DWIH Tokyo Conference Proceedings

German Research and Innovation Forum Tokyo | Conference Proceedings

Symposium on Industry 4.0:
Powering Smart Manufacturing –the TU9 Alliance of German Institutesof Technology
26 October 2016 | Tokyo, Japan

Table of Contents

02

Greeting

03

Introductory Statement
Presentations

07

Keynote Lecture

09

Session 1: Smart, Connected Products and Digital Infrastructure

13

Session 2: Advanced Implementation of Industry 4.0 and
Academia-Industry Collaboration in Smart Manufacturing

16

Editorial Notes
List of Contributors

German Research and Innovation Forum Tokyo | Conference Proceedings

Symposium on Industry 4.0:
Powering Smart Manufacturing –the TU9 Alliance of German Institutesof Technology
26 October 2016 | Tokyo, Japan

GREETINGS

2

Industry 4.0 is synonymous with the next stage of digitization of the
manufacturing sector. The fusion of ICT and manufacturing technologies has
the potential to transform entire systems of production. Real-time optimized
and self-organized supply chain networks across corporate boundaries willlead to long-term gains in efficiency and productivity and eventually open newmarkets.
Industry 4.0 offers multiple approaches for realizing potential related to thetransition from computer-integrated-manufacturing to “smart manufacturing”.
Based on the criteria functionality, efficiency, functional safety and cybersecurity, Industry 4.0 seeks to identify and link relevant technologies for“smart factories”.
The joint Symposium of the German Research and Innovation Forum Tokyo andthe TU9 Alliance of German Institutes of Technology focused on the progressthat leading German universities have made in implementing Industry 4.0 andprovided a platform for German and Japanese experts to meet and exchange
views on cutting-edge technology as well as the current state of education and
R&D in the field of “smart manufacturing”.
Representatives from academia and industry attended the symposium todeepen their understanding and exchange views on issues such as smart,connected products, digital infrastructure, integrated production systems andhuman-robot interaction.
We are pleased to present the Symposium’s proceedings, which, we hope,
will contribute to making its outcomes known to the wider academic
community and the general public.
Professor Dr Horst Hippler
President, German Rectors‘
Conference

Professor Dr Hans-Jürgen Prömel
President, TU9 German Institutes ofTechnology

INTRODUCTORY STATEMENT

Overview of Industrie 4.0 in Germany
Reiner Anderl

Industrie 4.0 was initiated by the German high-tech strategy. The term Industrie
4.0 is a play on words consisting of 3 parts. First, “Industrie” indicates that thisinitiative is dedicated to industry. Second, the “4” stands for the 4th industrial
revolution and aims at reaching a new level of industrial value chains covering
the whole product lifecycle. Third, “.0” is a reference to internet technology
and intends to create the association with Web 1.0, Web 2.0, Web 3.0, Web n.0
technology.
Industrie 4.0 aims to use technology to create new value-added chains covering
the whole product lifecycle. The technological approach is based on the
introduction of so-called Cyber-Physical Systems (CPS), which comprise modern
control systems containing embedded
systems equipped with a connectivity unit
(for example an internet address). CPS’s
combine digital representations (cyber) withreal parts, systems, products or production
equipment (physical). The approach is tobi-directionally reference the digital andthe real world. The CPS approach allows
future products and production equipment
I 4.0
to be interlinked and to communicate. The
strategic target of Industrie 4.0 is therefore
to enhance production flexibility as well as
product configuration and adaptability and tocontribute to enabling the individualizationof products, produced at the cost of mass
production.
To further develop Industrie 4.0 and its dissemination
and utilization in industry, “Plattform Industrie 4.0” wasfounded. This organization is a joint initiative of German
federal ministries, industry and academia. In addition,
joint research programs have been set up by the German

