Detecon Envisions the Car Production in 2020

A successful digital transformation starts with a clear vision. As experienced technology and management consultants in the automotive sector, we invite you to find out about our vision of automobile production in 2020 along core value added activities. Examples of innovative use cases for a very wide range of technologies give a concrete idea of the developments we expect. And with our Digital Navigator we can offer your help in finding your way around the various areas of activity for digital transformation—whoever masters these will profit from the digitalisation of production!

For us, shaping the future means: Sharing ideas, learning, and creating something new together. Therefore, we look forward to talking to you if you have questions or comments!

Technical development

Technical development

Cost Efficiency, Excellent Design, and Many Variants

In technical development, the focus is on product properties and feasibility of build. This is where individual components and the overall architecture of the vehicle are designed. The aim is to achieve a vehicle that can be made efficiently and meets the highest possible design and quality requirements.

Vision 2020

Vision 2020

Comprehensive simulation of vehicle properties and manufacturing processes, plus the return of real-time data from production help perfect vehicle development.

Vision 2020
Challenges for technical development

Technical development faces rapidly changing complexity at all levels. The increasing number of models and module variants, new combinations of materials and the growing share of electrical components, and complex IT applications intensify the demands on highly-precise vehicle development.

The central challenges are:

  • Ensure cost-efficient feasibility of build and product properties.
  • Integrate innovative materials and technologies.
  • Guarantee high level of vehicle safety.
  • Realise a continuous flow of information between development, manufacturing and vehicle use.
Vision 2020 for technical development

Development costs can be lowered with improving product and process quality, and the time to start of production (SOP) can be reduced.

The essential elements are:

  • Simulation of products, production processes and resources in mixed environments—virtual and real—allow successive adaptation to new challenges (software in the loop and hardware in the loop).
  • Internationally recognised standards facilitate the flow of data across systems, manufacturer boundaries, and different value added activities.
  • New technological processes and universal tools that can be used flexibly because they are controlled by software make cost-effective production of prototypes and pre-series products possible.
Examples of use

Examples of use

  • Feasibility of build and customer experience are ensured  digitally.
  • Universal tools make individual production possible.
  • Information about the model and workpiece is synchronised.
ARVIDA
The visualisation of components and the simulation of manufacturing accelerates and lowers the costs of development and subsequent production.
Reference architecture for virtual services and applications
ARVIDA

Description

In build feasibility and assembly checking workshops, participants interact in real time with a purely virtual reality or mixed reality scene depending on the development phase. While purely virtual scenes are used in the earlier phases in particular, in later phases components which are already complete or mock-ups can be integrated into the scenes to be evaluated. In general this service-based implementation based on ARVIDA reference architecture is aimed at the option of a simple configuration by the user.

Benefits

  • Differing and partly contradictory feasibility of build or assembly objectives can be resolved and therefore achieved more quickly (e.g. screwdriver accessibility an body position).
  • A higher degree of visualisation means real prototypes can be omitted in the development process.

Major action areas of digital transformation

  • Hybrid Reality Modeling
  • Management of Standards & Interfaces

Solution provider

  • ARVIDA joint project

Named User

  • Daimler
  • Ergonomics in commercial vehicles
  • Worker assistance
Incremental sheet forming
Prototypes can be made from metal sheets, early, quickly and cost-effectively.
Incremental Sheet Forming
Incremental sheet forming

Description

In incremental sheet forming, a computer programme calculates how a metal sheet can be shaped into the desired form using a series of incremental forming actions on a small area in each case. The metal sheet is shaped using a tool with a round tip, which is between 5 mm and 20 mm in size. This tool can be connected to a CNC machine or a robot arm, for example. Each individual shaping action of the metal sheet is millimetres in size.

Benefits

  • New metal bodywork shapes can be made as single items, without requiring a different punching or pressing tool every time.
  • The time taken from CAD design to finished component is reduced.

Major action areas of digital transformation

  • Operational Integration of CPS
  • Digital Delivery

Solution provider

  • Research of the Institut für Bildsame Formgebung, RWTH Aachen

Named User

  • unknown
  • Single component manufacture in tool making
3D-Scan-Service
Design data can be compared with the real data fully automatically and updated.
3D Reverse engineering
3D-Scan-Service

Description

A 3D scanner scans all visible surfaces of an object and generates a 3D point cloud of the object. Objects can be reconstructed digitally using this optical, touch-free measurement process. This allows a comparison of CAD designs with the object actually produced, so that the digital depiction of the real object is always up to data.

Benefits

  • CAD data can be kept right up to date after changes to tools.
  • The high-quality data continuity required for end to end process integration is assured, as data from the real object is sent on, not original CAD data.

Major action areas of digital transformation

  • Hybrid Reality Modeling
  • Data Lifecycle Management

Solution provider

  • 3D Scanworks

Named User

  • Continental, MAN, Volkswagen
  • Quality control during production
Digital action areas

Digital action areas

  • Cyber Physical Systems
  • Digital Information Management
  • Digital Process Management
Cyber Physical Systems

What does management of cyber physical systems mean?

Fast (re)action in the world of digital business demands a real-time depiction of processes in the virtual and real world. More and better information must be available for this. Sensors provide information about actual conditions such as movement, temperature, humidity or geographic position for evaluation purposes in the virtual world. Automatically introduced measures require actuators for execution in the real world. The planning, set up and management capabilities of these combined worlds are brought together in these digital capabilities.

Major action areas of digital transformation
  • Operational Integration of CPS: CPS such as smart glasses with virtual or augmented reality functions are integrated into the operative process of technical development.
  • Hybrid Reality Modeling: The digital world can be modelled in the real world, so that simulated objects can be seen in the real space.
Digital Information Management

What does management of digital information mean?

The flow of data is growing continuously. Not all the information which can be produced is equally valuable. Only when the raw data is handled correctly does it produce business-relevant information. An individual value creation logic for data starts with the selection of the right sources (sourcing), the analysis and the processing, as well as correct use and presentation. This must be complemented by life cycle and quality management. Handling personal data is a legal requirement and helps win trust in the marketplace.

Major action areas of digital transformation
  • Information Processing: Internal, purely digital construction data and external data from real objects are integrated.
  • Data Life Cycle Management: Data from objects is maintained over the whole life cycle in a structured and retrievable manner.
Digital Process Management

What does management of digital processes mean?

Processes describe the development and application of products and services across all involved firms and across the entire value-added chain—up to use by the customers themselves. Approximate automation means that human intervention is only required when this improves the service quality, or to avert a threat to safety. Agility, scalability, mobility (re)-combinability and the ability to learn are essential properties of digital modular process chains.

Major action areas of digital transformation
  • Management of Repository/Experience Database: Data on the status and behaviour of real vehicle components is compared with design data saved in databases.
  • Value Oriented Process Management: If required, processes can be adapted bases on experience and profiles.
Innovation & Transformation
Smart Business Network Management
Cyber Physical Systems
Risk & Trust
Digital Information Management
Digital Process Management
Production Planning

Production Planning

Accurate Planning Data for a High Level of Transparency and Efficiency

Production planning determines which products should be produced, where, in what sequence, and with which resources, in order to meet market demand. In parallel to the design of the vehicle, all the relevant manufacturing areas are planned so that the (new) vehicle can be built cost-efficiently and at the right quality level. In order to handle shorter production cycles and individual customer requirements (small batch sizes), accurate planning data is required.

Vision 2020

Vision 2020

The digital factory becomes a reality: A seamless flow of information between production planning, development, and production improves the efficiency of manufacturing processes.

 

Vision 2020
Challenges for production planning

Today, planning is at its limits when it comes to data quality and a seamless exchange of data. For example, to react quickly to changes of orders or to machine drop-outs, planning needs up to date, error-free information about the status of the production system at all times.

The central challenges are:

  • Optimise utilisation of the factory and reduce planning and set-up times.
  • Increase flexibility with regard to changes in orders, future market demands, developments in the labour market (e.g. shortage of specialist staff) and disruption to production (e.g. machine down time)
  • Over-arching control of logistics and production capacities at all times, based on a seamless flow of information between production and planning.
Vision 2020 for production planning

A seamless flow of information between production planning, technical development and production allows orders to be fulfilled faster, reduces set up times, and improves production efficiency.

