the question the highest security standards and clear remains: what does the future hold for data association. medium-sized engineering enterprises? With KUKA SmartProduction, KUKA KUKA SmartProduction ensures easy, paves the way for enterprises across all seamless, and manufacturer-independent sectors to position themselves in the cross-sector linkage of all production digital world. The challenge and chance machines in the cloud. Designed for max- for those enterprises is to seize the imum freedom, KUKA SmartProduction opportunities while not losing touch can be deployed across different hard- with own core competencies. ware and software landscapes. KUKA solution’s standardized interfaces and KUKA invites you, too, to become an im- future-proof architecture make it the portant part of KUKA SmartProduction. ideal IoT platform for enterprises in all markets and sectors. Hello Industrie 4.0�we connect you
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Hello Industrie 4.0�we go digital
Clear. Competent. Comprehensive. The KUKA Consulting approach for Industrie 4.0 Let’s be clear on one point before we So, to summarize – Industrie 4.0 is com- The 阀阀 Consulting approach is based even begin to talk about Industrie 4.0 plex and integrative in equal parts. Yet, on a modular, 昀椀eld-tested procedure solutions: Industrie 4.0 is not a product if everyone is already doing Industrie 4.0, that always focuses on the customer’s or service as is often mistakenly assumed. how can we pull the strings together individual added value. We develop Neither is it a speci昀椀c technique, model, without dampening initiatives? On the solutions according to customer require- or method that can be simply bought contrary, how do we boost their syner- ments in three phases. An important and used. Industrie 4.0 de昀椀nitely con- gies? We enjoy a distinct status in the aspect is that various Industrie 4.0 cerns the product portfolio of estab- market through our 阀阀 Consulting solutions from 阀阀 and our partners lished machinery and system builders, approach, based on our long-standing are 昀椀rst trialed as prototypes to validate their market di昀昀erentiation and posi- industrial know-how and specialists their relevance and e昀昀ective added tioning. All in all, it concerns the entire to speci昀椀cally foster and demand the value at short notice within a customer enterprise. Close examination already relevant Industrie 4.0 skills. In doing so, context. Not Industrie 4.0 for the sake shows that virtually all corporate areas we abide by our hands-on mentality, of digitization, but Industrie 4.0 as an are a昀昀ected one way or another by the because successful Industrie 4.0 opportunity for the integral development subject and are already engaged in consultants earn their laurels on the of individual components, processes, developing measures for future viability. shop 昀氀oor and not in steering systems, or indeed entire corporate areas. committees. This diversity o昀昀ers huge potential to The intrinsic 昀氀exibility of the 阀阀 create a cross-departmental dynamic We have been pairing this know-how approach means that phases can be through interdisciplinary initiatives that with Industrie 4.0 approaches and asso- adjusted to speci昀椀c and changing needs unite the enterprise on the transforma- ciated technologies now for several years. and the pros and cons of particular ini- tion path. Compartmentalized projects This ongoing development of our core tiatives weighed before taking decisions. and mentality have no place in a world competencies makes us the ideal project The scope of a project and the involve- of digital opportunity. partner for digitizing production and ment of further partners is are thus entire business processes in enterprises de昀椀ned by the customer in the course of all sizes and in all sectors. The of the cooperation. 阀阀 supports the Industrie 4.0 accelerator team comple- customer throughout as a sparring ments this existing expertise through partner with sound experience and targeted partnerships with established process know-how. Along with our team specialists. Experts from precisely those of experts from the respective disciplines, areas vital to promote cross-company we can bring structure to the complexity Industrie 4.0 measures, to initiate their of our customers’ speci昀椀c challenges, targeted implementation and, if required, plan de昀椀ned steps, and put them into to provide support. practice as required. From left to right Industrie 4.0 Accelerator Team Rohitashwa Pant Dirk Engelbrecht Robert Kamischke » Industrie 4.0 consulting Holger Jaksch Dr. Kerstin Hö昀氀e starts on the shop 昀氀oor, Stefan Ampenberger not in steering committees.« Dr. Martin Lehl Jonas Podszuweit Christoph Groll Industrie 4.0 Accelerator Team 52�53
The 阀阀 3-phase model Your path to measurable results 阀阀 has a 昀椀rm grasp of the challenges At the end of the around three-week fully satis昀椀es their needs and expectations posed by engineering, process, cell and phase the customer receives a custo- in short iteration cycles. The scalability system automation, and the incorporation mized Industrie 4.0 maturity evaluation, and user friendliness of the solution in of logistics solutions. We also comple- a draft of areas for action and recommen- the enterprise is thus ensured. ment this know-how with experts from dations and, frequently, also a 昀椀rst areas vital to Industrie 4.0, such as IT Proof of Concept (PoC) in the customer’s security, Big Data Analytics, and business own production environment. At this Phase 3: model innovations. Enterprises can point, the expert consulting models to Pilot access this expertise via 阀阀 Consulting, be speci昀椀cally applied in the follow-up easing their entry into a world of constant phases are also de昀椀ned. After the Explore and Design & Prototype transformation and already producing Phases, implementation of speci昀椀c me- practical results in just a few weeks’ time. dium- to long-term projects is launched. We devise customized solutions in three Phase 2: Based on collective insights, technologies separate phases for maximum optimi- Design & Prototype and solution modules are now speci昀椀cally zation potential to achieve the set targets. implemented and entire system areas Customers obtain optimal, comprehen- The areas for action from the preceding further optimized in this way. Applying sive guidance from 阀阀 Consulting analysis are now dealt with and practi- the 阀阀 Consulting approach we ad- whether their goal is to increase plant cally implemented at the beginning of the dress the customer’s objectives through e昀昀iciency, reduce total cost of ownership Design & Prototype Phase. The customer Industrie 4.0-focused automation solu- (TCO), or automate a speci昀椀c process can choose which projects and starting tions, individual potentials through for future viability. points are to be launched initially or even digital services or innovative business in parallel. We draw on our experience models. The Pilot Phase acts as a spring- and incorporate various specialist areas board for various projects that com- Phase 1: which must be taken into account when prehensively secure the customer’s Explore implementing Industrie 4.0 measures enterprise for the digital future. Increased into the project procedure. These include e昀昀iciency, accessibility and analysis of During the Explore Phase we engage optimization, digitization and simulation process data, reduced cycle times, or the with the customer’s relevant stakeholders of production processes, IT architecture, creation of integrated system concepts to get a full picture of the customer’s and the relevant security setups. The are all practical examples of added value. expectations, requirements, and goals. immense potential of Industrie 4.0 for The customer obtains them in the initial The procedure, the necessary project extending and adjusting the customer’s phases of 阀阀 Consulting – respec- scopes and resources are speci昀椀ed in own business models is also explored tively customized to their objectives. the course of workshops and interviews. and addressed with the customer. The All in all, the 阀阀 Consulting approach At the same time, we de昀椀ne with the Proof of Concept can also be developed o昀昀ers a coordinated start to your customer key areas for action in the into a prototype based on the customer’s journey into the digital future. 昀椀elds of process design, technology requirements and then used as a test and deployment, production and cell layouts, evaluation environment for downstream organization, and IT structure. The rele- installations. As the result of the vant digitization aspects are highlighted, Design & Prototype Phase the customer which can be capitalized on through obtains a speci昀椀c test setup (process, Industrie 4.0. We de昀椀ne the projects cells, components), as the decision- with maximum enhancement potential making basis for implementation of and so-called quick wins, while always further projects along with the process applying established standards, documentation and analysis. The key lean management speci昀椀cations, aspect of this phase is to draft with the and manufacturing principles. customer an Industrie 4.0 solution that Hello Industrie 4.0�we connect you
Phase 1 Phase 2 Phase 3 Implement Proof of Concept Pilot I 4.0 Design & Scoping & Readiness Prototype Projects Review Gains Explore 阀阀 Consulting Potential & Gap Vision » 阀阀 Consulting has developed a stringent model for customized solutions.« Industrie 4.0 Accelerator Team 5454�55�55
阀阀 Consulting 阀阀 Consulting ering Industrie 4.0 Readiness IT Security & olution o昀昀 Architecture S Prototyping Business Smart Process & Model Logistics Innovation Handling ering Gluing Robotics em o昀昀 Machining st Screwing y S Future IT system proved landscape business model Virtual commis- sioning Material flow opti- mization Maturity model Hello Industrie 4.0�we connect you
阀阀 Consulting Keeping an eye on the big picture We have to broaden our view, break down In doing so, four structural areas are compartmentalization, and foster inter- particularly in昀氀uential and relevant operability if we want to make the most to the evaluation of the measures of Industrie 4.0. In technical terms this required for the digitization process. means cross-domain data management, data harvesting via proprietary interfaces, 1. Enterprise resources end-to-end management of cyber-physical (including the digital skills of employees security and creating integrated adminis- and production automation) tration, communication and logistics structures. To achieve increased produc- 2. Organizational structure tivity, we have to abandon established (including goals and strategic alignment structures and rethink every aspect of and organic internal organization) our business models. 3. Information systems 阀阀 o昀昀ers customers access to the (including horizontal and vertical necessary competencies to steer enter- integration as well as data delivery, prises quickly, simply and dynamically processing, storage, and transfer) towards Industrie 4.0 while taking their speci昀椀c needs into account. 4. Corporate culture (including focus on customer bene昀椀t, collaboration, and ongoing quali昀椀cation) Industrie 4.0 maturity Based on this analysis phase by our con- The technological maturity of production sulting partner UNITY, we 昀椀nd out how environments and their components is con昀椀dent employees are in handling IT crucial for the customer’s procedure systems (resources), whether and if so, and development towards Industrie 4.0. how cross-site information exchange As every enterprise has its own current works (organization structure) and whe- status of smart products and de昀椀nes its ther all employees are involved in pro- own Industrie 4.0 goals and, for example, duction optimization (corporate culture). general IT structures, customers need an Once the enterprise’s Industrie 4.0 individual approach of their own. This maturity rating has been established, status can be analyzed for each customer a digitization procedure can be de昀椀ned and then incorporated into the overall for the customer and e昀昀iciently imple- process. mented. An important aspect of this pro- cedure is that the right areas for exami- nation within the enterprise are selected from the outset. This makes it possible to take reliable stock of the current status and to derive appropriate goals. 56�57