3

INTRODUCTORY STATEMENT

4

Federal Ministry of Education and Research (BMBF). The German Federal
Ministry of Economic Affairs and Energy (BMWi) has also funded programmes
for transferring Industrie 4.0 to industry, in particular to small and medium-sizedenterprises (SMEs). Furthermore, German state governments have also becomeaware of the importance of Industrie 4.0 and support the digital transformation ofindustry based on Industrie 4.0.
Through Industrie 4.0, new technological fundamentals have been developed andpublished. The major fundamental results comprise the “Reference Architecture
Model Industrie 4.0” (abbreviated RAMI 4.0) and the so called “Industrie 4.0
component”.
RAMI 4.0 defines the reference architecture consisting of three dimensions: thelifecycle and value stream, the hierarchy levels and the integration layers. RAMI
4.0 provides orientation for the development and the systematic application ofIndustrie 4.0 and also publishes consistent terminology.
The Industrie 4.0 component is an approach for enabling access to, for example,
control units by integrating an administrative shell. The advantage of the Industrie
4.0 component concept is that you can manage component configuration, datatransfer and access functionality depending on the complexity of the Industrie 4.0
component.
Resulting from the fundamental Industrie 4.0, approaches for various industrial
application scenarios have been described. A subset of these application scenarios
have been implemented in the so-called “Efficient Factory 4.0” at Technische
Universität Darmstadt as industrial use cases. These use cases comprise:Workpieces, manufactured parts and manufacturing equipment used as
information carriers,
Improved value-added chains,
Predictive maintenance,
Condition and energy monitoring,Flexible and intelligent worker assistance
IT-security, safety, privacy, knowledge and intellectual property protection.
To disseminate Industrie 4.0 to German industry, in particular to SMEs,
competence centres have been established. The scope of Industrie 4.0 competence
centres is to transfer Industrie 4.0 know-how to the industry, to develop advancedIndustrie 4.0 competences and to establish networks of excellence for promoting
best practice implementations.
An important contribution to support the digital transformation based on
Industrie 4.0 is provided by the Industrie 4.0 implementation guideline which
was funded and published by VDMA (Verband Deutscher Maschinen- undAnlagenbau e. V.). This implementation guideline proposes so-called tool kits
to identify the current performance of products and production of an enterpriseand to develop a strategy for further improvement with respect to approaching
Industrie 4.0 profiles.
Industrie 4.0 is a fascinating vision for strengthening industry´s competition
profile. Industrial enterprises are required to intensively assess the options ofan Industrie 4.0 implementation within the entire enterprise. In any case adecision has to be made about whether, and if so, how Industrie 4.0 should be
introduced in the enterprise. Furthermore, management needs to be aware thatthe establishment of new business models has to be decided on.

5INTRODUCTORY STATEMENT

6

Further reading:

http://www.hightech-strategie.de/de/The-new-High-Tech-Strategy-390.php
http://www.bmwi.de/DE/Themen/Digitale-Welt/Mittelstand-Digital/
mittelstand-4-0.html
http://www.plattform-i40.de/I40/Navigation/EN/Home/home.
html;jsessionid=DF9464842001F9AF824D585BBF60AEAD
http://www.plattform-i40.de/I40/Redaktion/EN/Downloads/Publikation/aspectsof-the-research-roadmap.html
http://www.effiziente-fabrik.tu-darmstadt.de/menue/index.de.jsp
https://www.mit40.de/

References:

Usländer, T.; Epple, U.;
Reference model of Industrie 4.0 service architectures: Basic concepts andapproach, Automatisierungstechnik (at), Volume: 63, Issue: 10, Page(s): 858–866,
2015
Anderl, R.:“Industrie 4.0 – technological approaches, use cases, and implementation,” at –Automatisierungstechnik 2015, Volume 63, pp. 753-765.
Abele, E.; Anderl, R.; Metternich, J.; Arndt, A.; Wank, A.:
Industrie 4.0 - Potentiale, Nutzen und Good-Practice-Beispiele für die hessische
Industrie. Meisenbach Verlag, Bamberg ISBN 978-3-87525-389-4, (2015)
E. Abele, R. Anderl, J. Metternich, A. Wank, O. Anokhin, A. Arndt, T. Meudt,
M. Sauer:“ E f f i z i e n t e Fa b r i k 4 . 0 - E i n z u g v o n I n d u s t r i e 4 . 0 i n b e s t e h e n d e
Produktionssysteme,” ZWF – Zeitschrift für wirtschaftlichen Fabrikbetrieb, pp.
150-153, 2015.
Anderl, R.; Picard, A.; Wang, Y.; Fleischer, J.; Dosch, S.; Klee, B.; Bauer, J.:“Guideline Industrie 4.0 - Guiding principles for the implementation of Industrie
4.0 in small and medium sized businesses,” VDMA Forum Industrie 4.0,
Frankfurt, 2015.

PRESENTATIONS – KEYNOTE LECTURE

The Japanese Initiative“Industrial Value Chain Platform for Connected Factories”
Yasuyuki Nishioka

The Industrial Value Chain Initiative (IVI), a Japan-based non-profit organization
for connected manufacturing, is beginning to provide IVI platform reference
specifications. IVI platforms are primarily for manufacturers who use their own
data extracted from the factory. Field-level requirements in the factory will bebuilt in bottom-up bases in accordance with IVI’s scenario-making procedures.
This talk presented how the IVI platform reference models act as a guide toretaining interoperability between the platform components. Concluding
remarks suggested that the specification of the platform reference model canbring stakeholders – such as application vendors, device makers, tool vendors,
infrastructure providers – to a connected manufacturing ecosystem in the future.

Robots and Humans in the Digital WorldSami Haddadin

Over decades, one of the primary goals of robotics research has been to enablerobots for direct physical interaction and cooperation with humans andpotentially unknown environments. The community‘s overall vision is to make7

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robots a commodity by putting the human at the centre of the robot design.
This design paradigm allows the seamless connection of efficiency, digitalizationand intelligent automation in order to achieve an optimum user experience. It
was outlined how human-centred robot design, control and planning may letconnected robots for humans become a commodity in our near-future society,and has already led to the first commercial interconnected systems capable ofinteraction. The primary objective of a robot’s action around humans is to ensurethat “a robot may not injure a human being or (through inaction) allow a humanbeing to come to harm”. For this, compliant and force/impedance controlled
ultra-lightweight systems capable of full collision handling serve as the “saferobot body”, enabling high- performance human assistance over a wide variety
of application domains. In this context, the concepts behind a new generation of
joint torque controlled soft-robots that are fully connected to the cloud and canbe programmed by anyone via their APP framework were outlined. Besides being
extremely cost-efficient and having high performance in both accuracy and force
control, the presumably first robot that actually builds itself – perfectly suited formass production – was presented.

PRESENTATIONS – Session 1

Smart, Connected Products and Digital Infrastructure

A Modular and Low-Cost Infrastructure for Industrie 4.0 Applications –Linking Real-Time Data to the Cloud
Tobias Ortmaier

Industrie 4.0 is an enabler of the industrial megatrend smart factory. A
prerequisite for the digitization of factories and production processes is theacquisition and interpretation of data. Mastering this challenge leads to both(a) an infrastructure linking the real-time automation level to a private (in otherwords not public) analytics platform and (b) easily deployable apps/services. The
overall concept including an app-store and an interactive dashboard is sketched inFig. 1.
The modular, scalable and hierarchical low-cost infrastructure not only allows
for the seamless integration of new production lines, but also facilitates theretrofitting of existing ones. This is achieved through independence frommanufacturers, based on the consistent implementation of standardized interfaces.
First, a machine-orientated off-the-shelf preprocessing unit collects real-timedata-streams (up to 1 kHz) either from the fieldbus (e.g. Ethercat, Profinet) or9