The essential elements are:

  • All logistics and manufacturing processes are depicted in the digital factory in real time. Construction in the real factory only takes place when volume and quality have been proven in the digital factory.
  • A seamless network allows production planning to react quickly to new (customer) requests or problems in production.
  • The whole production process can be planned and designed to be more energy efficient.
Examples of use

Examples of use

  • An engineering platform which can be used intuitively supports engineers.
  • The movements of robots are optimised in terms of energy use.
  • Processes are simulated and optimised digitally.
OPAK
Engineers without special programming knowledge can use an intuitive platform to plan, develop and set up production equipment.
Open engineering platform for automation components
OPAK

Description

In the research project OPAK, a 3D-supported engineering platform for intuitive planning, development and commissioning of production equipment was developed. Initially, the equipment should be planned on the platform independently of any manufacturer using purely functional descriptions of standard automation technology components. This makes the task easier for the designer and the assembler, as the program code for the machine is produced automatically in the background.

Benefits

  • The time required for planning, commissioning and maintenance of equipment components (time consuming assembly, cabling, configuration etc.) is reduced.

Major action areas of digital transformation

  • Hybrid Reality Simulation.
  • Innovation Implementation & Operation

Solution provider

  • Project OPAK of the Programm Autonomik für Industrie 4.0

Named User

  • e.g. Festo AG, fortiss GmbH, Hochschule Ostwestfalen-Lippe
EnEffCo
Optimisation of speed of movement of robots delivers significant energy savings.
Control of energy efficiency
EnEffCo

Description

In the EnEffCo research project, analyses and modelling techniques for energy efficient processing were developed. These include: Methods and tools for modelling of production processes, machines and equipment, use of data-mining processes for analysis of energy consumption profiles and the generation and evaluation of alternatives.

Benefits

  • Systematic failures are displayed, so that targeted saving measures can be introduced.
  • Energy use and energy costs are reduced.

Major action areas of digital transformation

  • Hybrid Reality Modeling
  • Analytics

Solution provider

  • Fraunhofer IPK in cooperation with ENSYS and ÖKOTEC

Named User

  • unknown
taraVRbuilder
The interplay of equipment, machinery and production sites is optimised in various scenarios using visualisation.
3D-Simulation
taraVRbuilder

Description

Using special software, scenarios from logistics and production can be planned and depicted three dimensionally. The user can compose and exchange virtual depictions of production sites. This gives a clear picture of the interplay between the equipment, machinery and production sites. The user becomes immersed in the planning scenario using virtual reality glasses.

Benefits

  • Planning and investment security are increased.
  • Improvements in logistics can be easily implemented.

Major action areas of digital transformation

  • Hybrid Reality Modeling
  • Operational Integration of CPS

Solution provider

  • Tarakos

Named User

  • Audi, BMW, Daimler
Digital action areas

Digital action areas

  • Cyber Physical Systems
  • Risk & Trust
  • Digital Information Management
  • Digital Process Management
Cyber Physical Systems

What does management of cyber physical systems mean?

Fast (re)action in the world of digital business demands a real-time depiction of processes in the virtual and real world. More, and better information must be available for this. Sensors provide information about actual conditions such as movement, temperature, humidity or geographic position for evaluation purposes in the virtual world. Automatically introduced measures require actuators for execution in the real world. The planning, set up and management capabilities of these combined worlds are brought together in these digital capabilities.

Major action areas of digital transformation
  • Operational Integration of CPS: Comprehensive use of sensors and actuators on all equipment makes production more flexible.
  • Real time Asset Management & Integration (IoT): Smart components and machinery are connected in real time and handle machine configuration between each other on an ad-hoc basis.
Risk & Trust

What does management of risk and trust mean?

Secure, trustworthy information is a fundamental element of value creation in the digital business world. Correspondingly, there must be an expansion in capabilities relating to management of information security, physical safety and trust. A central element of risk management is the ability to check the resilience of the business model against of the breakdown of the flow of information, and achieving the desired level of risk using appropriate measures.

Major action areas of digital transformation
  • Operate Control System Management: Normative, strategic and operational guidelines are managed intelligently, thus meeting strict governance and compliance requirements.
  • Safety Management: Information security and physical safety are ensured proactively, so that people and robots can work together without any danger.
Digital Information Management

What does management of digital information mean?

The flow of data is growing continuously. Not all the information which can be produced is equally valuable. Only when the raw data is handled correctly does it produce business-relevant information. An individual value creation logic for data starts with the selection of the right sources (Sourcing), the analysis and the processing as well as correct use and presentation. This must be complemented by Life Cycle and Quality Management. Handling personal data is a legal requirement and helps win trust in the marketplace.

Major action areas of digital transformation
  • Information Sourcing: Additional sensors and actuators—retro-fit to older equipment—deliver new data for more innovative production planning.
  • Information Processing: New methods create business-relevant data out of the mass of information (Big Data).
Digital Process Management

What does management of digital processes mean?

Processes describe the development and application of products and services across all firms participating and across the entire value creation chain - up to use by the customer themselves. Approximate automation means that human intervention is only required when this improves the service quality in a targeted way, or to avert a threat to safety. Agility, scalability, mobility (re)-combinability and the ability to learn are essential properties of digital modular process chains.

Major action areas of digital transformation
  • Life Cycle Management: A repository of standardised, reusable IT components facilitates automated, autonomously organised processes.
  • Agile Process Modeling & Implementation: Depending on requirements, process elements can be merged to create functioning processes and process chains.
Innovation & Transformation
Smart Business Network Management
Cyber Physical Systems
Risk & Trust
Digital Information Management
Digital Process Management
Tool Making

Tool Making

Affordable Flexibility with Increased Precision

Tools are an important operating resource in automobile construction. They enable the production of high-quality, flawless components and end-products in line with strict design and quality criteria. In tool making, complex equipment is produced — ranging from re-shaping and sheet cutting tools to complete systems for the application of various production processes. Innovative materials require new material processing methods and therefore new tools.

Vision 2020

Vision 2020

Tools are even more precise and flexible. Individual pieces and replacement parts in any shape can be produced quickly and cost-effectively. Sensors facilitate predictive maintenance.

Vision 2020
Challenges for tool making

The demand for tools is growing due to the increasing number of model variants and smaller batch sizes. Every new series demands custom manufactureto best realise the design guidelines for the components. At the same time, continuous improvement of tools and an increase in efficiency in tool manufacture remain important challenges.

The central challenges are:

  • Increase precision of the tools in order to achieve better quality components and end products.
  • Improve maintenance of the tools in order to guarantee permanent availability.
  • Produce new tools and replacement parts very quickly in a highly-flexible way in order to make fast changes of models possible.
Vision 2020 for tool making

The essential elements are:

  • 3D printing makes it possible to produce tools which could not be made in conventional tool making. At the same time, 3D printers are also flexible tools in their own right. Manufacturing times are getting shorter and material consumption is reduced.
  • Using simulation of the subsequent application, precision can be increased virtually (in the loop) for the development and manufacture of the tools. The data which has to be collected for later monitoring of the tool is determined.
  • Fitting the tools with sensors for data collection makes it possible to synchronise the virtual image of the tool with the actual status while the tool is in use, thus allowing efficient status dependent maintenance (predictive maintenance).
Examples of use

Examples of use

  • Flexible designs are manufactured additively.
  • Efficient maintenance based on monitoring of use.
  • Documentation of machines is carried out automatically.
Selective Laser Melting
Designs can be made which would not be possible with conventional processes.
3D printing
Selective Laser Melting

Description

Components which are not commercially sensible to produce using conventional processes can now be made if required. The additive manufacturing process even offers possibilities to produce components in ways which are not physically possible using conventional manufacturing processes. The design, which has been adapted to the manufacturing process allows e.g. integrated spring elements which remove the need for an additional spring in the component.

Benefits

  • The 3D printer itself can produce a wide range of products, thus replacing various special tools.
  • It is also possible to produce robust components for complex tools cost effectively as single pieces.