Smart Processes & Logistics Digitization in production and warehouse IT Architecture and Security Consulting logistics has already reached a very Process chains in modern production and advanced stage. Material 昀氀ow analyses, Increased networking of machines and logistics systems o昀昀er further starting condition monitoring, or digital shadow- industrial systems generates new threat points for optimization by integrating ing for 3D system visualization are already scenarios for manufacturing and digitized (real-time) data, for example. In-depth 昀椀rm 昀椀xtures in the Swisslog portfolio. companies. Yet even individual “smart” industry and technical know-how is essen- Yet which of these measures take cus- components may be targeted by cyber tial for the analysis and development tomers to the next crucial level? In this criminals. So it is good to know that of “smart” processes. 阀阀 Consulting’s case, too, 阀阀 Consulting opts for 阀阀 can come to the rescue. With the Smart Processes & Logistics solution joint, structured speci昀椀cation of opti- security consulting of our project partner area provides the relevant experts from mization possibilities and o昀昀ers the Giesecke & Devrient, we o昀昀er line oper- production processes, system design necessary solution expertise with the ators and component manufacturers (lean management, for example) to right partners. tailored threat and risk analyses that they entire (production) logistics setups and can use to assess the current security thus pools all the relevant skills. This situation. This permits initiation of tar- facilitates our customers’ entry into Digital Factory & Prototyping geted measures. Backed by a security a comprehensive digital transformation analysis based on proven approaches in and makes the process as smart and Many enterprises are very cautious when the IT industry, the procedure is adapted pragmatic as possible. it comes to implementing Industrie 4.0 to the circumstances and individual projects, considering them to be too features of industrial systems and their No matter whether existing systems expensive and time-consuming, and speci昀椀c requirements. 阀阀 and its or the development of new concepts, o昀昀ering only uncertain outcome and consulting partners support customers all areas can bene昀椀t from Industrie 4.0- bene昀椀t, etc. Precisely in the case of com- in setting up secure component and based technologies and developments. plex Industrie 4.0 challenges and tasks, system networking. Along with our consulting ecosystem it is vital to approach matters in a partners we identify the main potential structured manner: Via its ecosystem New complex issues related to IT in our customers’ systems within a few partner Zühlke, 阀阀 o昀昀ers all-impor- architecture in general arise in the wake weeks. And we achieve measurable tant access to proven design-thinking of digitization and Industrie 4.0: results in minimal timeframes simply components. One of the main elements by performing minor additions and of design thinking is a clearly structured • Safeguarding the security and adjustments to existing processes. By process in recurrent loops. Prototyping interaction of the various layers applying our partner NeoNex’s “Planning begins as early as possible and insights • Sustainable development in relation smart assembly lines” module, all the are recapitulated time and again. This to scaling & connectivity relevant steps from analysis and veri昀椀- process provides the customer with fast • Integration of existing systems cation to ordering the relevant system results, enabling sound decision-making and infrastructure modules for implementation can for next steps and follow-up projects. be completed within twelve weeks, • Solution combinations incorporat- for example. The bene昀椀ts of the model are plain: ing business processes, technology, Empathy for the needs of users leads to connectivity, and Big Data the development of solutions that are actually needed. Thanks to fast, e昀昀icient Here too, 阀阀 o昀昀ers the right advice prototyping, we do not beat about the on these issues and devises integrated bush, but try things out as quickly as solutions together with customers. possible, together with a cross-disci- plinary team. Any mistakes are made together to learn from them – all of this taking place within a set budget. This is the fastest route to innovation. Hello Industrie 4.0�we connect you
Business Model Innovations inured practices. The procedure of the St. Gallen University Institute for Tech- Innovative products and solutions arising nology Management spin-o昀昀 unlocks from Industrie 4.0 approaches call for hitherto dormant potential and metho- a new mindset on value creation and ab- dically develops new business models. sorption. Not only technologies change, Highly innovative business ideas are but also how customers and other stake- devised in the course of a two-day work- holders in the extended ecosystem shop based on the St. Gallen method. interact. Consolidating market position in the age of digital change hinges on 阀阀 and BMI Lab help enterprises to setting yourself apart from the crowd directly translate the insights gained with services, tapping new sales channels, from all consulting approach stages into or establishing new payment models. new business model templates and ripen Along with its solution partner BMI Lab, them to market maturity as quickly and 阀阀 enables enterprises to transcend inexpensively as possible. 58�59
Envisioned. Done. Delivered. KUKA offers tailor-made HRC systems and IT solutions that equip customers for Industrie 4.0.
Frank Klingemann CEO 阀阀 Systems GmbH Automotive Market Owner Hello Industrie 4.0�we connect you
» Our experts develop customized solutions to make sure new business models are successful.« 62�63
Industry and business, characterized by market trends New challenges between consumer behavior and business models Industry and business are in昀氀uenced by Human-robot collaboration, connec- �To round up, the transparency and market trends. Mobility, digitalization, tivity, and future-oriented hardware and connectivity created by our Industrie 4.0 and sustainability change consumer be- software solutions smooth our partners’ solutions facilitate our customers’ havior and in turn the value chain. This way to help them satisfy customers’ progress towards globalization and poses industry with the challenge of requirements. In the e-mobility sector, individualization of their production. uncertain future development, requiring for example, we o昀昀er an extensive so- it to react 昀氀exibly to changing market lution portfolio from adaptable body demands. We can o昀昀er our customers construction and battery module pro- this 昀氀exibility, giving them the scope to duction to e-drivetrain assembly systems. create new business models. E-mobility is far more than just a new type of drive, it is actually an established Our new production concepts pick up on aspect of how we will be mobile in this and combine our experience with the future. The paradigm change from new technologies. 阀阀 has been imple- ownership to mobility consumption menting operator models in the auto- forms the basis for new business models. motive industry for many years, paving the way towards cost-e昀昀ective, scalable These market trends can be identi昀椀ed and smart factories, and supporting in various forms in all industries, not the production of more than two million only in the automotive sector. Our car bodies. experts develop customized solutions to make sure your new business models are successful. 阀阀 already provides solutions today for future service-based business models with networking and 昀氀exibility as enablers. Backed by data transparency and consistency on the shop 昀氀oor, digital services can increase customer added value by improving cycle time or availability, for example. Hello Industrie 4.0�we connect you
Envisioned. Done. Delivered. » e-mobility is far more than just a new drive type, it’s an established aspect of how we will be mobile in the future.« Frank Klingemann 64�65
Effective KUKA software for optimizing production Starting a new era with detailed data analytics A supply chain is as fast as its slowest link – this insight is law in the era of Industrie 4.0. After all, in a networked manu- facturing operation, a delayed process has a severe impact on the speed of production. That is why companies are interested in successively optimizing their cycle times. They are supported in doing so by an intelligent analytics tool for the factory of tomorrow – 阀阀 SmartProduction�management. Industrie 4.0 needs speed. Everything KUKA SmartProduction�management, �These optimizations enabled the global needs to become faster and more which is capable of examining the acting transmission manufacturer effective – over the entire value chain. performance of an entire system down to significantly improve the cycle time However, this requires the production to the smallest detail. It communicates of the overall production system. dynamics to keep pace without com- with the individual stations and collates KUKA SmartProduction�management promising quality. That this can already the results. The outcome was extremely is to remain networked with the system be accomplished today is demonstrated satisfactory: 500,000 data points were in the future too in order to allow the by a joint project of KUKA and a well- acquired on a daily basis and investi- processes to be continuously analyzed known transmission manufacturer. This gated directly from the system. This and corrected if necessary. company is a leading supplier of drive scanning in turn allowed highly relevant train components and systems for the conclusions to be drawn regarding avail- automotive industry and is the only ability, cycle times and daily output. tier 1 supplier worldwide to design, Ultimately it proved possible to network develop and manufacture complete a total of 18 stations using KUKA all-wheel drive systems in-house. The SmartProduction�management – interest of automotive manufacturers manual workplaces as well as joining, is correspondingly high. In order to measuring and assembly stations. Over cope with the great demand from the a period of six weeks, KUKA’s data industry, the company focused on analysts were able to isolate problematic optimizing its processes at an early stations and propose specific improve- stage and scrutinized its system in the ments on the basis of the production USA together with the strategy experts data. For example, this included the from KUKA. All procedures were exchange of worn holding points for analyzed and the results used as a basis measuring pinions and the installation for formulating targeted suggestions for of shock absorbers on the counter- improvement. The analysis was carried weight to accelerate positioning of out using the Industrie 4.0 tool the pneumatic cylinders. Hello Industrie 4.0�we connect you
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The KR titan on a linear unit in a perfect work昀氀ow with the KR AGILUS Hello Industrie 4.0�we connect you
KUKA SmartProduction Augsburg Step by step to production of the future As a thought leader and technology pioneer, 阀阀 also implements its own solution concepts in production at the Augsburg site. “阀阀 SmartProduction Augsburg” is the name of the project in which production cells with robots, processes and a great many other assets are all interconnected. The experience with digitization in the company’s own manufacturing operations shows that the development potential and future prospects of this approach are enormous and a genuine bene昀椀t for the production workers. The majority of robot types are built on KR AGILUS, KR titan or KMR iiwa, �The success of the project opens up a production line at KUKA’s Augsburg non-KUKA assets too, like the cell attractive perspectives for continued plant. For example in the cell for controller (PLC) or torque wrenches, development. For this purpose, the assembly of axis 1, where compo- are connected and visualized on the responsible parties involved call on nents for the first robot axis are KUKA SmartProduction user interface. assistance from the company’s own joined fully automatically. The KUKA Consulting group. In an intensive SmartProduction project kicked off This simultaneously demonstrated the exchange with the production specia- with this assembly procedure as the performance of the KUKA middleware lists, new potential applications are preconditions for networking the that is used, whose flexible and open developed which are to be implemented production cell were ideal. All assets architecture allows third-party assets to in the near future. employed there are already “intelligent” be connected without any problems. To or have a controller with an interface provide a specific example, a dashboard suitable for networking. Connecting all with various performance indicators for machines, also known as assets, to the the production managers was created cloud enables data to be collected and via the cell controller (PLC). Integration evaluated. The data and their analysis of the wrenches also makes it are visualized and presented to the possible for verification of all screw user via a graphical user interface. These connections to be displayed on the so-called asset views can be adapted as KUKA SmartProduction interface. In the desired and also provided with alarm event of a defect, the point at which functions in the case of faults. Besides a problem occurred with one of the KUKA’s own products, such as the wrenches can thus be quickly identified. 68�69
Flexibility is the be-all and end-all in automobile production. Low fault susceptibility and high speed Producers in the automotive industry are under pressure to minimize throughput times. This is why appropriate solutions are required: conveyor systems, which allow for quicker processes in body-in-white production, are thus attracting more and more attention from vehicle manufacturers. KS PULSE (Propulsion Using Linear Synchronous Energy), the pallet-based transport system from 阀阀, quickly and safely moves the various body components through the individual workstations of an automated assembly line – thus reducing non-productive times and downtimes. It is no longer possible to imagine manu- The system stands out for its low sus- facturing shops without them: auto- ceptibility to malfunctions because very mated transport systems are today an few moving parts are used. The key integral part of production. Particularly advantages of KS PULSE are its high for automotive manufacturers, moving transport speed and flexibility: the skids large vehicle bodies from A to B is are interchangeable in terms of cycle essential. This calls for handling systems time, enabling multiple models to be that are robust and yet nevertheless produced on one line. Beyond this, addi- fast and flexible. For this purpose, KUKA tional components such as turntables has developed a pallet-based transport or buffer stations can be integrated into system for automated assembly lines the PULSE system, ensuring that the in body-in-white production: KS PULSE. system can be adapted as required for The main element of the transport individual production scenarios. system is a carrier. Using various trans- port platforms, called skids, this carrier Carrier control (i.e., moving to the individ- transports the individual body compo- ual stations as well as collision protec- nents through the assembly line. The tion) is carried out via software. No carriers are moved through the process further sensors are required for precise stations of the system by means of positioning to ± 0.1 millimeters. linear synchronous motors. �KS PULSE is the optimal solution for high-volume production systems. KUKA’s experts implement it in the context of complete solutions. Hello Industrie 4.0�we connect you