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the logic controller (e.g. via OPC UA or web services) and pre-analyses it inaccordance with the installed services. The latter leads to a significant reductionin the amount of data being sent to the cloud. Thereafter, the results areanonymized, compressed and transferred to the analytics platform for further
interpretation, e.g. based on machine-learning algorithms. This centralization andsynchronization of various data-streams enables complex analyses, taking different
production lines or even production sites into account.
In order to demonstrate the capability of the developed infrastructure, two
example use cases were developed and implemented: energy optimization for a
simple handling process involving several kinematics and fast error detection for astacker crane. The respective results concluded the presentation.
Fig. 1: Concept of data acquisition and processing

Smart Products and Digital Industry
Dietmar Goehlich

The upcoming intelligent products communicate not only with us, the users, butalso with other products and even with the production system when productson the assembly line tell shop-floor machinery how they are to be processed.
Innovative digital business models offer completely new services. Smart Products
in conjunction with Digital Industry 4.0 create a fully digital value chain, the 4th
industrial revolution enabled by the Internet of Things.
Although this transformation process will largely be implemented by industry

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itself, there is still a substantial need for research. The Technische Universität
Berlin (TU Berlin), one of the largest universities of technology in Germany witha full spectrum of engineering supported by outstanding experts in mathematics
and natural sciences as well as the humanities and social sciences, is addressingthat challenge in numerous ways; only some of them can be discussed here.
Research and teaching at the Institute of Machine Tools and Factory Management
revolve around the technological and management aspects of industrial factory
operation. This includes the development of process technologies and production
plants as well as their respective computer-based modelling. Two examples related
to Industry 4.0 are presented in the following.
Virtual methods and simultaneous engineering are considered well-establishedtools in product development. Despite this, medium-sized plant manufacturers inGermany often still employ conventional development methods using a sequential
development scheme. The joint research project “Virtual Start-up with Smart
Hybrid Prototyping” (VIB-SHP) seeks to optimize the development processof production machines and entire plants using a virtual approach. Demands
arising from Industry 4.0 are accounted for during all stages of development.
For example, a methodology is developed to optimize the deployment of system
control in production plants following their extensive evaluation at a virtual stage.

12

In current production facilities, multiple layers of control systems are separated
by a strict hierarchy. Each control layer computes set points for its respective
subordinate layers, based on measurements and static algorithms. The aim of thisresearch project is to increase efficiency through the flexible deployment of control
technology for cyber-physical systems in industrial production. The existing,monolithic control technology is broken up, reorganized into modules andextended by cloud computing methods, such as central data handling and serviceorientated software architecture. This enables optimum utilization of expert
knowledge available within the plant operator’s or plant constructor’s business.
A cloud-based control system offers a suitable framework to supply aggregatedcomputing power for cyber-physical systems in production technology.
These examples show how in a manufacturing environment, vertical networking,end-to-end engineering and horizontal integration across the entire value networkof increasingly smart products will become feasible.
But the “Internet of Things and Services” will make its presence felt in other areas
as well. This transformation is leading to the emergence of smart grids in the fieldof energy supply, sustainable and smart mobility systems and smart health. This
far-reaching digitalization is addressed by many renowned research organizations.
In which way should Berlin be able to compete successfully in this challenge?
In order to address these challenges, the TU Berlin recently initiated an Einstein
Center Digital Future (ECDF), which will adopt an innovative structure going
beyond already-known research structures. It implements – for first time on
this large scale – a private / public partnership (PPP between 20+ industry
corporations, governmental organizations, and other sponsors and all four Berlin
universities, the Charité University Medical Center, and 10+ associated partners
from the scientific community in Berlin.
The strategy of ECDF foresees focusing research on Digital Infrastructure,
Methods, and Algorithms and three innovation areas:
Digital Humanities and Society
Digital Health
Digital Industry and Services
In this presentation, some examples will be given of future research at ECDF in
the areas of Digital Transformation and Smart Mobility, which will demonstrate
the cutting-edge research of interdisciplinary methods, systems, and processes thatmerge knowledge from different disciplines thus exploiting the benefits of datadriven infrastructures in order to enable and develop future smart products.