Major action areas of digital transformation

  • Digital Delivery
  • Operational Integration of CPS

Solution provider

  • SLM Solutions

Named User

  • Volkswagen
  • Production of prototypes
  • Production of innovative components
Mold-ID
Monitoring usage allows targeted maintenance at the best possible point in time, so that maintenance cycles can be optimised.
RFID based tool administration for injection moulding tools
Mold-ID

Description

Mold ID supports the status oriented maintenance in an automated manner and increases transparency and efficiency of tool handling. The self-sufficient system uses industrial RFID and can be retro-fit to any machine worldwide without the manufacturer and without accessing the control system. Evert tool can be identified clearly, as all relevant data such as drawing number, last maintenance or service life are saved on it. This data can be called up at any time - for example on an NFC enabled smartphone.

Benefits

  • Status dependent maintenance increases run times and increases reliability in the business.
  • Incorrect allocations or wrong shapes are avoided.

Major action areas of digital transformation

  • Information Sourcing
  • Event Driven Management

Solution provider

  • Balluff

Named User

  • unknown

Quellen

CyberSystemConnector - CSC
Intelligent creation and use of machine documentation ensure the real and digital world are permanently synchronised.
CyberSystemConnector - CSC

Description

When handing over and commissioning machinery and equipment, the manager is obliged to provide documentation in line with industrial standards in accordance with the machine guidelines. The high level of demands placed on them can lead to a situation where the status of the documents are scarcely be kept up to date after delivery and setup of the equipment. The technical component CSC forms the interface for all the connected system components of a machine and any equipment. Every change to the real machine or piece of equipment is reflected in an equivalent virtual depiction.

Benefits

  • A synchronised virtual depiction of the equipment over the whole production life cycle is guaranteed.
  • The enormous extent of technical documentation for today’s equipment is reduced.
  • Maintenance processes can be planned and implemented efficiently using the virtual depiction.

Major action areas of digital transformation

  • Real Time Asset Management & Integration (IoT)
  • Data Lifecycle Management

Solution provider

  • Research project Cyber System Connector

Named User

  • Cloos, IBG Automation, KHS
Digital action areas

Digital action areas

  • Cyber Physical Systems
  • Digital Information Management
  • Digital Process Management
Cyber Physical Systems

What does management of cyber physical systems mean?

Fast (re)action in the world of digital business demands a real-time depiction of processes in the virtual and real world. More, and better information must be available for this. Sensors provide information about actual conditions such as movement, temperature, humidity or geographic position for evaluation purposes in the virtual world. Automatically introduced measures require actuators for execution in the real world. The planning, set up and management capabilities of these combined worlds are brought together in these digital capabilities.

Major action areas of digital transformation
  • Real time Asset Management & Integration (IoT): Tools fitted with sensors deliver real time status data to a monitor unit.
  • Event Driven Management: Certain events trigger fully-automatic, targeted actions.
  • Hybrid Product, Production, Service Integration & Value Creation: The required infrastructure is built based on an IT reference structure and connects all systems across all value creation levels.
  • Further information about the Digital Navigator
Digital Information Management

What does management of digital information mean?

The flow of data is growing continuously. Not all the information which can be produced is equally valuable. Only when the raw data is handled correctly does it produce business-relevant information. An individual value creation logic for data starts with the selection of the right sources (Sourcing), the analysis and the processing as well as correct use and presentation. This must be complemented by Life Cycle and Quality Management. Handling personal data is a legal requirement and helps win trust in the marketplace.

Major action areas of digital transformation
  • Information Sourcing: Relevant data is identified and generated both during the tool manufacturing process and also over the course of the life cycle.
  • Analytics: Innovative analyses using big data deliver valuable findings for condition-based maintenance of tools.
Digital Process Management

What does management of digital processes mean?

Processes describe the development and application of products and services across all firms participating and across the entire value creation chain - up to use by the customer themselves. Approximate automation means that human intervention is only required when this improves the service quality in a targeted way, or to avert a threat to safety. Agility, scalability, mobility (re)-combinability and the ability to learn are essential properties of digital modular process chains.

Major action areas of digital transformation
  • Management of Standards & Interfaces: Standards and interfaces guarantee efficient collection of tool data in the utilisation phase.
  • Process Mobility: Mobile solutions are provided to identify the tool affected and to support action required for condition-based maintenance.
Innovation & Transformation
Smart Business Network Management
Cyber Physical Systems
Risk & Trust
Digital Information Management
Digital Process Management
Logistics

Logistics

Rapid Reaction and High Level of Stability

Logistics ensures the just-in-time and just-in-sequence supply of all parts in the factory — from tooling to final assembly. This includes the planning, control, and checking of transport, handling, and warehousing processes, making it an important complement to procurement. An essential objective of logistics is to guarantee the stability of production.

Vision 2020

Vision 2020

De-centralised control concepts revolutionise rigid logistics and make them more flexible — the production system can react quickly to demands or faults.

Vision 2020
Challenges for logistics

More and more new models and versions of a product are produced in any one site. Transport of goods and intermediate buffering stretch capacity with regard to tight takt timings. Decentralised, flexible logistics concepts are needed to meet the tough challenges of efficient production and new manufacturing concepts (e.g. production islands).

The central challenges are:

  • Guarantee just-in-time and just-in-sequence delivery of parts to the lines - even with small batch sizes and fast changes of models.
  • Recognise deviations from the production plan early and adapt the logistics chain flexibly.
  • Align your own capabilities with the capacities offered by suppliers and avoid intermediate storage.
Vision 2020 for logistics

De-centralised control concepts revolutionise rigid logistics and make them more flexible - the production system can react quickly to demands or faults, and order goods automatically if needed, for example. This makes storage space more flexible and increases asset turnover.

The essential elements are:

  • Components and operating materials are fitted with intelligence and coordinate with each other in the dynamic manufacturing process, ensuring adequate availability themselves.
  • Small, networked, automated guided vehicles (AGVs) for multifunctional use replace heavy, rigid equipment.
  • A flexible logistics process supports dynamic job sequencing—even over several sites and company boundaries.
Examples of use

Examples of use

  • Smart glasses support order picking.
  • Intelligent containers increase supply reliability.
  • Automated guided vehicles (AGVs) can work together.
xPick - eXact Picking
Instructions regarding correct commissioning are given ergonomically and supervision of execution prevents errors.
Smart glasses solution
xPick - eXact Picking

Description

The pick-by-vision commissioning solution allows both manual commissioning and goods in and out. Sorting goods as well as inventory and management of shortages are supported. Error rates are reduced using additional modules for weight checking, barcode scanning, localisation or with the help of language editing codes.

Benefits

  • The speed of commissioning is considerably increased.
  • At the same time, error rates are reduced.

Major action areas of digital transformation

  • Operational integration of CPS

Solution provider

  • Ubimax

Named User

  • Daimler, DHL, Volkswagen
  • Assistance for assembly workers

iBin – Intelligenter Behälter
Intelligent containers ensure availability of parts automatically and at the ideal point in time.
Smart warehouse system
iBin – Intelligenter Behälter

Description

At the container level, information for fill level, count and ordering for the article is possible via an integrated camera. The data is transfered automatically to the stock management system. This means that not only is consumption-oriented delivery of smaller parts for production requirements manageable on a just in time basis, but supply of C parts is done in real time using a picture format.

Benefits

  • The requirement for racking and floor space in production falls.
  • Utilisation of the warehouse is optimised.
  • Stock control happens fully automatically at the touch of a button.

Major action areas of digital transformation

  • Information Sourcing
  • Operational Integration of CPS

Solution provider

  • Würth

Named User

  • unknown
Multi Shuttle Move
Hordes of vehicles are no longer rigid and tied to a fixed destination, rather they can now handle different situations flexibly.
Driverless transport vehicles
Multi Shuttle Move

Description

As a group of autonomous vehicles, the Multi Shuttle Move can operate independently in various warehouse aisles and equipment areas. The vehicles move freely in the space and can go practically anywhere: under the racking into the stock picking aisles, goods in, or goods out. They steer themselves directly to their destination and are no longer subject to rigid route planning. As part of this, the vehicles coordinate with each other.