Robust and 昀氀exible: KS PULSE transports body components quickly and safely through the production stations. 70�71
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HRC system for automated screw fastening When robots help to build their colleagues. Even the production of robots can be automated one step at a time. 阀阀 is demonstrating this at its own factory in Augsburg, where the company is using a versatile HRC system to automatically fasten two types of gear units for the KR QUANTEC robot. The sensitive lightweight robot LBR iiwa For this purpose, KUKA developed a ver- �Certified by the employer’s liability is a pivotal element in a large variety satile HRC solution to make a non-ergo- insurance association, the system thus of human-robot workstations at many nomic workplace more productive. helps to boost productivity using direct companies. Either stationary or as a The system, which is controlled using collaboration with its human colleagues. mobile assistant in the form of the gestures, sensitively distinguishes This is an important milestone on the KUKA flexFELLOW, it is ideally suited to between components and independently way to intelligently networked automated playing an important role in the pro- calibrates itself to determine its position robot production. duction process at the KUKA plant in at the workplace. The LBR iiwa then Augsburg. Indeed, it is now successfully fastens 36 or 30 inserted screws on four used in KUKA’s robot manufacturing housing variants with a torque of 104 Nm operations to support the human and documents the work steps through workforce with the production of its the wrench controller. The LBR iiwa colleague, the KR QUANTEC. pushes against the gear unit and is thus able to achieve the torque required for the screw fastening. At the same time, it can reach all screw positions without any restrictions. The HRC-capable LBR iiwa works hand- in-hand with humans and, as a result, is revolutionizing industrial production and manufacturing. 72�73
90 tonnes positioned with millimeter precision Robot platform assists in the A380 hangar. Wingspan 80 meters, length 72 meters, deadweight 275 tonnes: according to any criteria in the aerospace industry, the Airbus A380 is a giant. Entirely new procedures had to be developed for its production in some instances, with great challenges for manufacturing technology. This is also evident at the Airbus site in Hamburg-Finkenwerder, where, among other things parts of fuselage of the A380 are built. One of the difficult tasks to be mastered to transport the gargantuan aircraft in Hamburg is also the transport of large components with millimeter precision parts along the production flow line. At in confined spaces. Airbus uses two of 15 meters long and weighing 90 tonnes, these innovative vehicles at its plant these are among the largest individual in Hamburg-Finkenwerder. This makes components processed. This is then it possible for the desired cycle time complicated by the fact that the space for the transportation of the fuselage in the hangar is limited by the different sections to be maintained. As a result, work stations and the huge fuselage Airbus employees profit from simple, sections. easy-to-learn handling, flexibility and precision as well as the easy steerability As a solution to meet this challenge, the of the KUKA omniMove. Another plus Airbus engineers turned to cutting-edge point: the transport platform operates technology from KUKA: two powerful tirelessly for 48 hours without the need mobile KMP omniMove heavy-duty to recharge the battery. After all, aircraft transport vehicles are used to transport components do not wait. the parts. Their most important charac- teristic: they can turn from a standing start. This is made possible through the use of Mecanum wheels. They allow the vehicle to execute omnidirectional maneuvers, without requiring mechan- ical steering. The Mecanum wheels move �Precisely transporting heavy parts in in every direction and operate with the confined space – this is the specialty of utmost precision even with a maximum the KMP omniMove. Millimeter preci- payload of up to 90 tonnes. This wheel sion work facilitating aircraft production: design enables the KUKA omniMove flexible, economical and easy to use. Hello Industrie 4.0�we connect you
Where high-tech giants are being built, extra extra large parts have to be moved safely, quickly and with millimeter precision. At the Airbus plant in Hamburg-Finkenwerder, 阀阀 omniMove heavy-load mobile platforms take care of this tricky task masterfully and reliably. 74�75
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Automated software upgrades Fountain of youth for warehouse management software Digital solutions require continuous updating. Particularly in the era of Industrie 4.0 it is of great importance for the imple- mented solutions to be kept continually up to date and not cause performance bottlenecks due to inconsistencies or missing upgrades. ForeverYoung is a service o昀昀ered by Swisslog for automatically migrating the SynQ warehouse management solution to the current version. The great advantages of this service are proving e昀昀ective in practical operation at Norwegian trading company Harlem Food. Alongside product quality, speed and solution to the most recent version �This service reduces downtime and flexibility are the most important every year so as to be able to use the errors resulting from incomplete demands to be met by food retailers. latest features of the platform and upgrades. As even minor updates are Modern trading companies can hardly also to support appropriately certified implemented promptly, the company satisfy these demands in the long term solutions from third-party vendors. As also avoids more extensive upgrade without sound digitization solutions. experience has shown that compatibility procedures. ForeverYoung really keeps Major players in this sector therefore problems may repeatedly arise in the SynQ continuously up to date with implement high-performance warehouse interaction between hardware, databases the latest releases – a key element in systems. The Scandinavian Harlem Group, and operating systems on account of a smart warehousing solution and the for example, relies on the warehouse upgrades not being promptly implemen- basis for further future Industrie 4.0 management and business intelligence ted, the Harlem Group opted to make applications. platform SynQ from Swisslog, which use of a Swisslog service that is becoming makes warehouse management ready ever more important for Industrie 4.0 for Industrie 4.0. environments: the ForeverYoung migration service. This is an optional feature of The Harlem Group is a fully integrated Swisslog support and automates admin- Swisslog’s upgrades allow access to new trading company specialized in buying istration of the SynQ environment. features such as 3D visualizations. and selling consumer goods on an international scale. The company offers The ForeverYoung process begins by com- products and services for the retail paring the productive version of SynQ market and food industry with a port- deployed by the Harlem Group with the folio including commodities, consumer youngest platform version available at goods and private label products. It the time. An upgrade version of the markets an assortment of more than Harlem Group solution, adapted to any 800 products and makes annual trades new features introduced in the mean- of over 300,000 tonnes of commodities. time, is then automatically tested and As a user of SynQ software, the Harlem validated before being migrated to the Group has the option to migrate the active work environment. 76�77
Automated fastening of pump wells Measure. Fasten. Perfect fit. As part of Industrie 4.0, monotonous and ergonomically straining manufacturing tasks are gradually replaced with automation solutions that enhance e昀昀iciency and productivity. This is demon- strated in the example of the changeover that took place at BSH GmbH for screwing pump wells into place on the dishwasher production line. An innovative solution is used with the 阀阀 昀氀exFELLOW, equipped with the LBR iiwa. In order to precisely fasten the pump in four seconds, and doing so with the �And, as is deemed appropriate for an wells, the operator is required to bend highest precision. The operator can walk intelligent Industrie 4.0 solution, over into the dishwasher housing – right up to the robot during operation the LBR iiwa contributes to collecting an uncomfortable posture and a to observe and monitor the process. No information: it documents its tasks monotonous work step. This task per- safety fences are required. and reports whether or not the screw fectly lends itself to automation. fastening process was successful. Bosch Siemens Hausgeräte GmbH The robot relieves the employees and decided to take the leap and selected a increases productivity by adjusting itself: mobile solution: the KUKA flexFELLOW, it calibrates independently within the which is customized for the environ- workstation, uses search run mode to ment at the company’s Dillingen plant. locate the screw positions, carries out fine adjustment of the part, and tightens The robot was flexibly integrated into the four screws. If the component con- the production line, so that the existing cerned is not perfectly adjusted, the manual workstation could be left un- robot recalibrates the dishwasher changed. It is now independently housing. For this, it develops a search fastening the pump wells – 16 screws strategy for the screw positions and recalculates them. The mobile KUKA flexFELLOW platform enables this solution to be flexibly deployed at various locations. Thanks to its sensory capabilities, the LBR iiwa independently and reliably moves to the exact position of the workpiece to perform sensitive assembly tasks. Hello Industrie 4.0�we connect you
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Chinese hospitals are subject to intense activity when it comes to dispensing drugs. On average, this outpatient clinic processes 4,500 prescriptions daily, with peaks of 600 per hour. The UniPick 2 Automated Drug Dispensing System swiftly transports the drugs from storage racks to the transport basket after veri昀椀cation. Patients bene昀椀t from signi昀椀cantly shorter waiting times. Hello Industrie 4.0�we connect you
Automated dispensary for Chinese clinics Robotics as a remedy for stressed pharmacists Tight spaces and little time – these are the conditions that pharmacists have to deal with in Chinese hospitals. In order to optimally exclude errors in administering medications, outpatient pharmacies can now rely on an automated dispensing system from Swisslog. This solution also o昀昀ers hospital pharmacies an important edge in terms of productivity by increasing the process e昀昀iciency and quality. Chinese hospitals and their pharmacies it possible to fill the transport basket �As a result, the Swisslog solution pro- are under ongoing pressure; thousands and distribute the drugs at the same time. vides an enormous increase in terms of patients need to be treated and On average, ten prescriptions per minute of speed, but above all it offers a drastic supplied with medication daily. The phar- can be processed, which reduces the reduction of drug dispensing errors. macies are subject to constant intense customers' waiting time. During dispen- activity, handling up to 600 prescriptions sing, the system checks the storage in per hour. Medications are dispensed real time using a laser scanner to ensure every second. Human error is unavoid- that plenty of stock is available. able due to the highly stressful work environment. This automation technology is embedded in a software application, which auto- This has now fundamentally changed matically checks the prescription and thanks to an intelligent hospital dispen- thereby ensures that the right drug at sary solution from Swisslog, developed the right strength is removed from the specifically for the Chinese market. The respective cabinet every time. The pre- combination of a special management scription analysis, patient information, app and the UniPick 2 automation largely and drug handling process are paperless prevents. largely prevents errors. In throughout. In addition, important addition, the manual process of drug performance indicators are measured and prescription management is digitized, and presented in real time on a KPI increasing the hospitals’ productivity. (key performance indicator) dashboard. Information about prescription category, UniPick 2 consists of a conveyor that dispensing status, inventories etc. moves vertically up and down on the stor- can be compiled in a graphical report age racks as well as a robotic loading and archived. This enables continuous module, the combination of which makes digitized inventory management. 80�81