PRESENTATIONS – Session 2

Advanced Implementation of Industry 4.0 and

Academia-Industry Collaboration in Smart Manufacturing

Industrie 4.0 – Gateway for Industry Enabling the Digital Transformation
Reiner Anderl

Industrie 4.0 is an initiative of the German High Tech Strategy. Industrie 4.0 aims
at improving added value in product engineering and production processes. The
fundamental approach is to equip future products and future production resources
with so-called cyber-physical systems. These cyber-physical systems are able toconnect with each other and to communicate. Industrie 4.0 environments enablehigh flexibility, high adaptability and resilience. This contribution explained thefundamental principles of Industrie 4.0, how Industrie 4.0 has been transferred
to industry so far and demonstrated use cases indicating its applications.
Furthermore, an approach for the implementation of Industrie 4.0 in industrial
enterprises was presented.

Industrie 4.0 at the Technical University of Munich
Gunter Reinhart

The Technical University of Munich (TUM) combines top-class facilities for
cutting-edge research with unique learning opportunities for students. TUM was
one of the first universities in Germany to be named a University of Excellence.
Thirteen departments of the TUM provide an excellent environment for research
and for the education of roughly 39,000 students. At TUM, there are 528
professors and 1,021 doctorates doing research. In 2015, 5,781 peer reviewed
publications have been published.
At TUM and especially within the Department of Mechanical Engineering, theinterest in the research area of Industrie 4.0 is strongly increasing. The Instituteof Machine Tools and Industrial Management (iwb) is the largest institute at the
Department of Mechanical Engineering and is represented by the Head of theInstitute Professor Dr.-Ing. Gunther Reinhart.
Prof. Dr-Ing. Gunther Reinhart presented the TUM and the university’s close
linkages with Japanese universities, such as the University of Tokyo. In an
overview of ongoing research activities at the TUM, in total eight research projectsof five different institutes were presented. Each research project outlined practicalexamples focusing on the objectives, related challenges, implemented approaches
and the results. The selected research projects addressed different Industrie

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4.0 topics such as Big Data Analytics and Assistance Systems. Combined withdifferent application areas (e.g. assembly line production and supply chain), theresearch projects provided a broad overview of ongoing activities at TUM.
The presentation was concluded with a short summary and an outlook on how
Industrie 4.0 will influence the future of research in the area of production and at
TUM in general.

Abstract: Toolbox for the Efficient Implementation of Industrie 4.0
Based on Use Cases
Juergen Fleischer

Implementation of Industrie 4.0 is a challenge for small and medium-sizedenterprises (SME). For a successful implementation of Industrie 4.0, it isimperative to deduce a strategic roadmap with small steps based on use cases. The
deduction of such use cases requires a high level of creativity and an awareness ofthe competences within the SME. Therefore, a toolbox and a workshop concept
have been derived together with the Mechanical Engineering Industry Association(VDMA) to first asses the competences of the SME, to create new ideas based on
existing competences and internet technologies. Within this presentation boththe concept and the toolbox were discussed, and the approach for the creative
generation of ideas for Industrie 4.0 within SMEs using the example of a smartball screw drive was outlined.
The toolbox has a dual focus: the product view and the production view.
Within each toolbox, six application levels show the main requirements andfunctionalities for Industrie 4.0 products and production. Each layer features fivedevelopment stages describing the implementation of Industrie 4.0.
The “Products” section is divided into the six application levels “Integration of
sensors and actuators”, “Communication and connectivity”, “Functionalities
for data storage and information exchange”, “Monitoring”, “Product-related IT
services” and “Business models around the product”. Each of these applicationlevels features five development stages. These stages range, for example, from “nointegration of sensors” up to “the product is reacting autonomously based on thederived data”.
As an example, the use of a ball screw drive (BSD) was discussed. Currently usedball screw drives are mechanical components which have no functionality forcommunication, have no sensors and no functions for data exchange. The use ofsuch BSDs within a machine tool has three main challenges:
First, the BSD has to be built into the machine tool. After the mechanicalintegration, the ball screw drive’s technical key parameters such as diameter, pitch
and pitch error have to be implemented within the machine tool control. Second,a BSD is subjected to wear which will finally end its usage. This wear is notconstant, and failure sometimes occurs at very short notice. This creates downtime
and results in high costs for maintenance and standstill. Third, each BSD isindividual. Although manufactured with the greatest of efforts, high quality
standards and a lot of experience, each BSD varies in friction torque during its
lifetime and pitch error. For reduced maintenance and high quality, it is therefore
imperative to know the individual behaviour of each ball screw and adapt themaintenance strategy as well as the control to the individual drive.
These use cases of the BSD were discussed with regard to the Industrie 4.0
toolbox, and the challenges and the approach for their usage were shown. Finally,in a joint workshop, the use of the toolbox in the Japanese and German context
was discussed.