Benefits

  • It is possible to adapt flexibly to amended job structures and customer requirements.
  • Capacity can be moved between the warehouse and transport process and the individual sub-areas (e.g. racking aisles).

Major action areas of digital transformation

  • Agile Process Modeing & Implementation
  • Capability Management

Solution provider

  • Fraunhofer-Institut IML, marketed by Dematic

Named User

  • unknown
Digital action areas

Digital action areas

  • Cyber Physical Systems
  • Risk & Trust
  • Digital Information Management
  • Digital Process Management
Cyber Physical Systems

What does management of cyber physical systems mean?

Fast (re)action in the world of digital business demands a real-time depiction of processes in the virtual and real world. More, and better information must be available for this. Sensors provide information about actual conditions such as movement, temperature, humidity or geographic position for evaluation purposes in the virtual world. Automatically introduced measures require actuators for execution in the real world. The planning, set up and management capabilities of these combined worlds are brought together in these digital capabilities.

Major action areas of digital transformation
  • Operational Integration of CPS: Smart glasses and other wearables are used operationally in commissioning.
  • Real Time Asset Management & Integration (IoT): Smart devices up to complex CPS (e.g. driverless transport systems) are networked with control units in real time.
Risk & Trust

What does management of risk and trust mean?

Secure, trustworthy information has become a fundamental element of value creation in the digital business world. Correspondingly, there must be an expansion in capabilities relating to management of information security, corporate security and trust. A central element of risk management is the ability to check the resilience of the business model with regard to disruption to the supply of information, and achieving the desired level of risk using appropriate measures.

Major action areas of digital transformation
  • Safety Management: Risks to physical safety, e.g. accidents involving transport vehicles or due to distraction by smart glasses, are managed.
  • Business Resilience: Resilience is increased by flexible measures against delivery bottlenecks.
Digital Information Management

What does management of digital information mean?

The flow of data is growing continuously. Not all the information which can be produced is equally valuable. Only when the raw data is handled correctly does it produce business-relevant information. An individual value creation logic for data starts with the selection of the right sources (Sourcing), the analysis and the processing as well as correct use and presentation. This must be complemented by Life Cycle and Quality Management. Handling personal data is a legal requirement and helps win trust in the marketplace.

Major action areas of digital transformation
  • Information Sourcing: Data is collected and processed at a wide variety of points along the supply chain.
  • Information Processing: Logistics systems and wearables can communicate their location independently and synchronise with the location of parts to be commissioned and transported.
Digital Process Management

What does management of digital processes mean?

Processes describe the development and application of products and services across all firms participating and across the entire value creation chain - up to use by the customer themselves. Approximate automation means that human intervention is only required when this improves the service quality in a targeted way, or to avert a threat to safety. Agility, scalability, mobility (re)-combinability and the ability to learn are essential properties of digital modular process chains.

Major action areas of digital transformation
  • Agile Process Modeling & Implementation: Processes can be re-modelled and implemented repeatedly meaning logistics processes can react to rapid changes such as changes of product.
  • (End-to-End) Integration & Automation: End-to-end integration of the supply chain requires continuous, data-consistent processes.
Innovation & Transformation
Smart Business Network Management
Cyber Physical Systems
Risk & Trust
Digital Information Management
Digital Process Management
Body Construction

Body Construction

Smooth Collaboration between Machinery and Equipment

Car body construction is a highly-automated area of production. The metal coils delivered are first turned into sheet components for the automobile in punching and pressing works. Then, the parts are added to the bodywork over several stages. After comprehensive quality checks, the bodywork is cleared to go to the paint shop.

Vision 2020

Vision 2020

Seamlessly connecting all machinery and systems and continuous supervision reduce set-up times and increase production efficiency.

Vision 2020
Challenges for car body construction

The potential of automation has already been almost fully exhausted in car body construction. However, high levels of investment in machinery and high energy use in this area remain core drivers of production costs in general. In order to achieve further efficiencies — and to manage even shorter production cycles in the future — common standards and improved communication between the automation components must be implemented.

The central challenges are:

  • Achieving greater flexibility through consistent standardisation and modularisation along all automation processes.
  • Reduction of set-up and production down times, as well as improving machine availability.
  • Improving energy efficiency.
Vision 2020 for car body construction

Seamlessly connecting all machinery and systems and continuous supervision reduce set-up times. Flexibility and energy efficiency of the production process increase.

The essential elements are:

  • Synchronising the real and digital production enures a continuous monitoring of the effectiveness of planning and implementation. This facilitates remote maintenance of the machinery and equipment, e.g., as well as optimal capacity utilisation and energy optimisation.
  • All machine segments interact with each other smoothly thanks to common standards. Components from different manufacturers can be integrated quickly, using the plug & produce principle.
  • Intelligent sensors on all major operating stations and processes such as 3D scanning allow continuous quality control. The quality of the end products increases even further.
Examples of use

Examples of use

  • Condition-based maintenance uses data from sensors.
  • Intelligent pressing tools self-correct.
  • Optical scanners speed up quality checking.
Condition Monitoring System
Continuous monitoring using the most diverse sensors allows a smooth production operation.
Status monitoring
Condition Monitoring System

Description

Sensors record vibrations, which can be compared with the data from the drive and motor manufacturers, in order to identify changes in frequency response. In addition, other equipment and operating data flows into the condition monitoring system, e.g. purity of the hydraulics fluid, oil temperatures and flows, vibrations or pressures. Deviations are documented automatically using intelligent data evaluation.

Benefits

  • Smooth production operation is guaranteed.
  • The availability of pressing aisles is increased, making production more efficient.
  • Potential energy savings can be identified.

Major action areas of digital transformation

  • Information Sourcing
  • Partner Relationship Management

Solution provider

  • Cooperation between Volkswagen and Siemens

Named User

  • Volkswagen (Presswerk Wolfsburg)
  • Status dependent maintenance of the cars in the usage phase
Intelligent pressing tool
Intelligent pressing tools recognise problems before they arise, and make necessary corrections independently.
Intelligent pressing tool

Description

The tool in the pressing aisle “thinks” too. It monitors the position of the sheet during the pressing process and takes corrective action, if necessary. Sensors measure how the sheet is drawn over the die. Actuators independently regulate how strongly the sheet has to be stretched. This means it can be pressed in the ideal manner depending on its condition.

Benefits

  • Complex design lines and demanding components can be made right across ongoing standard production, with consistent quality.
  • Minor deviations in form (some tenths of a milimetre) deliver the highest possible precision and quality.

Major action areas of digital transformation

  • Operational Integration of CPS
  • Event Driven Management

Solution provider

  • Nobody (internal Audi tool makers)

Named User

  • Daimler
  • Automation of more manual interventions using actuators in machines
ABIS II System
Optical scanners automatically check the optical surfaces of unpainted outer skin parts for purpose of fault finding.
Automatic Body Inspection System
ABIS II System

Description

The robust design of the ABIS II sensor in an encapsulated aluminium housing guarantees measurement data is recorded safely, both in typical acceleration loads where robots are used and also environmental conditions near production (vibrations, shop floor lighting, temperature etc) Using the 1 picture technique ensures an extremely short image recording time of 0,1 milliseconds, so that vibrations and oscillations commonly found in the manufacturing process on shop floors are negligible.

Benefits

  • The costs of ensuring an immaculate outer skin surface can be reduced by fast (2 minutes instead of 30 minutes) and early identification plus objective classification of faults.

Major action areas of digital transformation

  • Operational Integration of CPS
  • Digital Delivery

Solution provider

  • Steinbichler

Named User

  • Audi, Daimler, Volkswagen
  • Quality control of other components
Digital action areas

Digital action areas

  • Cyber Physical Systems
  • Digital Information Management
  • Digital Process Management
Cyber Physical Systems

What does management of cyber physical systems mean?

Fast (re)action in the world of digital business demands a real-time depiction of processes in the virtual and real world. More, and better information must be available for this. Sensors provide information about actual conditions such as movement, temperature, humidity or geographic position for evaluation purposes in the virtual world. Automatically introduced measures require actuators for execution in the real world. The planning, set up and management capabilities of these combined worlds are brought together in these digital capabilities.