KUKA ready2�use for 4.0 production Digital support with a high IQ The road to e昀昀icient manufacturing facilities in the Industrie 4.0 concept involves technologies with “built-in” process expertise. The solutions used must 昀氀exibly adjust to production processes while also being individually adaptable and versatile. This only works if they are designed from the outset for use in networked automated production facilities. With ready2�use, 阀阀 has created a portfolio of 昀氀exible solutions which makes various automation technologies ready for Industrie 4.0. All packages are, for example, designed for integration into a cloud environment and can be integrated into any modern smart factory concept. Every market segment has very speci昀椀c variants, is an ideal 昀椀eld of application requirements for the automation of for tailor-made networked automation production. And even companies in the and application solutions. The space same market segment di昀昀er in their restrictions require utmost agility individual manufacturing processes – and accuracy to meet quality and and therefore in the scope, degree and throughput speci昀椀cations. type of automation required. Solutions for networked automation must there- As an Industrie 4.0 pioneer and world fore be extremely adaptable and versatile. market leader in industrial robotics, 阀阀 Against this background, the new provides the electronics industry with ready2�use packages from 阀阀 are the perfect solution in the KR 3 AGILUS optimal solutions that are modularly for meeting its challenging requirements. scalable according to demand and can The KR 3 AGILUS is optimized for the pro- be adapted to the speci昀椀c system. duction of the smallest components and products. Its reach of 540 mm is ideally Fastening M1 screws with consistent tailored to the 60 cm x 60 cm surface of torque in a very short space of time and an average workplace in the electronics with the same quality and pose repeat- industry. Using a special screwdriver tool, ability – is a perfect 昀椀eld for a it masters the attachment of micro ready2�use application. The fast-moving screws in a wide range of positions with electronics sector, with its extremely utmost precision. It is the 昀椀rst six-axis short product lifecycles, its rapid pace robot for the fastening of type M0.8 to A delicate touch is called for: of innovation and its wide range of M2 screws on the global market. with great sensitivity, the KR 3 AGILUS fastens micro screws even with a diameter of just 0.8 mm! Hello Industrie 4.0�we connect you
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This solution of an intelligent screw- driver for fastening micro screws with previously unprecedented quality and precision is called “ready2�fasten�micro”. ready2�fasten�micro stands for a pre- con昀椀gured complete solution which is easy to implement when using 阀阀’s comprehensive process knowledge and can be quickly integrated into individual production units. In terms of 昀氀exibility, this concept is unbeatable. If the pro- duction speci昀椀cations change, so too does the cell. The ready2�fasten�micro solution is simply recon昀椀gured or com- bined with other units. The solution is cloud-capable and can be integrated into a smart factory via platforms such as 阀阀 Connect. Typical Industrie 4.0 functions such as process analysis and quality assurance are easy to implement with ready2�fasten�micro. The substantial backlog of demand for automation in the electronics industry can be covered cost-e昀昀ectively and sustainably using solutions like ready2�fasten�micro. �The smallest screws are positioned quickly and precisely by intelligent high-tech helpers – this is what smart manufacturing looks like in the elec- tronics industry. ready2�fasten�micro from KUKA makes it easy to enter the world of automation. Hello Industrie 4.0�we connect you
Powerful automation begins with “ready2�”. Advanced Pro Basic ready2�use solutions support a more We have the solution – efficient, faster and more agile automa- the choice is yours. tion of industrial production. They facilitate the path to the smart factory Various ready2�use solution packages through preconfigured and task- are available to meet individual require- oriented solution packages that can ments. The three levels Basic, Pro and be easily implemented. Advanced create different ones possi- Basic + Pro + Advanced bilities of use. The different packages can be combined, resulting in a wide range of further solution options. Practical, immediately available, ready2�use solutions: ready2�use ready2�grip precon昀椀gured gripper solution Each ready2�use solution meets parti- based on the KR AGILUS cular, industry-specific requirements. ready2�spray It seamlessly fits into the individual precon昀椀gured automation manufacturing environment and handles solution for painting tasks tasks where the automation of ready2�arc processes is effective and profitable. precon昀椀gured arc welding auto- mation for the metal industry Increase flexibility and productivity, ready2�spot precon昀椀gured spot welding gain time, cut costs automation solution Processes automated with ready2�use ready2�powerlink solution for integrating improve the agility of manufacturing, 阀阀 robots in third-party optimize production performance, can controller systems be quickly integrated into the existing ready2�pilot manufacturing environment and work solution package for the easy cost-effectively in precisely the areas control of a robot without a need where they quickly pay for themselves. for training ready2�fasten�micro complete automation solution for fastening of micro screws 84�85
Smartphone instead of clipboard Mobile data management in the automotive industry The manufacturing shops of the modern automotive industry are showpieces demonstrating automated production methods. Thanks to the full-scale introduction of industrial robots, the industry has been able to make a signi昀椀cant quantum leap in terms of e昀昀iciency and productivity. With a mobile data management solution, 阀阀 helps to extend the potential e昀昀iciency gains through digitization to processes that currently still have to be largely performed with analog technology. The processes that have often not yet All incoming data such as information central storage of the data makes for been digitized even in the automotive on the status of the construction a substantial improvement in quality, industry include the management and measures or corrected and confirmed currency and system safety. KUKA offers monitoring of procedures in the construc- design plans are stored and managed in its customers the option of now also tion or integration of manufacturing this database. By means of user profiles deploying this tried-and-tested system systems. As efficiency gains due to digi- and defined responsibilities, the MDM for documenting manufacturing systems tization translate into time and cost system makes sure that all users can and optimizing maintenance work. The savings, KUKA offers a smart solution access precisely the information that is focus here is primarily on speeding up for mobile data management (MDM) relevant for them. If a project team mem- the training of new personnel, reducing in systems engineering. It makes all rele- ber scans a QR code affixed to a robot downtime through more effective prob- vant data and documents for the con- or another item of equipment, all data lem localization and the additional struction or conversion of a system of importance for their field of activity option of building up a knowledge data- accessible on mobile devices such as at the system location are displayed on base. For this purpose, the MDM system tablet PCs or smartphones. As it is cur- their mobile device. Additionally, a state- can access real data from the system rently used on KUKA’s own construction of-the-art OCR text recognition system controller and display error messages sites, the system architecture is centered enables them to retrieve information directly on the mobile devices. on the cloud-based storage and manage- using the labels on existing system ele- ment of data and documents. The ad- ments. In the automotive industry, the vantages of this solution are obvious: MDM system even provides yet another �With this mobile data management mechanics, electricians or project option for increasing process efficiency: solution, KUKA has been able to put an managers can download all required as all relevant data are collected cen- end to the analog age at a central node information from the central database trally, the time is saved that the per- of the value chain – a further, important using any compatible mobile device, sonnel previously needed to search for step towards the Industrie 4.0 pro- allowing them to work offline as well. the appropriate documents. Moreover, duction environment. Hello Industrie 4.0�we connect you
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Hello Industrie 4.0�we connect you
Human-robot collaboration in the manufacture of axle transmissions The worker with seven axes While not too long ago operators at the BMW Group plant in Dingol昀椀ng had to lift and 昀椀t di昀昀erential cases for front-axle transmissions in the tightest of spaces, the early adaptation to Industrie 4.0 has now radically changed the workplace. A specially designed human-robot collaboration (HRC) solution from 阀阀 Systems is now relieving the sta昀昀 of all strenuous tasks while making the plant future-proof at the same time. Lifting 5.5 kg differential cases that are The robot fits seamlessly into the pro- �This highly effective KUKA solution is difficult to grip, and fitting them with duction environment. Not a single forward-looking Industrie 4.0 technology millimeter accuracy in the tightest of adjustment of the production line was at its best – individually adapted to spaces – thankfully, this back-breaking necessary for installation. The biggest the conditions of a production line, intel- task is now a thing of the past for the benefit of the new automation solution ligently networked with the control operators at the BMW plant in Dingolfing. from KUKA is that the human colleagues systems, space-saving, and designed for Today, this immensely arduous work of the LBR iiwa robot can safely move close collaboration with the machine step is handled by an LBR iiwa light- about in the production zone. For this operators. In short: the production of weight robot with utmost precision and purpose, the robot gripper is equipped the future is already underway at efficiency. with an HRC case, so that the operator the BMW Group plant in Dingolfing. is protected from injury at all times. To maximize the LBR iiwa’s efficiency, And this is what the collaboration KUKA has developed a slim steel structure, between humans and robots looks like: which is mounted on the ceiling. From the processed components are auto- an overhead position (and thus saving matically transported to the system via space), the powerful yet sensitive ma- a conveyor and are prepared by the chine goes to work. The entire control operator. The operator places all of the technology including the interfaces for small and lightweight parts, such as the system controller has also been spacers and ball bearings, into the trans- accommodated in the available space. mission case and the cover. The worker then activates the robot, which fits the heavy differential case in place. Next, the operator fastens the cover to the trans- mission. The procedure takes no more than 30 seconds. Human operators and robots collaborate to install di昀昀erential cases for front-axle transmissions. 88�89
阀阀 Industrie 4.0�Glossary » Robotics, automation technology and digitization will shape the next half-century in the same way that the internet, smart- phones and computers have shaped the past half-century. Our grandchildren will grow up as the 昀椀rst generation ‘R’ of ‘robotic natives’ – and we have to start taking responsibility for this today!« Dominik Bösl Vice President Consumer Driven Robotics 阀阀 Aktiengesellschaft
Administration Shell �All data in a single shell. The administration shell is the virtual image of a hardware or software component in a production process, containing all the speci昀椀c production data. This data opens the way to entirely new possibilities and added value in networked production. One decisive bene昀椀t is that all information – from CAD data and maintenance information through to con昀椀guration details – is located in one place without media discontinuity. Data and functions are available on the component itself, in the company network and/or in the cloud. This collection of information results in an all-encompassing knowledge which, once stored, can be made available for any user and any application. App �Expertise from the cloud. Apps for industrial scenarios – programs for defined, specific applications – are the answer that experienced specialists with extensive process and industry know-how offer up for customers’ challenges. Intelligent mobile apps make modern companies Industrie 4.0-capable. KUKA offers apps for a wide range of challenges across the entire value chain – in manufacturing, for example, their functionalities encompass Maintenance Services through Asset Management to Demand Planning. App Store �New capabilities on demand. Already equipped for the future: for generations, KUKA robot controllers have featured a modular and scalable configuration on the basis of mainstream technologies. Among other things, KUKA has thus created the foundation for making smart tools available via app stores and marketplaces. Intelligent digital forms or complete applications, such as those familiar today from well-known app stores for smart- phones, tablets or computers, and which endow robots with new capabilities and functions on demand at the click of a mouse. For example, programs that only require entry of the desired parameters. With regard to Industrie 4.0, the immediate availability of new production capabilities will open up a whole new dimension of versatility for robots. Arti昀椀cial Intelligence _Machines as intelligent partners. Arti昀椀cial Intelligence (AI) is the step required for implementing the fourth stage of the robotic revolutions. It