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EDITORIAL NOTES

16

Published by:German Research and Innovation Forum Tokyo (DWIH Tokyo)
Sanbancho KS Bldg. 5F, 2-4 Sanbancho,
Chiyoda-ku, Tokyo 102-0075
Tel: +81 (3) 5276 8820
Fax: +81 (3) 5276 8733
info@dwih-tokyo.jp
www.dwih-tokyo.jp
Tokyo, December 2016
© DWIH Tokyo
The DWIH Tokyo is jointly organized by the German Rectors’ Conference (HRK)and the German Chamber of Commerce and Industry in Japan. It is funded by
the Federal Foreign Office in Germany and supported by the German Federal
Ministry of Education and Research.

LIST OF CONTRIBUTORSProfessor Dr.-Ing. Reiner Anderl is Professor of Computer Integrated Design
at the Technical University of Darmstadt.
Professor Dr.-Ing. Jürgen Fleischer is Head of the Institute of Production
Science at Karlsruhe Institute of Technology.
Professor Dr.-Ing. Dietmar Göhlich is Head of Methods for ProductDevelopment and Mechatronics (MPM) at the Technical University of Berlin.
Professor Dr.-Ing. Sami Haddadin is Director of the Institute of AutomaticControl at the University of Hanover.
Professor Dr.-Ing. Yasuyuki Nishioka is President of the Industrial Value Chain
Initiative (IVI) and professor at the Faculty of Engineering and Design at Hosei
University.
Professor Dr.-Ing. Tobias Ortmaier is Head of the Institute of Mechatronic
Systems at the University of Hanover.
Professor Dr.-Ing. Gunter Reinhart is Director of the Institute for Production
at the Technical University of Munich.

17www.dwih-tokyo.jp
TU9 German Institutes of Technology
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TU9 is the alliance of leading Institutes of Technology in Germany:
RWTH Aachen University, TU Berlin, TU Braunschweig, TU Darmstadt,
TU Dresden, Leibniz Universität Hannover, Karlsruhe Institute ofTechnology, TU Munich and University of Stuttgart.
All TU9 members enjoy an excellent reputation both in Germany andinternationally. They were founded in the age of industrialization andhave shaped the development of engineering sciences ever since. Theirscientific potential, range of studies and number of students havegrown continually over a period of almost 200 years. This common
ground forms the basis of the university association TU9.

www.tu9.de

Symposium on Industry 4.0: Powering Smart Manufacturing – the TU9 Alliance of German Institutes of Technology

The German Research and Innovation Forum Tokyo (DWIH Tokyo) acts
as an umbrella for German scientific and research interests in Japan.
It presents German research organisations and innovative companies
in a concerted effort, thereby strengthening scientific and economic
cooperation with Japanese partners. The German Research andInnovation Forum Tokyo has been set up jointly by the German Rectors’
Conference (HRK) and the German Chamber of Commerce and Industry
in Japan.

26 October 2016 | Tokyo, JapanThe German Research and Innovation Forum Tokyo