Major action areas of digital transformation
  • Real time Control & Business Activity Monitoring: Equipment is monitored in real time in order to detect deviations from standards which could lead to production faults.
  • Event Driven Management: The machinery and equipment can handle minor irregularities using corresponding actuators directly on an event driven basis.
Digital Information Management

What does management of digital information mean?

The flow of data is growing continuously. Not all the information which can be produced is equally valuable. Only when the raw data is handled correctly does it produce business-relevant information. An individual value creation logic for data starts with the selection of the right sources (Sourcing), the analysis and the processing as well as correct use and presentation. This must be complemented by Life Cycle and Quality Management. Handling personal data is a legal requirement and helps win trust in the marketplace.

Major action areas of digital transformation
  • Information Sourcing: The data needed to monitor and control equipment is collected using sensors.
  • Analytics: Innovative analyses discover patterns in the data which reveal causes of faults in good time and allow preventative intervention.
Digital Process Management

What does management of digital processes mean?

Processes describe the development and application of products and services across all firms participating and across the entire value creation chain - up to use by the customer themselves. Approximate automation means that human intervention is only required when this improves the service quality in a targeted way, or to avert a threat to safety. Agility, scalability, mobility (re)-combinability and the ability to learn are essential properties of digital modular process chains.

Major action areas of digital transformation
  • (End-to-End) Integration & Automation: End-to-end integration of processes with a continuous, data-consistent process chain facilitates automatically interconnecting equipment.
  • Management of Repository/Experience Database: Database management organises and structures data from process elements and their behaviour.
Innovation & Transformation
Smart Business Network Management
Cyber Physical Systems
Risk & Trust
Digital Information Management
Digital Process Management
Paint Shop

Paint Shop

The Principle of Zero Tolerance for Faults

The vehicle is given its individual colour in the paint shop. The paint job is carried out after thorough cleaning in several stages: First of all, the functional coats are applied, then the cover coat, and final the clear coat. A perfect finish is the prerequisite for further processing of the bodywork.

Vision 2020

Vision 2020

Further automation of the paint shop and intelligent checking processes deliver even higher quality in end products and a shorter throughput time for the vehicles.

Vision 2020
Challenges for the paint shop

Colour is a key recognition factor when it comes to vehicles. This means a perfect paint job is decisive for the high quality of a product, and also for a short throughput time—time-consuming re-works should be avoided. At the same time, shorter processing times are important in order to reduce high energy costs in this area.

The central challenges are:

  • Avoid quality issues and returns.
  • Ensure high level of availability and reduce throughput time (non-stop production).
  • Improve energy efficiency.
Vision 2020 for the paint shop

Further automation of the paint shop and intelligent checking processes deliver even higher quality in end products and a shorter throughput time for the vehicles.

The essential elements are:

  • The degree of automation increases further and allows even greater precision in painting. A new generation of modular paint shop systems opens up a more varied and extremely resource efficient execution of steps in the painting process.
  • Comprehensive use of sensors and optical inspection also reduces quality issues and improves the quality of processes and products (heat consistency, distribution of flow).
  • Intelligent processes improve and speed up the final quality checks.
Examples of use

Examples of use

  • Modular painting concepts make individualisation possible.
  • Gesture recognition makes quality documentation easier.
  • Environmental impact is monitored in a mobile manner.
Modularisation of InnoCaT 5
Different bodywork components made of various materials are painted individually with an optimally adapted modular paint concept.
Modular product/painting concept
Modularisation of InnoCaT 5

Description

In sub-project 5.2.1 of the Innovation Alliance Green Carbody Technologies (InnoCat 5), a modular concept for decentralised powder coating integrated into manufacturing has been developed, which works on the basis of the pistol-less “TransApp” system. This concept allows networking with highly-flexible, decentralised production structures, alongside fast pre-treatment and burning-in processes. The objective is to facilitate faster reactions to changing customer requirements in accordance with the industry 4.0 strategy.

Benefits

  • Manufacturing is accelerated and delivery times reduced.
  • Costs of investment in equipment fall, non value-creating steps in the process are eliminated and cost savings in production planning and control lead to a reduction in unit costs of 10%.
  • New materials (e.g. reduced weight for electro-mobility) can be painted.

Major action areas of digital transformation

  • Event Driven Management
  • Agile Process Modeling & Implementation

Solution provider

  • Innovation Alliance "Green Carbody Technologies“

Named User

  • Audi, Daimler, Dürr, Wörwag, Fraunhofer IPA
Quality documentation using gestures
Quality issues detected by staff are flagged to the system, which documents them automatically.
Optical gesture recognition and evaluation
Quality documentation using gestures

Description

Car bumpers go through a quality check with a touch-free gesture recognition process - with finger pointing. A swipe gesture over the component identifies the bumper as perfect in terms of quality. If an employee points to a faulty area on the bumper, cameras register this gesture. The program evaluates this and saves the event. Previously, the result of every checked workpiece had to be documented laboriously on a PC.

Benefits

  • Considerably less time is needed for very time-consuming fault documentation.

Major action areas of digital transformation

  • Operational Integration of CPS
  • Hybrid Reality Modeling

Solution provider

  • Fraunhofer

Named User

  • BMW
  • Quality control of other components
Yellowbox
The demands on the production environment can be determined locally and precisely in terms of time, and conveniently evaluated.
Mobile measurement and environmental impact
Yellowbox

Description

Yellowbox allows monitoring and reduction of emissions in industrial environments The mobile system measures the concentration of volatile organic compounds (VOC’s), ozone, carbon oxides, nitrogen compounds, ammonia and methane. This deliver spot measurements over a longer period “along the way”. The data delivered by particle meters and semiconductor sensors inside the Yellowbox is transferred to mobile devices.

Benefits

  • Environmental protection and health/safety at work are improved.
  • The workplace can be monitored automatically.
  • A process analysis can be carried out which leads to a low-emission process design.

Major action areas of digital transformation

  • Information Sourcing
  • Presentation/Exposure

Solution provider

  • Fraunhofer IPK

Named User

  • unknown
Digital action areas

Digital action areas

  • Cyber Physical Systems
  • Digital Information Management
  • Digital Process Management
Cyber Physical Systems

What does management of cyber physical systems mean?

Fast (re)action in the world of digital business demands a real-time depiction of processes in the virtual and real world. More, and better information must be available for this. Sensors provide information about actual conditions such as movement, temperature, humidity or geographic position for evaluation purposes in the virtual world. Automatically introduced measures require actuators for execution in the real world. The planning, set up and management capabilities of these combined worlds are brought together in these digital capabilities.

Major action areas of digital transformation
  • Operational Integration of CPS: The integration of CPS, e.g. connected optical sensors, into the operational process speeds up quality control.
  • Real Time Asset Management & Integration (IoT): Optical sensors record gestures in real time.
  • Event Driven Management: An event driven management system ensuring the highest possible quality is introduced in the context of measurement of environmental impact or with a modular paint shop.
  • Further information about the Digital Navigator
Digital Information Management

What does management of digital information mean?

The flow of data is growing continuously. Not all the information which can be produced is equally valuable. Only when the raw data is handled correctly does it produce business-relevant information. An individual value creation logic for data starts with the selection of the right sources (Sourcing), the analysis and the processing as well as correct use and presentation. This must be complemented by Life Cycle and Quality Management. Handling personal data is a legal requirement and helps win trust in the marketplace.

Major action areas of digital transformation
  • Information Sourcing: Sensors collect new data, e.g. staff gestures or environmental impact.
  • Information Processing: Information about work pieces and necessary activites are automatically made available and processed.
Digital Process Management

What does management of digital processes mean?

Processes describe the development and application of products and services across all firms participating and across the entire value creation chain - up to use by the customer themselves. Approximate automation means that human intervention is only required when this improves the service quality in a targeted way, or to avert a threat to safety. Agility, scalability, mobility (re)-combinability and the ability to learn are essential properties of digital modular process chains.