presupposes that machines, information systems and robots are capable of becoming still much more intelligent and responsive. In the 昀椀elds of service robotics and home assisted living, these intelligent machines with their cognitive and sensitive capabilities will become increasingly important as helpers for humans. Today, these systems are still fully dependent on programming by humans. As the degree of autonomy of the systems increases, however, the issue of responsible management of arti昀椀cial intelligence will become ever more pressing. Batch Size 1 �Unique, one-off products for everyone. Industrie 4.0 is creating the basis for implement- ing the highest levels of customization – all the way down to batch size 1 – within industrial manufacturing. This means high-quality, single-piece production at the price of current uniform, mass-produced goods. The networking of all systems involved in production, and their extreme flexibility, will make the fulfillment of individual customer requirements a matter of routine in the smart factory. While the desire for customized products is already a megatrend today, it will develop to become one of the decisive competitive factors in the near future. This trend not only offers new market opportunities for products, but also gives traditional industrial nations the option to return previously outsourced production capacity to locations in high-wage countries. Big Data �Data is the new oil. The term “Big Data” refers to quantities of data that are too large or too complex, that change too quickly or are too weakly structured for them to be evaluated with manual and conventional methods of data processing. In this context, experts talk about an inconceivably large data volume of currently more than eight zettabytes – with an increasing tendency. A substantial proportion of this already comes from the Internet of Things (IoT) and from the ever more numerous sensors in machines and vehicles. Data is increasingly being generated in real time. In connection with Industrie 4.0, however, it is the ability to evaluate and process this flood of data that is of paramount interest. That is how Big Data becomes Smart Data. The challenge is therefore not only for IT systems to be able to handle heterogeneous data correctly but also for them to analyze the data in order to create a reliable basis for business decisions – preferably in real time. Only in this way can processes be controlled intelligently and adapted to changing parameters. Taking the metaphor further, Big Data is thus the new oil of the 21st century. Cloud Robotics �Shared intelligence. Nowadays smartphones, tablets and computers utilize data and processing power from the cloud as a matter of course. In the context of Industrie 4.0, robots too will be able to access decentralized data in networks or in the cloud, thereby significantly boosting their performance and flexibility. The robot itself will only require a small chip to control functionality, motion and mobility. For the task at hand, specific services will be retrieved from the cloud or individual robots networked on an ad hoc basis to form temporary production teams. In this way, specialists will become universalists that can be used for a wide range of different manufacturing processes. Cloud robotics enables the implementation of a broad spectrum of different industry-specific applications via ® “Robotics as a Service ”. Another effect of the cloud: robots learn from one another. If one robot encounters an obstacle, for example, it posts this information to the connected systems, which can use it to respond intelligently to the obstacle. Hello Industrie 4.0�Glossary
Collaborative �Hand-in-hand. Collaborative robots – sometimes also known as “cobots” for short – are robots that are capable of human-robot collaboration (HRC) and work hand-in-hand with Robots their human colleagues. As collaborative robots operate without physical safeguards, they have to permanently calculate the risk of colliding with humans, constantly checking this via the robot controller. The strict safety requirements have been rede昀椀ned in the revised EN ISO 10218 standard, parts 1 and 2, and in the ISO/TS 15066 speci昀椀cation initially drafted in 2010. Besides the robot itself, the standard also covers the adapted end-of-arm tooling with which the robot performs its tasks, and the objects moved with it. With the LBR iiwa, 阀阀 has made the world’s 昀椀rst series-produced, collaborative lightweight robot for industrial applications ready for the market, thereby proving that the visions of Industrie 4.0 can be turned into reality. Committees �Strong alliances with KUKA. As a leading supplier of intelligent automation solutions, KUKA is directly involved in Industrie 4.0 and sees itself as responsible for forming strong alliances with the goal of actively shaping the factory of the future together with other key players. That is why KUKA is a member of all major national and international advocacy groups and committees, such as the Industrie 4.0 Platform coordinated by the German Federal Ministry for Economic Affairs and Energy, the Industrial Internet Consortium IIC, the OPC Foundation, the German industry association VDMA and the associations BITKOM and VDE. As a trailblazer for Industrie 4.0, KUKA is a sought-after interlocutor for decision-makers in the worlds of politics, research, and business. CPS (Cyber- �Physical world meets virtual world. A cyber-physical system (CPS) is a “thing” in the Internet of Things (IoT). It is a combination of mechanical and electronic software components that Physical System) communicate via a data infrastructure such as the Internet, react flexibly to external influ- ences and exchange data with information systems and other CPSs. In future manufacturing facilities, cyber-physical systems will communicate with intelligent, networked industrial production and logistics units – also known as cyber-physical production systems (CPPS). The CPSs exchange information, trigger actions in production and reciprocally control themselves autonomously. This enables industrial processes in manufacturing, engineering, use of mate- rials, supply chain management and life cycle management to be fundamentally restructured and optimized. Data Ownership �Who owns the data? The data must belong to their originator. A principle that is regrettably contested in the cloud. The open exchange of data and information, however, is a vital ingredient of Industrie 4.0. Information that was generated in the company prior to storage in the cloud is generally subject to local copyright laws. But if the data are created in the cloud, things become somewhat more ambiguous. Cloud providers have a different approach to dealing with user data in terms of access rights and at times create confusion as to ownership. It is therefore important to ensure transparency in the use of cloud services and to select secure encryption for all data sent to the cloud. This gives users control over their data and thus some form of ownership, regardless of legal issues. Particularly with a view to the hori- zontal networking of various companies within a production process, the question of data sovereignty is of central importance. With cloud solutions meeting the highest data security standards, KUKA offers unique platforms on the basis of which customers can exchange their own data with others or enrich them with new intelligence and additional information. Decentralized �Intelligence evolves in the swarm. Decentralized intelligence will play an important role in Industrie 4.0: all parties can communicate with one another – workpiece with machine, Intelligence machine with machine or with higher-level processes. No central “brain” will control and monitor the things, but rather autonomous production units will carry out this function for both heterogeneous and homogeneous teams. Decentrality makes for greater flexibility and quicker decisions. Intelligence evolves in the swarm or through joint networking with the cloud. Demographic �Society is getting ever older. In principle, the term “demographic change” is a neutral reference to any alteration in the age structure of a society. At present, however, it is being Change widely used as a synonym for increasing overaging in the industrial nations. A trend that is diametrically opposed to the rapid growth of the global population. By the year 2020, more than half of the German population will already be over 50 years of age. An ever smaller number of people in employment will have to generate the entire productive output for the social systems. This challenge can only be met if the remaining workers become considerably more productive than all generations before them. At the same time, opportunities must be created for older, experienced employees to participate in the world of work for longer. In order to make new working environments both highly productive and ergonomically beneficial for the labor force, KUKA is developing central key technologies for Industrie 4.0: collaborative robots, mobile assistance systems, autonomously controlled vehicles and smart, digitized automation solutions that support humans in the work setting, easing the workload in a variety of ways. Development �Innovating together. Intelligent solutions benefit from the expertise of many creative professionals. KUKA offers interested developers access to a powerful platform that serves as Community a central point of contact for exchanging a vast variety of information. This community assists its members with expertise, support and resources. This platform by developers for developers, a “KDN – KUKA Developer Network” so to speak, facilitates the very exchange of information that makes the added value of team creativity fruitful. The bundled expertise further strengthens the potential of the KUKA ecosystem. As an example, the platform makes it easier for start-ups to generate business processes and develop new business models. II�III
Digital Business �Creating the business of the future. Digitization is upending a large number of existing business models. Networked automation, intelligent processes, shared expertise across Transformation companies and industries, and a holistic view of the value chain with involvement of the customer – these are the characteristics of digitized business models. They open up com- pletely new business opportunities and options, and offer competitive advantages – and only they make it possible to fulfill customer requirements optimally. There is no economi- cally successful future without the digitization of business models. With its own Consul- ting center of excellence, KUKA is assisting companies along the way to a digital future. Digital Customer �Journey through the digital business landscape. In general terms, the “Customer Journey” represents the sequence of (digital) contacts that a customer may encounter Journey when dealing with another company. Depending upon the issue, the first point of contact and subsequent contacts may vary. If a purchase is intended, for example, the customer’s journey may start off with the links in a search engine request or a rating portal, followed by a shop visit. The app store and support website are other possible starting points that are implemented in industry. For business-to-business processes, the initial contact may take place through the business cloud instead of a website, for instance by visiting a developer platform. KUKA serves its customers as a hub for organizing their digital journey. Digital Shadow �Virtual image of real things. The digital shadow is a digital image of a real object. This data contains both the current status and the desired status of the object, the possible ways and processes for achieving this desired status, and the history of what the object has already gone through. Only through the combination of a digital shadow and a physical object does a smart thing result. Every physical product can be manufactured more efficiently and with higher quality in the digitized production facility if a digital shadow has been created for it and it bears its own specific DNA. Digital �Transcending all boundaries. The digital supply chain merges the major business processes of all parties involved – from the suppliers to the manufacturer and the end customer. The Value Chain potential of a digitized value chain lies primarily in the acceleration of the production and logistics processes, the reduction of effort for data acquisition and the optimization of data security and consistency. With integrated networking, the digital value chain is able to overcome current media discontinuity. One example from the field of procurement: where a steel-processing company previously had to activate a complicated process via different media for purchasing and replenishment, in the future purchasing will be automated on the basis of predefined parameters. Companies today are already making use of digital value chains to optimize individual production islands and processes within their organi- zation. In the factory of tomorrow, the digital supply chain will also encompass global procedures across company boundaries, controlling them largely autonomously. As the most flexible machine ever conceived by man, the robot plays a central role in the digital supply chain. In its function as the core component of intelligent automation solutions, it increases the entrepreneurial freedom of action, creates competitive advantages, speeds up production processes and assures quality in the long term. Integration into the KUKA Connect platform accelerates the conversion to a digitized value chain. Digitization �Potential of the digital transformation. Converting real products and analog sequences into digital data and processes is referred to as digitization. In Industrie 4.0, people, machines and industrial processes are networked on the basis of cyber-physical systems incorporating state-of-the-art information and communications technology. In this context, the intelligent exchange and interpretation of data determine the entire life cycle of a product: from the idea to development, manufacturing, use and maintenance through to recycling. Production and logistics processes will be globally networked beyond the factory gates in the future for the purpose of optimizing the flow of materials, detecting non-conforming parameters at an early stage and enabling a highly flexible reaction to changing customer requirements and market conditions. Edge Cloud Gateway �The Cable Modem of the shop floor. Much like a DSL Router connects peripherals to the Internet, an edge cloud gateway connects the various devices at the production level to a network or a cloud environment via EtherNet or wireless / mobile connection, so that data can be collected, exchanged and processed. Features such as secure communication and quality of service are implemented. Flexibility �Flexibility in all dimensions. Flexibility is the ability to react quickly to changing influences. In the smart factory, utmost flexibility results primarily from the combination of IT technologies, such as the Cloud and Big Data, with intelligent, generic production units incorporating robots and autonomously controlled mobile units. The factory of the future will not have any predefined routes or rigid processes. Mobile units will equip robots “on the fly” with other tools, enabling them quickly to carry out new tasks or process other workpieces. The smart factory is therefore able to manufacture different products or product versions without any significant retooling times. It thus completely redefines the concept of flexibility in production. Hello Industrie 4.0�Glossary
