Bilbao, October 15, 2014

Industrie 4.0:
The Fourth Industrial Revolution
based on Smart Factories
Professor Wolfgang Wahlster
CEO of DFKI

Saarbrücken, Kaiserslautern, Bremen, Berlin, Osnabrück

Phone: +49 (681) 85775-5252/4162
Fax: +49 (681) 85775-5383/5341
Email: wahlster@dfki.de
WWW: http://www.dfki.de/~wahlster
Towards Intelligent Environments based
on the Internet of Things and Services
5) Intelligent
Environments

4) Embedded Computers Smart Factory

1) Central Computer 90% of all

3) Smart Phone
2) PC, Notebook Smart Card computers are
embedded

1 Computer
1 Computer
Many Users
1 User Many Computers, 1 User

1941 1960 1980 2000 2020

© W. Wahlster
The Internet of Things in the Smart Factory:
A Network of Intelligent Objects
Digital Product Trusted
Memories Cloud

M2M
Context- sensitive
Capturing Communication and Location-Based
Context Information Between Intelligent Smart Services
Objects

Cross-linking of
Assets and Products
in the Factory Internet
© W. Wahlster
Future Project Industrie 4.0 of
German Chancellor Dr. Angela Merkel

Internet of Things
Vision: Internet der Dinge

Intelligent Environments/Smart Spaces

Intelligente Umgebungen
z.B. Smart City
Digital City

Cyber-Physical Systems
Smart Factory, Smart Grid
500 M€ for 3 Years
National Program: Eingebettetes
250 M€ Funding of Networked Embedded System (ES)

Ministry for Research and Systems

Ministry for Economics Intelligent Street Crossing

Evolution from Embedded

Embedded Systems Systems
to Cyber-Physical Airbag
Systems National Roadmap Agenda
Embedded Systems Cyber-Physical Systems
© W. Wahlster
The Role of Software for Industrie 4.0

today (Industrie 3.0):

Machine plus Software

ICT as Innovation Motor No. 1

tomorrow (Industrie 4.0): and Advanced Manufacturing

Software plus Machine

© W. Wahlster
From Industrie 1.0 to Industrie 4.0:
Towards the 4th Industrial Revolution

4. Industrial Revolution
based on Cyber-Physical
010001101 Production Systems
001010100
100101010
010010101 Industrie 4.0
3. Industrial Revolution

Degree of Complexity
through Introduction of
electronics and IT for a
further automization
of production Industrie 3.0
2. Industrial Revolution
First through introduction of mass
Mechanical production based on the division
Loom of labour powerde by
1784 electrical energy Industrie 2.0
1. Industrial Revolution
through introduction of
mechanical production
facilities powered by
water and steam Industrie 1.0
End of Start of Start of today t
18th 20th 70ies
Century Century © W. Wahlster
The German Future Project: Industrie 4.0
 Industrial production is the backbone of Germany‘s economic performance:

 jobs direct: 7,7 Million. indirect: 7,1 Million, every second job
 more than als 158 € Billion trade surplus from export of industrial products
 (export : machine tool industry, automotive industry)
 Disruptive Paradigm Shift in Production based on the Future Internet

1. M2M and All-IP Factories are shifting from central MES to decentralized
item-level production control
2. The embedded digital product memory tells the machines, which production
services are needed for a particular emerging product.
3. Green and urban production based on cyber-physical production systems
4. Apps for software-defined products and smart product services

Germany is preparing the 4th Industrial Revolution based on the

Internet of Things, Cyber-physical Production Systems, and the
Internet of Services in Real industry. © PG Kommunikation der Forschungsunion
© W. Wahlster
Socio-Economic Drivers of Industrie 4.0
Lack of Skilled Aging Society
Workforce Later Retirement

Volatile Markets Resource-

and Cost Efficient and Clean
Reduction Urban
Pressure Production

Dynamic Batch Size 1, Mass

Value Chain Customization
Networks Low-volume High-
mixture Factories

Shorter Increasing
Product Lifecycles Product Variability

© W. Wahlster
Outline of the Talk
1. From Embedded Systems to
Cyber-Physical Systems in the Smart Factory

2. The Role of Digital Product Memories

for Mass Customization

3. Semantic Web Services in Decentralized Cyber-Physical

Production Systems

4. The Importance of Skilled Workers: Industrial Assistance

Systems

5. The Role of New Standards for Industrie 4.0

6. Conclusion
© W. Wahlster
Industrie 4.0: The Fourth Industrial Revolution

© W. Wahlster
Digital Production with Batch Size 1
Internet of Services Future Project:

Using Internet portals to configure and order a personalized product

Smart Shop: Make to Order Smart Factory:

Innovative Retail Software Innovative Factory Software

Tailored production:
566 billion
variants of custom-
mixed cereals
from:

Future Project:
Internet of Things
Active Product Memories
Service-based manufacturing control based on CPSS

© W. Wahlster
Mass Customization of Bottles: Tailored
Digital Decoration by Parallel Jet Printing

© W. Wahlster
Mass Customization of Perfumes and
their Packaging

• Customer can create her own

perfume from millions of
possibilities via a web portal

• Smart Factory can produce

36 000 Unique Perfume
Packages per day

• 24 hours after the order via the

Internet has been completed
the individualized product is
ready for shipment.