Major action areas of digital transformation
  • Agile Process Modeling & Implementation: Processes based on agile process modelling and implementation facilitate fast changes of product.
  • Management of Standards & Interfaces: Standards and interfaces increase the flexibility and efficiency of processes.
Innovation & Transformation
Smart Business Network Management
Cyber Physical Systems
Risk & Trust
Digital Information Management
Digital Process Management
Assembly

Assembly

Automation and Worker Assistance

Today, assembly is one of the least automated areas within automobile manufacturing. The painted car bodies are assembled into finished vehicles in complex work processes, and the engine, drivetrain, and the body are “married”. A series of comprehensive functional tests are carried out once assembly is complete.

Vision 2020

Vision 2020

Assistance systems and a close human–machine collaboration give the assembly workers the ideal support in their work and enhance the quality of the production process.

Vision 2020
Challenges for assembly

The level of automation increases – assistance systems and close collaboration between man and machine give the operators the ideal support in their work.

The central challenges are:

  • Physically relieving workers, providing them with required knowledge depending on the situation, and enabling them to carry out a very wide range of tasks flexibly.
  • Keeping descriptions of builds and documentation up to date and available, even with short-term, unplanned changes in equipment or production sequences.
  • Reducing downtimes and, in case of problems, flexibly diverting jobs to different stations, depending on availability of resources.
Vision 2020 for assembly

The level of automation increases—assistance systems and a close human–robot collaboration give the workers ideal support in their work.

The essential elements are:

  • People and robots work together, without being separated by protective barriers. This means robots support manual activites and increase the assembly workers’ convenience at work.
  • Assistance systems give employees guidance and feedback on the execution of the work and ensure processes run smoothly. Employees become qualified for new tasks in a virtual production environments.
  • The synced factory twin enables assembly to be made flexible, as capacities, interruptions and disruptions in planning can be considered.
Examples of use

Examples of use

  • Cooperative lightweight construction robots assist workers.
  • Individual components are made cost-effectively using 3D printing.
  • Machinery can be maintained remotely.
Baxter
Robots work hand-in-hand with people and can be “trained” by them for a very wide variety of activites.
Collaborative Robots (Cobots)
Baxter

Description

“Baxter” is a Safe-By-Design robot, who works “Hand-in -Hand” with people, without posing any risk to them. The robot can also be “trained” simply by staff without programing knowledge, in order to carry out supporting activities. Different elements for the robot arm make it possible for Baxter to pack items. load or unload containers, feed machinery or handle materials.

Benefits

  • This relieves human staff of strenuous, repetitive tasks.
  • Programing the robots is intuitive, without any need for specialist knowledge.

Major action areas of digital transformation

  • Operational Integration of CPS
  • Safety Management

Solution provider

  • Rethink Robotics

Named User

  • John Deere, Steelcase, Schneider Elec., Flambeau, Vanguard
  • Order picking in the warehouse
Rapid Repair Solution
Complex parts, which would be inefficient to keep in the warehouse, can be made quickly internally when required.
3D printing
Rapid Repair Solution

Description

Using a laser melting process, even very complex parts can be made very quickly from metal powder. At the Swedish Siemens Finspång site, laser melting units process defective gas turbine burner heads. To do this, technicians separate the defective parts and replace them one for one in laser sintering process. The commissioning of complete burner head sets now takes four weeks instead of 44 weeks.

Benefits

  • Down time can be reduced significantly.

Major action areas of digital transformation

  • Digital Delivery
  • Operational Integration of CPS

Solution provider

  • SLM Solutions

Named User

  • Siemens
  • Single component production in tool making
Remote Services
Connectivity allows constant monitoring and web-based remote configuration or triggering of a presence service.
Predictive Maintenance Plattform
Remote Services

Description

Advanced Remote Diagnostic Technology allows remote diagnosis and also achieves pro-active (forward-looking) maintenance of robots. To do this, the robotic systems are monitored constantly.If a fault occurs, the defective robot notifies a central database independently, which, in turn, sends a message to a service technician. in 50% of cases, the robot can be re-commissioned remotely. Parameter setting, remote configuration and diagnosis are all done via a web-based engineering tool.

Benefits

  • Equipment faults can be avoided pro-actively.
  • Down time is drastically reduced.

Major action areas of digital transformation

  • Information Sourcing
  • Analytics
  • Partner Relationship Management

Solution provider

  • ABB

Named User

  • Swedwood, Tetley, Comforsa

Sources

  • Status dependent maintenance of cars in the usage phase
Digital action areas

Digital action areas

  • Cyber Physical Systems
  • Risk & Trust
  • Digital Information Management
  • Digital Process Management
Cyber Physical Systems

What does management of cyber physical systems mean?

Fast (re)action in the world of digital business demands a real-time depiction of processes in the virtual and real world. More, and better information must be available for this. Sensors provide information about actual conditions such as movement, temperature, humidity or geographic position for evaluation purposes in the virtual world. Automatically introduced measures require actuators for execution in the real world. The planning, set up and management capabilities of these combined worlds are brought together in these digital capabilities.

Major action areas of digital transformation
  • Operational Integration of CPS: Thanks to operationally integrated CPS, systems for relieving or better guidance of workers, such as robots and wearables, can be utilised.
  • Real time Asset Management & Integration (IoT): Real time integration of systems ensures smooth running of takts.
Risk & Trust

What does management of risk and trust mean?

Secure, trustworthy information has become a fundamental element of value creation in the digital business world. Correspondingly, there must be an expansion in capabilities relating to management of information security, corporate security and trust. A central element of risk management is the ability to check the resilience of the business model with regard to disruption to the supply of information, and achieving the desired level of risk using appropriate measures.

Major action areas of digital transformation
  • Safety Management: Management of physical safety ensures that robots can work closely with people without posing any danger.
  • Business Resilience: A high level of resilience makes it possible to overcome unexpected situations that threaten the business.
Digital Information Management

What does management of digital information mean?

The flow of data is growing continuously. Not all the information which can be produced is equally valuable. Only when the raw data is handled correctly does it produce business-relevant information. An individual value creation logic for data starts with the selection of the right sources (Sourcing), the analysis and the processing as well as correct use and presentation. This must be complemented by Life Cycle and Quality Management. Handling personal data is a legal requirement and helps win trust in the marketplace.

Major action areas of digital transformation
  • Information Sourcing: Sensors on robots provide data for smooth (semi-)automated processes and allow monitoring of production.
  • Information Processing: Complex data from a connected factory is integrated, structured, consolidated and transformed.
Digital Process Management

What does management of digital processes mean?

Processes describe the development and application of products and services across all firms participating and across the entire value creation chain - up to use by the customer themselves. Approximate automation means that human intervention is only required when this improves the service quality in a targeted way, or to avert a threat to safety. Agility, scalability, mobility (re)-combinability and the ability to learn are essential properties of digital modular process chains.

Major action areas of digital transformation
  • Agile Process Modeling & Implementation: Processes are modelled and implemented in an agile manner, thus realising more dynamic production processes.
  • Management of Standards & Interfaces: A reference process framework, corresponding IT systems, process repositories and standardised interfaces allow flexibly creating new process chains.
Innovation & Transformation
Smart Business Network Management
Cyber Physical Systems
Risk & Trust
Digital Information Management
Digital Process Management
CRM

CRM

Far-Reaching Changes in Customer Relationship Management

The customer is already involved in certain cases at the premium end of car manufacturing today. From the composition of the product to live tracking of the production process, he can choose and co-design his vehicle in line with his own, individual wishes — a major new opportunity and challenge for close customer relationship management.

Vision 2020

Vision 2020

The car itself and the mobility services offered with it are an essential part of the communication with the customer—connected car evolves to connected customer.

Vision 2020
Challenges for CRM

OEM’s need to further differentiate their offer to meet the increasing demand for personalised products and stand out among the competition. Besides “cold, hard steel”, digital services are increasingly playing a decisive role. Only those who foster direct contact with end customers and supplement the product of the vehicle with digital mobility services can successfully exploit new business potential.

The central challenges are:

  • Set up a direct exchange of information with the end customers.
  • Tie in marketing, sales and after-sales closely to production (cover the entire life cycle).
  • Create innovative mobility services for a closer customer connection and new turnover potential, e.g., car sharing.
Vision 2020 for CRM

The car itself and the linked mobility services are essential components of customer communication—the connected car gives way to the connected customer. This happens directly controllable by the OEM, not just indirectly via the retail organisation (dealers and workshops).