Framework �The programming kit. Generally speaking, a framework is a defined structure for the programming of software or dynamic websites. So-called “pre-programs” allow developers to save time: frequently recurring program steps are already pre-programmed and can simply be called up when needed. Thus, it is no longer necessary to repeat certain functions and computer tasks. Frameworks provide valuable support particularly for quickly program- ming apps. In robotics, a framework provides software components for industrial use. This includes algorithms, libraries and methodological know-how. Standardized interfaces and appropriate middleware make it easy to replace hardware and software components. This simplifies and speeds up application development in automation. Home Assisted Living �Living independently – even in later life. Our society is becoming ever older: in 2035, one in every three Germans will be over 60 years of age. Everybody wants to stay autonomous and active for as long as possible when old, however. Home assisted living enables the elderly to continue an independent life within their own four walls. Besides service robots, which take care of household activities, and smart home applications, services in the medical and nursing sectors will be a part of daily life in the future. With the aid of intelligent robots, rehabilitation treatment, for example, will be possible at home. Mobility assistants will help people to remain agile into old age, improving the quality of millions of lives. Horizontal �Dynamic company networks. Exact coordination is not only indispensable for internal process optimization within a company, but also between all companies involved in the Integration value chain. This horizontal integration – networking between different enterprises and their assets – is the starting point for the flexible design of their shared value creation processes. In the era of Industrie 4.0, companies will form dynamic networks in the future, linking order-specific and product-specific capacities in virtual production communities. Current data from the production-relevant processes will enable fast and precise reactions – for instance to planning changes or unexpected events occurring inside or outside an indi- vidual company. Production and logistics processes adapt to the real situation in real time, boosting the long-term flexibility and efficiency of the companies acting within an integrated concept. Process analyses to increase productivity involve many different components – and thus also their manufacturers. See also Manufacturing Ecosystem. Individualized �Meeting every customer requirement. Individualized, or customized, production refers to the concept of an intelligent, highly automated production system that allows high variance Production and dynamism in the product range with production costs at the level of mass production. The goal is to resolve the conflict between the customer’s desire for individualization and the process efficiency of production in an industrial setting. A batch size of 1 is the highest level of customized production. Besides proprietary solutions in the automotive sector, Industrie 4.0 with its universally networked production environments represents the world’s most advanced approach for implementing customized production. Industrie 4.0 �Production meets digitization. Industrie 4.0, Smart Production or Internet of Things (IoT) – even if the names and terms used vary from one country to another, they all share the same goal. What is called for here is nothing less than a long-term transformation of our global perception of industrial production through the seamless connection of the digital and real worlds. KUKA is at the interface between these two worlds and is playing a decisive role in advancing this transformation as a thought leader and trailblazer for Industrie 4.0. It was back in the 1990s that KUKA as a first mover recognized the potential to be gained by combining the world of IT with conventional automation technologies. The company was also the world’s first robot manufacturer to develop open, interoperable and flexible systems on the basis of standardized mainstream technologies and to make them ready for the market. In collaboration with experts from diverse sectors, KUKA is now already implementing highly flexible, digitized manufacturing processes that will open up new opportunities in a competitive environment and lastingly change the way we work and produce. KUKA supports companies with the digitization of production across industries – from small and medium-sized companies to large OEMs. This provides a platform for anyone who is ready to step into the world of Industrie 4.0. Internet of �Basis for efficient production. Both the Internet of Automation (IoA) and the Internet of Robotics (IoR) make use of defined open communications and data standards to network Automation (IoA) / interoperable production processes even across company boundaries. In the IoR for example, KUKA robots, the KUKA App Store, middleware and monitoring tools are networked to form Internet of Robotics a highly efficient production environment in which analog and digital devices can easily communicate with one another. In the near future, it will be possible for all the cyber- (IoR) physical elements involved in the automated manufacturing process to be networked in the IoA and to communicate with the IoR. Extensive standardization of protocols and technologies is required for this Internet-based infrastructure. See also Committees. IV�V
Internet of �Everything communicates with everything else. Like Industrie 4.0, the Internet of Things (IoT) presupposes a network of physical objects – devices, vehicles, buildings and other Things (IoT) items – which are fitted with electronic components, software and sensors, all of them being linked interoperably via the Internet. Unlike Industrie 4.0, the IoT rather non-selec- tively refers to all things that could be connected to the cloud. The IoT thus also encom- passes the private domain, including, for instance, the already well-known “smart home” applications. Strictly speaking, the smart factories of Industrie 4.0 along with all their production and logistics processes are a part of the IoT. Experts forecast that the IoT will comprise 50 billion objects by the year 2020. Interoperability �Everything works together. Interoperability (IOP) describes the ability of an object, device or machine to communicate with other things in the network. It must be able to do so regardless of whether the devices are from the same or different manufacturers. Inter- operability is a fundamental precondition for creating a layer that enables cyber-physical systems to be interconnected such that interactions are possible without the participants knowing which technologies the implemented devices are based on. It is also the basis for the capability of the things in the network to communicate without any restrictions and to act intelligently as a swarm. See also Committees. KMP omniMove �Strong on the move. Wherever size, load-bearing capacity and precision are required, the KMP omniMove heavy-duty mobile platform is in its element. Individually or as part of a fleet, the KMP omniMove can effortlessly move beneath, and lift, workpieces weighing more than 90 tonnes and move in any desired direction with millimeter precision from a standing start, thanks to the multidirectional omniWheels. The KMP omniMove can move autono- mously, under guidance along a programmed path or conventionally under manual control. KMR iiwa �New horizons. Shorter response times and greater 昀氀exibility going beyond full automa- tion: these are the requirements of markets that are changing at an ever faster pace. The industrial manufacturing of the future will require modular, versatile and, above all, mobile production and manufacturing concepts. That is why the KMR iiwa unites the sensitive and compliant LBR iiwa lightweight robot with 阀阀’s mobile platform technology to form a new, intelligent and fully mobile combination that can work in the vicinity of humans. Just like humans, the 阀阀 Mobile Robots (KMR) can also track moving workpieces, move around them freely and link solitary production islands to form new production units. KMR QUANTEC �Large-dimension e-mobility. Anyone thinking big and looking for 昀氀exible mobility will 昀椀nd the perfect powerful partner in the KMR QUANTEC. The combination of 阀阀 six-axis robots, mobile platforms, high-performance energy storage units and industrial- grade components creates a mobile solution for virtually any scenario. Despite its strength, the KMR QUANTEC is characterized by outstanding precision and maximum electromobility. Its small power plant supplies it with electricity for a full eight-hour shift. The position and number of robots installed are variable, as too are the size and payload capacity of the platform. Grippers, power-hungry tools and special equipment can also be transported on the KMR QUANTEC and continuously supplied with power. 阀阀 昀氀exFELLOW �Mobility on demand. The KUKA flexFELLOW automation unit can be moved manually and allows ad hoc localized variation of the degree of automation in production. Without the need to alter the production layout, for example, the KUKA flexFELLOW is able to open the safety doors at machines, which it can then load and unload independently. It can also assist the operator in performing work steps in ergonomically unfavorable situations. In alternating operation, humans and robots can ideally complement one another. The combinability of manual and automatic tasks means that production can be optimally adapted to the specific requirements. 阀阀 LBR iiwa �Robotic colleague. KUKA is starting a new chapter in the history of industrial robotics with the lightweight robot LBR iiwa (intelligent industrial work assistant). As the first series-produced sensitive robot for human-robot collaboration (HRC), the LBR iiwa is tapping new applications that were previously closed to automation. Thanks to its sensory capabilities, it can intuitively learn new tasks on an ad hoc basis, simply through being guided by its human partner. The machine becomes a “robotic colleague”. It works hand in hand with the operator, thereby enabling him to work more efficiently, more ergonomically, more precisely and with greater concentration. As a robot that can genuinely be deployed universally, it is defining new standards on the road to the fourth industrial revolution. Hello Industrie 4.0�Glossary