The essential elements are:

  • Telematic platforms collect data about car usage. The data is evaluated with big data and predictive analytics, and new products and service offers are developed.
  • Findings relating to purchasing and usage habits flow back into production, optimising production planning and contributing to even better products.
  • Augmented and virtual reality technologies engage the customer in the purchasing and manufacturing process in new ways.
Examples of use

Examples of use

  • Customers are involved in design and assembly.
  • Digital showrooms improve the customer experience.
  • Data from the usage phase are integrated.
Audi City
Digital showrooms in the best shopping locations in urban locations reach customers without having to supply actual models over a wide area.
Digitale Showrooms
Audi City

Description

There are very few real cars in digital showrooms, but there are digital power walls and multi-touchables, with which the customer can surf through the range of models and design their very own, individual, dream car. For example, the Q3 all-terrain car, with over 3 million equipment variants can be thrown interactively and life size onto the wall or sent via YouTube and Facebook. To do this, the entire product range has been digitally prepared (around 17 terabytes of data are held locally).

Benefits

  • The number of potential customers increases, as sound customers can be reached where they are out and about, and inspired to share their experience with friends over the internet.
  • The attractive setup has a positive effect on the customer’s feeling of wellbeing and trust, and improves the relationship with the customer.

Major action areas of digital transformation

  • Digital & Social CRM/Digital Customer Engagement
  • Hybrid Reality Modeling

Solution provider

  • Audi (internal solution)

Named User

  • Audi
3D Printed Car
Design based on crowd-sourcing of small production runs of (electric) cars using 3D printing involves customers in technical development and assembly.
Co-Creation and Micro-Factoring
3D Printed Car

Description

Co-creation means that many people, and in Local Motors, very many people, are involved in the design of the vehicle. Currently around 48,000 people from 130 countries are working on the speedster from the printer on a crowd-sourcing basis. Every user can make suggestions and develop existing ideas, which are then aligned. The cars are then made in micro-factories, where every vehicle is put together in collaboration with the customer - most of the parts come from the 3D printer.

Benefits

  • Development time is drastically reduced to under 18 months (compared to 4 to 5 years for conventional OEM’s).
  • De-centralised production of cars in micro-factories makes it possible to involve the customer in assembly, and therefore build up a close customer relationship and brand profile.

Major action areas of digital transformation

  • Digital Sourcing
  • Digital Delivery

Solution provider

  • Local Motors

Named User

  • Domino‘s Pizza (Ultimate Delivery Vehicle Project)
OpenCar Plattform
OTA collection of driver data, app usage data, vehicle performance data and diagnosis data which is fed back to improve products or processes
Connected Car Platform
OpenCar Plattform

Description

The platform facilitates the collection of vehicle status data (health check), vehicle performance data, plus driver and driver behaviour data. This allows the driver to be contacted, to prevent technical problems (Predictive Maintenance), or to communicate more targeted offers based on analysis of the data, which are tailored individually to the vehicle and driver needs (Predictive Marketing). Feeding the data back to technical development and production also helps improve the products.

Benefits

  • Monitoring the functionality of the vehicle prevents negative customer experiences such as restricted driving performance and break downs.
  • Feeding the data back to technical development and production accelerates improvements in production and helps avoid major recall activity.
  • New functionality and services can be provided in line with requirements.

Major action areas of digital transformation

  • Customer Experience Management
  • Identity, Profile and Access Management
  • Analytics

Solution provider

  • OpenCar

Named User

  • unknown
Digital action areas

Digital action areas

  • Innovation & Transformation
  • Smart Business Network Management
  • Cyber Physical Systems
  • Risk & Trust
  • Digital Information Management
  • Digital Process Management
Innovation & Transformation

What does management of innovation & transformation mean?

With holistic, agile approaches, innovations can be recognised more quickly in a highly-dynamic environment, and evaluated with regard to their business impact and ability to be implemented. A digital strategy describes the timeframe and roadmap for digital transformation in line with the themes modularisation, standardisation and digitalisation. Successful implementation requires active control of diversity, culture, knowledge, and skills while considering ethical and social circumstances.

Major action areas of digital transformation
  • Digital Sourcing: Connected car platforms make it possible to collect vehicle use and user data and thus identify relevant trends.
  • Knowledge Management: Smart knowledge management facilitates conclusions for product and processinnovation.
Smart Business Network Management

What does management of the smart value creation network mean?

In complex digital value networks, companies must be able to define the depth of their own value creation and then interact closely and intensively with customers and partners using various channels. Alongside a comprehensive flow of information in real time, concrete service commitments (e.g. via service level agreements) play an essential role, as well as the management of customer and partner expectations. Finding suitable partners and an intensive dialogue via social channels takes place at the outset.

Major action areas of digital transformation
  • Digital & Social CRM / Digital Customer Engagement: Digital CRM improves customer service and orientation through linking social-media data and data collected personally.
  • Multi Layer CRM: A multi-layer approach ensures data flow between value creation stages within the company and from/to suppliers.
Cyber Physical Systems

What does management of cyber physical systems mean?

Fast (re)action in the world of digital business demands a real-time depiction of processes in the virtual and real world. More, and better information must be available for this. Sensors provide information about actual conditions such as movement, temperature, humidity or geographic position for evaluation purposes in the virtual world. Automatically introduced measures require actuators for execution in the real world. The planning, set up and management capabilities of these combined worlds are brought together in these digital capabilities.

Major action areas of digital transformation
  • Real time Asset Management & Integration (IoT): A (real time) internet connection in the car makes it possible to collect data about status, use and user and also push OTA updates.
  • Information Exchange: Reliable information is processed and made available at the right time in the right place.
Risk & Trust

What does management of risk and trust mean?

Secure, trustworthy information has become a fundamental element of value creation in the digital business world. Correspondingly, there must be an expansion in capabilities relating to management of information security, corporate security and trust. A central element of risk management is the ability to check the resilience of the business model with regard to disruption to the supply of information, and achieving the desired level of risk using appropriate measures.

Major action areas of digital transformation
  • Information Security Management: Internal company and customer related information is protected against unauthorised access.
  • Identity, Profile and Access Management: The basis for secure access to information includes identity, profile and access management.
Digital Information Management

What does management of digital information mean?

The flow of data is growing continuously. Not all the information which can be produced is equally valuable. Only when the raw data is handled correctly does it produce business-relevant information. An individual value creation logic for data starts with the selection of the right sources (Sourcing), the analysis and the processing as well as correct use and presentation. This must be complemented by Life Cycle and Quality Management. Handling personal data is a legal requirement and helps win trust in the marketplace.

Major action areas of digital transformation
  • Information Sourcing: New sources of information are gained when cars are equipped and connected with appropriate sensors.
  • Data Life Cycle Management: Life cycle management ensures that data is stored securely, and in a structured, retrievable way.
Digital Process Management

What does management of digital processes mean?

Processes describe the development and application of products and services across all firms participating and across the entire value creation chain - up to use by the customer themselves. Approximate automation means that human intervention is only required when this improves the service quality in a targeted way, or to avert a threat to safety. Agility, scalability, mobility (re)-combinability and the ability to learn are essential properties of digital modular process chains.

Major action areas of digital transformation
  • (End-to-End) Integration & Automation: End-to-end integration means that data from the utilisation phase can flow back into production for purposes of improvement.
  • Management of Repository/Experience Database: Management of data from the behaviour of process elements from user, machine, car, and system perspectives make innovative solutions possible.
Innovation & Transformation
Smart Business Network Management
Cyber Physical Systems
Risk & Trust
Digital Information Management
Digital Process Management
Technology and IT Management

Technology and IT Management

Managing the Convergence of Technologies

Today, the technologies and IT used in production, in commercial areas and in the products themselves are mainly planned and used separately from each other. The different areas pose different challenges. Accordingly, the control mechanisms are set up differently. The convergence of technologies demands cross-company IT management — as a basis for more efficient production and business processes, and innovative products.

Vision 2020

Vision 2020

IT and technology management merge. An over-arching platform integrates all business and IT processes and creates the conditions for greater flexibility and innovation.