Logistics �Now. Everything. Always. Customized products and same-day delivery – customers have a growing expectation that everything will be available in all places, at all times. This ubiquity places the utmost demands on the logistics and process chains and is increasingly embra- cing the stationary retail sector and the structure of merchandise 昀氀ows. The boundaries between individual delivery channels are successively vanishing and modern distribution centers are often being set up directly in metropolitan areas thanks to the reduced space requirements. Changes that can only be addressed through highly transparent, digitized networking of production and logistics. In this context, 阀阀 sees itself as a solution provider translating the individual requirements of the market participants into 昀氀exible, networked and software-supported logistics concepts. M2M Communication �The universal communicator. Machine-to-machine communication, or M2M, is the automatic exchange of information between machines. These may be vastly di昀昀erent Protocol end devices, from production machines through vending machines to vehicles or household appliances. A standardized set of rules is needed for M2M communication to work – in modern terms: a protocol. Such a standardized software interface enables universal communication. The most promising protocol at this time is the Open Platform Communications Uni昀椀ed Architecture (OPC UA). Machine Learning �Knowledge through experience. Intelligent machines garner their knowledge through experience. In the case of networked machines, it is irrelevant whether the experience is their own or originates from swarm intelligence. An artificial system always learns by comparing the desired objective and any anomalies that occur. It can recognize correlations, patterns and general rules, draw conclusions from them and modify its future behavior, this synthetic process being referred to as machine learning. Especially in unstructured environments and with highly flexible processes like Industrie 4.0, machine learning in a swarm or in the cloud is an effective method of adapting production processes intelligently and autonomously to the individual framework practically in real time. Manufacturing �Access rather than ownership. Digitization has substantially changed the approach to physical possession. This is increasingly being replaced by temporary access to goods or as a Service (MaaS)/ services. The best example: music streaming. What has already become an everyday situ- ation in many consumer segments will also revolutionize the industrial environment over Robotics as a Service the next few years. As the name implies, manufacturing processes are provided as a service when offering “Manufacturing as a Service”: the machine does not change ownership, and ® only the service of the machine is paid for (for example in the form of a cost-per-uptime (RaaS) model). What applies to complete production systems will, in the future, also hold true for individual elements within a manufacturing facility – for robots, for example. On the basis of a “pay-per-use” model, it will not be the physical object itself that is purchased in ® conjunction with “Robotics as a Service ”, but rather its performance, such as weld spots in vehicle body production, for instance. The smart factory of the future integrates these services seamlessly into its production processes and thus has the capability of reacting to varying capacity requirements and goods flows exceedingly flexibly and efficiently while conserving resources at the same time. Ultimately, these business models uproot traditional ideas of what a value chain may look like: the principle of shared production will become more important, allowing the end user to act as a co-producer. If desired, KUKA Consulting analyzes the business models of companies to determine whether they can be marketed profitably as a service (“Product as a Service”). Manufacturing �Expertise is the raw material for creating value efficiently. If the best available expertise can be focused upon every single process step and every single level of activity, all parties Ecosystem involved benefit: product designers, developers, manufacturers, logistics specialists and end customers. A complex network that optimally brings together all relevant expertise in terms of personnel, economy and technology is considered an ecosystem. This comprises hardware and software resources, process and project know-how, consulting expertise and complex networked architectures of production and information technology. What is important for such an interdisciplinary system is that the combined expertise is not just limited to a single company, but that the best possible personnel and the best available knowledge on the market is brought together under one project umbrella. As an experienced player across industries, products and processes at the interface of OT and IT, KUKA is in a unique position to “fuse in” the ideal experts and expertise for any given project. This yields an unbeatable team of resources provided by the customer, KUKA and external partners, with superior know-how and advanced technology from the shop floor to the business model level. Ecosystems add value beyond just optimizing the value creation processes: this bundled creativity allows for new products, solutions and business models to be developed jointly. VI�VII
Megatrends �What makes the world go round. Customization, digitization, responsible use of natural resources and demographic changes are the megatrends that will need to be mastered in the coming decades. With a forecast world population of eight billion by the year 2025 and ten billion by 2060, ever more customer requirements of increasing diversity will need to be satisfied. At the same time, demographic changes will be confronting industrialized and emerging countries with economic and social challenges over the long term. Humanity is thus facing a fundamental paradigm shift which will undoubtedly have far-reaching conse- quences for our worldwide economic systems. That is why Industrie 4.0 does not describe a purely technical innovation scenario but rather a way in which intelligent technology can help to overcome the global challenges of the 21st century. As a thought leader and trailblazer for Industrie 4.0, KUKA is working on production environments that increase economic efficiency while also using resources responsibly, which make high-quality goods more affordable and are instrumental in sustainably improving human working conditions in factories. Mobility �Robots on the advance. The production of the future requires greater flexibility – for both faster manufacturing and customized products. One indispensable prerequisite for creating a higher degree of flexibility in industrial environments is greater mobility. This can be achieved by means of episodic, periodic or permanent mobility concepts that each bring about acceleration in industrial production in their own specific ways. For this reason, KUKA is paving the way for this key technology with platforms that can move intelligently and autonomously in order to transport things or machine workpieces. They can find their own way if necessary, aligning themselves with workpieces to within a millimeter or even moving the robot to them. They are also capable of responding autonomously and adaptively to changing conditions in complex logistics and production chains. Mobile auto- mation solutions from KUKA show today what the future holds in store for highly flexible production in Industrie 4.0. Monitoring & �Data in real time. Monitoring and stream analytics compare and analyze data that is available to the smart factory from diverse sources – devices, sensors, infrastructure, etc. Stream Analytics/ In real time they make comparisons with data records from the past, recognize anomalies and are able to categorize faults with the aid of machine learning. On this basis, intelligent Micro Services systems initiate immediate countermeasures and generate forecasts and recommended actions for the future. On-Premises �Software on board. On-premises solutions rely on the infrastructure of the company’s in-house IT. The deployment model of such software can be designed as a service and thus take on the function of a “local cloud”. People First �Production and products for people. In the factory of the future, the focus of thought and action will shift to the human worker with his changed requirements, desires and capabilities. Networked and flexible production technologies combine the cost advantages of mass production with the customization potential of craft manufacturing. This means that the customers’ desire for high-quality individualized products does not lead to higher prices, as is currently the case. But humans are at the center of the future world of goods not only in their role as customers. Intelligent robots that collaborate with humans, and mobile assistance systems will improve the world of work in many different ways. They handle heavy loads, carry out activities that are not ergonomic or are simply too dangerous for people and perform tasks which require levels of precision and speed of which humans are not capable or which are cognitively stressful. Predictive �Eliminating static maintenance intervals. Dependable production planning and maximum machine availability through the avoidance of unscheduled downtime are the practical Maintenance advantages of what is internationally known as predictive maintenance. On the basis of real-time data, all relevant parameters of the machines involved in the manufacturing process are acquired and evaluated for anomalies by means of stream analytics. In a subsequent machine learning process, speci昀椀c fault patterns and the causes of a problem are detected in good time. This results in fewer rejects and maximum availability over the entire life cycle of the production line. The requirements on machine operating times vary depending on the speci昀椀c branch of industry and its product cycles. While this could be up to 30 years in the aerospace sector, it is a matter of just a few months in the case of fast-moving goods, such as smartphones. With the aim of enabling an accurate assessment of the future performance of the machine or one of its components, intelligent predictive maintenance systems interconnect the largest possible amount of data from decentralized sources for the purpose of analysis. Hello Industrie 4.0�Glossary
Preventive �Efficiently controlling necessary downtime. Preventive maintenance is usually carried out on the basis of fixed contracts, which provide for an inspection of critical elements of Maintenance the production systems at regular intervals or at fixed times. This may include analyses and cleaning the machines, for example. One of the advantages offered is the easy-to-plan and predictable maintenance times, which serve to prevent unforeseen downtime and ultimately save costs. Reshoring �Available is the new cheap. Whereas in the past purchase decisions were often primarily made on the basis of the lowest price, in the future it will be the product that is available most quickly and with a high level of customization that will be at the top of consumers’ shopping lists. This necessitates new manufacturing and marketing methods and structures that will only become possible as a result of networked production in smart factories. Short distances will be an important factor in achieving fast availability. Due to the high degree of automation, production steps that are currently outsourced to low-wage countries can be repatriated to high-wage countries in a process known as “reshoring”. Irrespective of wage structures, intelligent automation allows cost-efficient and high-quality production in the vicinity of the consumers. Resource E昀昀iciency �Sustainable production. The ability of humanity to handle the future will be determined by a responsible and sustainable approach to natural resources. In a just world, it may be assumed that ever more people will want to be supplied with ever better products. Flexible, intelligent and networked production as envisaged in Industrie 4.0 offers the opportunity of using raw materials more efficiently and more sustainably along the entire value chain and recycling them to a great extent for the sake of the planet. Robofacturing �Craftsmanship meets robotics. Unlike a conventional factory, with its high degree of uniform mass production, craft manufacturing combines the virtues of skilled craftsmanship with a low level of mechanization. Craft-manufactured products convince with high-quality and a distinctly unique character. Robofacturing unites the advantages of craft manufac- turing with the low price of a mass product, making individual and high-quality products affordable for large parts of the global population. Robotic Governance �Creating a responsible future world for generation “R”. Robotic governance is a concept which, among other things, considers the ethical/moral, socio-cultural, socio-political and socio-economic e昀昀ects of robotics on society and provides a framework for solving problems resulting from these changes. The governance principles include accountability, responsibility, transparency of structures and fairness. In this way, robotic governance helps to create a sustainable and responsible future world for the upcoming generation “R”. Robotic Natives �Robots as natural companions. Future generations, “robotic natives”, will see robots as the state of the art, as a lifestyle, or quite simply as normal. Just as commonplace as smartphones and the Internet, for example, are for the digital natives of today. They will have overcome the old human versus machine antagonism. The robot-oriented generation will shape a society that not only works differently, but also thinks differently. They will see the capabilities of robots as universal, networkable services that can be requested via the Internet and flexibly adapted to the requirements and desires of the individual at the click of a mouse. While nowadays robots are primarily known as work assistants in industrial processes, in the future they will be found in all areas of our daily lives as driverless cars, robo-furniture, carebots and a wide range of home and personal assistants. By 2050, a robot in every household will be part of everyday life. Security �No success without security. The issue of safety and security is one of the most multi- faceted business aspects of modern companies. In the separate worlds of production (OT) and information (IT), a basic distinction is made between safety and security: in OT con- texts, the term “safety” is used to refer to the safeguarding of people and machinery as well as the availability and reliability of production equipment. In the IT environment, the term “security” primarily relates to data security, integrity and con昀椀dentiality. OT and IT are merged in the networked world of Industrie 4.0, which brings the issue of safety and security to a new level of complexity. The use of cloud models and the networking of entire companies and organizations exacerbates the security aspects (see also Data Ownership). 阀阀 Consulting o昀昀ers well-founded advice on all safety and security questions and can draw on a broad network of expertise, including strategic alliances with international experts. VIII�IX