Vision 2020
Challenges for IT and technology management

The separation of IT between top floor and shop floor as well as automation technology must be overcome in order to exploit the full potential of digital technologies and to allow more flexible reactions to new challenges in production.

The central challenges are:

  • Developing a company-wide digital strategy that establishes IT and technology management as a driver of innovation and allows new business models to be adopted.
  • Creating an organisation that aligns the technology with agile or classic methods, according to the technical speed of change required.
  • Optimising the depth of value creation in new IT management according to the global requirements of production.
Vision 2020 for IT and technology management

IT and technology management merge with each other.

The essential elements are:

  • A modular IoT platform with standardised interfaces can combine products from various suppliers and makes the complexity in the interplay of processes and technologies manageable.
  • IT applications for planning and control of production are based on the IoT platform and operate independently of the underlying machine pool.
  • Processes and organisation of technology management are set up in line with the three speeds model. “Fast” for frequently arising changes close to the business, “medium” for changes in the platform, “conservative” for stable back-end systems. Job descriptions must adapt to the new demands for IT know-how.
Examples of use

Examples of use

  • Retrofit solutions connect all machinery.
  • An IoT suite creates the software basis for the connected factory.
  • Machines are integrated flexibly into the production process.
BaZMod
Manufacturer-neutral retro-fit solutions allow older machines to be included in the networked factory.
Component-appropriate machine configuration using additional modules
BaZMod

Description

BaZMod is an integrated solution approach for communication between machines, control and the production environment. The development of suitable cyber physical additional modules facilitates self-configuration in the sense of Plug & Produce. Efforts are underway to create an international standard for the relevant interfaces in the machining area. The interfaces should be manufacturer-neutral and easy to integrate into the machinery.

Benefits

  • Manufacturer-independent cyber -physical additional modules allow tool machines to take on extra process steps, which open up new possible uses, improve manufacturing quality and increase efficiency.
  • Through-put times and costs are reduced.

Major action areas of digital transformation

  • Information Sourcing
  • Management of Standards & Interfaces

Solution provider

  • BaZMod research project

Named User

  • Blum-Novotest, KESSLER, Renishaw, Fraunhofer, TU München
  • Retro-fitting older cars with connected car solutions
Bosch IoT Suite
An over-arching platform forms the basis of all-encompassing networking of the factory and applications built on top of this basis.
Internet of Things Platform
Bosch IoT Suite

Description

The IoT platform forms the technological basis for the interplay of devices, applications, companies and partners. It enables fast development of applications for the smart factory and common access for all devices (based on open standards). The following services are integrated: Device Management, Business Rules Management, Business Process Management, Big Data Processing, Identity Management, User Interface Integrator. The IT world consists of the IoT platform and applications built on top of this.

Benefits

  • As middleware between the physical and IT worlds, the platform enables the development of IoT applications/solutions.
  • Bringing the two worlds together and providing the necessary connectivity completes the value creation chain in the Internet of Things.

Major action areas of digital transformation

  • Real Time Asset Management & Integration
  • Real Time Control & Business Activity Monitoring

Solution provider

  • Bosch

Named User

  • unknown
AutoPnP
Standardised interfaces ensure agility and enable fast re-configuration of production.
Software Architecture for Plug & Produce
AutoPnP

Description

In the AutoPnP research project, a software architecture has been developed which supports the easy integration of hardware and software components for automation systems. The software architecture developed is based on the Plug & Play enabled middleware CHROMOSONE. By using a data-centric communication paradigm, CHROMOSONE allows a loose connection of components based on the data they offer and require.

Benefits

  • Complex systems can be developed and adapted more easily, faster and more cost-effectively.
  • New components can be included and configured with little effort.
  • Production can be adapted quickly to new products/variants.

Major action areas of digital transformation

  • Agile Process Modeling & Implementation
  • Management of Standards & Interfaces

Solution provider

  • Research project “AutoPnP – Plug&Play for automation systems”

Named User

  • TU Berlin, fortiss, Dussmann, Festo, Fraunhofer, Schunk
Digital action areas

Digital action areas

  • Innovation & Transformation
  • Smart Business Network Management
  • Cyber Physical Systems
  • Risk & Trust
  • Digital Information Management
  • Digital Process Management
Innovation & Transformation

What does management of innovation & transformation mean?

With unified, agile approaches, innovations can be recognised more quickly in a highly-dynamic environment, and evaluated with regard to their business use and ability to be implemented. A digital strategy describes the timeframe and roadmap for digital transformation un line with the themes modularisation, standardisation and digitalisation. Successful implementation requires active control of diversity. culture, knowledge and skills with consideration of ethical and social conditions.

Major action areas of digital transformation
  • Recognising and evaluating innovations: Condense information from various (digital) sources into business relevant statements and evaluate it—from a formulated idea to implementation—using a common methodology.
  • Controlling costs and benefits of the transformation: Establish a common set of objectives with a company-wide digital strategy, in order to allocate scarce resources to the right initiatives in a lean portfolio.
  • Further information about the Digital Navigator
Smart Business Network Management

What does management of the smart value creation network mean?

In complex digital value creation networks, companies must be able to define their own value creation and then interact closely and intensively with customers and partners using various channels. Alongside a comprehensive flow of information in real time, concrete service commitments (e.g. via service level agreements) play an essential role, as well as the management of customer and partner expectations. Finding suitable partners and an intensive dialogue via social channels takes place at the outset.

Major action areas of digital transformation
  • Identifying network partners: Look for suitable partners and customer profiles in a very wide range of digital channels.
  • Integrating network partners: Adapt communication proposals and standards of communication platforms of potential partners and customers.
Cyber Physical Systems

What does management of cyber physical systems mean?

Fast (re)action in the world of digital business demands a real-time depiction of processes in the virtual and real world. More, and better information must be available for this. Sensors provide information about actual conditions such as movement, temperature, humidity or geographic position for evaluation purposes in the virtual world. Automatically introduced measures require actuators for execution in the real world. The planning, set up and management capabilities of these combined worlds are brought together in these digital capabilities.

Major action areas of digital transformation
  • Digitalise the real world: Digitalise status information of production equipment with sensors and make it available with appropriate interfaces.
  • Create connections: Set up network technologies which are sufficient for the special conditions within the production environment.
Risk & Trust

What does management of risk and trust mean?

Secure, trustworthy information has become a fundamental element of value creation in the digital business world. Correspondingly, there must be an expansion in capabilities relating to management of information security, corporate security and trust. A central element of risk management is the ability to check the resilience of the business model with regard to disruption to the supply of information, and achieving the desired level of risk using appropriate measures.

Major action areas of digital transformation
  • Guarantee operational safety: Modelling of movement processes in order to minimise health and safety hazards even virtually.
  • Increase resilience: Modularise production processes and set up automated measures, in order to prevent production down-time in the even of a fault.
Digital Information Management

What does management of digital information mean?

The flow of data is growing continuously. Not all the information which can be produced is equally valuable. Only when the raw data is handled correctly does it produce business-relevant information. An individual value creation logic for data starts with the selection of the right sources (Sourcing), the analysis and the processing as well as correct use and presentation. This must be complemented by Life Cycle and Quality Management. Handling personal data is a legal requirement and helps win trust in the marketplace.

Major action areas of digital transformation
  • Provide information: Meet the users’ need for information, and realise additional business value from big data.
  • Establish standards: Identify and co-design relevant standards and make them binding for procurement of components.
Digital Process Management

What does management of digital processes mean?

Processes describe the development and application of products and services across all firms participating and across the entire value creation chain - up to use by the customer themselves. Approximate automation means that human intervention is only required when this improves the service quality in a targeted way, or to avert a threat to safety. Agility, scalability, mobility (re)-combinability and the ability to learn are essential properties of digital modular process chains.

Major action areas of digital transformation
  • Set up process modules: Develop and make available process components from standardised, digitalised modules for planning and simulation.
  • Re-work processes: Optimise processes in logistics, car body construction, paint shop and assembly by using the new process modules.
Innovation & Transformation
Smart Business Network Management
Cyber Physical Systems
Risk & Trust
Digital Information Management
Digital Process Management
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