Service Robotics �Robots enter daily life. Even today, useful robotic assistants are making everyday life easier. Small, specialized service robots, for example, have long since established them- selves in our private sphere. They are deployed as assistants in the home – vacuuming, mowing the lawn or cleaning windows. As yet, their capabilities are mostly limited to a single task. However, they do demonstrate one thing: collaboration between humans and robots works in everyday life. Thanks to the progressive development of service robotics, robots will shape daily life in the future in various ways. Whether it be as a nursing robot in clinical settings, as helpers for the elderly at home or as assistants in many other areas which today sound futuristic. For the robotic natives of tomorrow, service robots will be as self-evident as smartphones are for people of the present. Smart Data �Intelligent data exchange. If Big Data is the oil of the future, then Smart Data is the fuel that drives the production of the future. Currently, data is just data. To turn it into information, it must be interpreted. This is the step from perception (recognizing) to cognition (understanding). Books, for example, are at first merely collections of letters. They only become knowledge when they are processed and interpreted in the brain. KUKA is developing smart data technologies for the digital domains in the age of Industrie 4.0. In the context of intelligent automation, the central focus is on the topics of data commu- nication, process modeling, machine learning, autonomous self-configuration and process optimization. Smart Factory �Intelligent and self-organizing. The intelligent factory of the future is a production facility in which manufacturing systems, robots, logistics systems, products and their components are largely able to organize themselves autonomously. The smart factory is undergoing a paradigm shift towards an entirely new production logic: smart products, components, tools and machines are unambiguously identi昀椀able, can be localized at all times and are aware of their history, their current status and multiple ways to the desired goal. With the smart factory’s high degree of 昀氀exibility, customization with a batch size of 1 will become reality in the context of industrial mass production. To achieve this, the production systems must, on the one hand, be networked vertically, for example with business processes within factories and companies. On the other hand, they must also be linked horizontally across company boundaries – from the purchase order through to outbound logistics – to create distributed value creation networks that can be controlled in real time. Smart Platforms �Intelligent and flexible. New, intelligent platforms will be created for the implementa- tion of Industrie 4.0. They will support collaborative industrial processes and use their services and applications to network people, things and systems. The result will ensure greater flexibility and a continuous flow of information: smart platforms will document the entire business process, work safely and reliably at all levels, and support mobile end devices and collaborative production, service, analysis and forecast processes along the entire digital supply chain. For the smart factory, KUKA already has modular software architectures in its portfolio, based on mainstream technologies and prepared for the entire evolutionary process of Industrie 4.0. The Java platform of KUKA Sunrise makes it ideally suited to future app-based programs. Such a platform sets the stage for cross- industry digitization and thus increased value creation. This forms the foundation for the smart factory of the future. Social Machines �Interconnected. Intelligent. Flexible. Machines in production that are intelligently interconnected, communicate with one another and can instantaneously react to deviations and changes in an independent and situation-based manner are called social machines. They are part of the Industrie 4.0 vision. The underlying idea is that machines are able to share their knowledge like in social networks – information about themselves as well as experiences and “lessons learned” from their processes. At the same time, social machines coordinate the information received and learn from the network too. Similar to Facebook users, they independently obtain information from the Internet and connected social machine networks. Through swarm experience, they are aware of the best parameters for machining a particular material, for example, and they exchange them with “befriended” machines. Standardization �General requirements for reliable interaction. In the course of any technical evolution, di昀昀erent solutions, formats and approaches usually compete with one another – developed and propagated by various factions, committees or companies. Only standardization, with its exact and binding de昀椀nition of framework parameters and the possible interfaces, makes it possible to create appropriate expansions, counterparts and communication bridges to a new technology. Of particular importance in this context with regard to the implemen- tation of Industrie 4.0 are the new de昀椀nitions of safety in the area of human-machine collaboration and the standardization of interoperability in the area of data exchange. 阀阀 is striving for OPC UA to be established as one of the future standards. This protocol not only transports machine data, parameters, process values and measured data, but can also, in combination with other standards, de昀椀ne them semantically in a way that is machine-readable. Hello Industrie 4.0�Glossary
Standards �The basis of all constructive cooperation. Standards are the elementary basis for brea- king down barriers in the globalized world of Industrie 4.0. As a world leader in automation, KUKA sees itself as responsible for playing a key role in shaping the areas of standards and standardization. To this end, KUKA is driving forward the harmonization of commu- nications, data exchange and safety, for example, in the field of direct human-machine collaboration. In this way, it is creating new standards to ensure interoperability in the smart factory of tomorrow. As one of the key players in the paradigm shift from the third industrial revolution to the fourth, KUKA is thus laying the foundation for successful coope- ration between all those involved. Time to Market �Meeting customer requirements more quickly. The time to market (TTM) denotes the length of time from development of a product to its availability on the market. In the factory of the future, this time, which is often decisive for the sales success of a product, will be signi昀椀cantly shortened. Positive e昀昀ect: changing requirements and trends in increa- singly volatile markets can be met with corresponding products much more quickly than previously. Traceability �Keeping track. Traceability here refers to the ability to fully trace all raw materials, pro- ducers, upstream suppliers, individual parts or assemblies as well as the complete product and its consumers in the digital value chain. It is possible at all times to determine when, where and by whom the goods were produced, processed, stored, transported, used or disposed of. Irrespective of whether an individual part or a finished product is concerned, a distinction is made between two directions of traceability: from the manufacturer to the consumer and from the consumer to the manufacturer. Value Data �From worthless data to valuable information. Individual data is like isolated objects in a void. They only make sense in context, and meaningful data can yield information that increases in value through being made exploitable for various purposes. Without being assigned, processed, compared, etc., data about the actual states of different parameters of a machine are nothing but loosely connected numbers. Intelligent evaluation of these data can provide valuable assets, for example by using forecasts that minimize or prevent maintenance and downtime. Vendor Cloud �Cloud with limited access. Large manufacturers with extensive supply networks avoid amalgamating di昀昀erent production data in the cloud, as they are concerned that this could reveal information about the production processes. But since the various suppliers and partners need important information from the production process, the manufacturers implement their own production cloud on the Internet or on their premises. In this vendor cloud, the production company can give suppliers access to exactly the data and information that are relevant to them, while all the rest remains hidden. 阀阀 can develop, implement and operate such cloud solutions for OEMs. 阀阀 is the ideal partner for opera- ting vendor clouds thanks to its many years of experience with similar projects (including infrastructure work and coordination with suppliers and customers). Vertical �Internal networking optimizes the production landscape. Networking the various assets within a company into an e昀昀icient production unit is one of the prerequisites for creating Integration a smart factory. The di昀昀erent manufacturing stages with their respective speci昀椀c assets can thus be merged into an integrated production process, for example. The networking of individual levels and assets via a cloud enables company-wide horizontal integration of the value chain as described in the Industrie 4.0 concept. For example, it allows integration into the 阀阀 ecosystem with all the resulting bene昀椀ts (see Manufacturing Ecosystem). X�XI
Four Robotic Revolutions �The disruptive force of robotics. Robotics have already changed the world. In the next 50 years, it will have a disruptive in昀氀uence similar to the one exerted by the internet and information technology over the past 昀椀ve decades. The societal change that will accompany this is re昀氀ected in the “four revolutions in automation technology”. Alongside industrial robotics, which will continue to grow strongly with new, networked manufacturing processes, the area of service robotics – and ultimately robots – will become more established in private settings. In addition to ever faster response and development times for new robot genera- tions, this step will also require a radically new approach. Innovation Cognitive, Sensitive and Safe Robot-Based Automation Solution Mobile, Sensitive and Safe Robot-Based Automation Solution Sensitive and Safe Robot-Based Automation Solution Robot-Based Automation Solution First Second Third Fourth Revolution Yesterday – �Robot-Based Automation Solution. The age of robotics began in the 1960s and 1970s. Industrial robots brought greater e昀昀iciency and productivity to simple manual tasks st such as lifting, spot welding and packaging. They began their triumphant advance in the The 1 robotic automotive industry, spreading successively to other sectors. In this manufacturing revolution environment, the robot operated in a 昀椀xed location within safety enclosures or zones to which humans had no access. Its tasks were clearly de昀椀ned: relieving humans of monotonous work and assembling cars or other goods in large volumes as quickly and as precisely as possible. Today – �Sensitive and Safe Robot-Based Automation Solution. What was science 昀椀ction just a few years ago is now a reality: robots and humans work hand in hand. Collaborative robots nd like the LBR iiwa developed by 阀阀 enable an entirely new relationship between humans The 2 robotic and robots: direct and safe collaboration – without any safety enclosure. Where there is revolution no fence restricting freedom, the way is open for new, highly e昀昀icient and far more 昀氀exible applications. The robot is now a machine that can be touched and with which interaction is possible. It will shape daily life in various ways in the future. Whether it be as a work assistant in industry, a service robot in the public sphere, a nursing robot in clinical settings, a helper in the home or in many other areas which today still sound futuristic. On the starting �Mobile, Sensitive and Safe Robot-Based Automation Solution. As autonomous mobile units, collaborative robots are able not only to react intelligently to their surroundings, but rd also to change their place of use. The ability to interact with people, machines or work- grid – The 3 pieces in varying locations gives mobile robots virtually boundless application potential. robotic revolution Mobile robots can already perform logistics tasks independently, collaborate directly with humans or quickly take on new tasks at di昀昀erent workstations. Essentially, there are as many potential applications as there are ideas for such applications. In the future – �Cognitive, sensitive and safe robot-based automation solution. If the robots of the future are characterized by arti昀椀cial intelligence, they will re昀氀ect on and cognitively The 4th robotic understand what they do. They will increase the productivity of humans to a much greater extent than today, while the interactions between humans and robots will become ever revolution simpler. They will have the ability to interpret human language and gestures (smartphone voice recognition systems are already a 昀椀rst step in this direction). On this level, robots will 昀椀nally become active companions for humans. The “thinking” maid, Rosie, from the science 昀椀ction cartoon “The Jetsons” or Lieutenant Commander Data from “Star Trek” will indeed remain 昀椀ction for a long time, but in terms of their capabilities robots will come ever closer to these imagined characters. Hello Industrie 4.0�Glossary
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