Since the customer of an individualized product, that she has designed by

herself, does not accept long delivery times, the product should be produced
close to the customer - > advantage for local European production industry.
© W. Wahlster
Interoperability for M2M-Communication
in Industrie 4.0

µ webserver
OPC-UA
(Open Process Control
32bit ARM processor
Unified Architecture)
8MB SDRAM
100Mbit Ethernet &Wi-Fi
Server for M2M
LINUX on DIGI Connect

The heart of an industrial CPS: XML-based Web server or very

fast binary communication based on the TCP protocols

© W. Wahlster
Active Semantic Product Memories for
Industrie 4.0
Cyber-Physical System (CPS) Includes Information about …

• Maintenance • Embedded
Components,
• Context Conditions
+ • Security
• Interfaces
• CO2 Footprint
• Location
• Materials
• Status
Physical Production Active Semantic Product • Handling
Component Memory as a Digital Model

The Semantic Product Memory Is Continiously Updated and Serves as a Lifelog

of the History of an Individual Product

Product Production Production Smart

Production
Design Planning Engineering Services

adapted from Siemens

© W. Wahlster
Products with Integrated Dynamic Digital
Storage, Sensing, and Wireless Communication
Capabilities I was

 The product as an information

produced on
30 April 2010
container and shipped
on 3 May 2010

– The product carries information

across the complete supply chain and its
lifecycle. Grasp at
the middle

 The product as an agent

– The product affects its environment
2 mins open
 The product as an observer Please close!

– The product monitors itself and its

environment
© W. Wahlster
The Smart Keyfinder with its Semantic
Product Memory Chip

Semantic Product Bluetooth circuit Personalized

Memory Chip in the board with key- keychain with custom
backcover plastic finder logic metal tag on the front
frame with product packaged inside produced by an
specification a plastic shell engraving machine

© W. Wahlster
The Service-Oriented Architecture of Industrie 4.0
Knowledge Base of Semantic
Service Descriptions

Service Offers Service Usage

0
0 Service Disco-
Smart Factory very and Selection
0 Smart Product
Dynamic
Service
Context Orchestration Abstract
Information Process
Description

Concrete Process Description

© W. Wahlster
From Bits and Bytes to Semantics
driven by
Software To semantic services
Engineering
driven by
Electrical common
Engineering Via functions ontology

SOAPprod_Core
From bits and bytes
knowledge
based

Semantic
Technologies
driven by

Adapted from D. ©Zühlke

W. Wahlster
Semantic Description of all Factory
Components as Services in OWL-S Ontology

Adapted from Losykll

© W.2013
Wahlster
Key Components of Service-Oriented Cyber-
Physical Production Systems
M2M CNC Milling Machine M2M
Machine 1 Communication Communication Machine N
Active Semantic
Product Memory … … Active Semantic
Product Memory

Production Service Discovery, Matching and Execution

Workpiece Workpiece
Carrier 1 … … Carrier N
Active Semantic Active Semantic
Product Memory Product Memory

Production Pathplanning Based on Semantic Product Memories

Emerging
Product 1
… … Emerging
Product N
Active Semantic Active Semantic
Product Memory Product Memory
Semantic Product Memory
• Top Shell Selection
• Circuit-Top Shell Packaging
• RES-COM Engravature
• Top and Bottom Shell Assembly
© W. Wahlster
Dynamic Planning Based on Service Compo-
sition in a SOA Architecture for Smart Factories
Green
Fast Track
Production
Production
Minimize CO2

X
Abstract
Process
Plug &
Produce Specification

Conveyor1.transport Pick&Place.insertBottom Pick&Place.insertBoard Pick&Place.insertCap AssemblyPlace4.compress

AssemblyPlace2.compress
AssemblyPlace3.compress
AssemblyPlace1.compress
(fullSpeed)
(lowSpeed) (AssemblyPlace4)
(AssemblyPlace1)
(AssemblyPlace2)
(AssemblyPlace3) (AssemblyPlace1)
(AssemblyPlace3)
(AssemblyPlace4)
(AssemblyPlace2) (AssemblyPlace2)
(AssemblyPlace1)
(AssemblyPlace3)
(AssemblyPlace4)

Adapted from Losykll

© W.2013
Wahlster
The Intelligent Workpiece Carrier:
A Complex Cyber-Physical System

The Taxi to Production Services © W. Wahlster

Plug&Produce based on Adaptive Service
Ontologies

• Plugin of CPS production

components on a physical,
digital and semantic level

• Automated Expansion of the

Service Ontology

New Assembly Component

is installed on-the-fly
Adapted from Losykll
© W.2013
Wahlster
The Retrofitting of Legacy Factories with
an Additional Layer of Cyber-Physical Systems
Rasberry PI 1 WLAN Router
CPS as an Active Product Memory Gadgeteer with
for the Emerging Product Classical SPS Sensors for
Acceleration,
Shock,
Humidity and
Temperature

Rasberry PI 2
CPS for Processing Sensor Data from
the Additional Sensor Web

© W. Wahlster
Human-Centered CPS-based Assistance
Systems for the Smart Factory
Physical
Assistance by
Exoskeletons

Context-adaptive Mobile,
Assistance for Personalized,
Fault Diagnosis Situation-Adaptive,
Tutoring Systems

AR/VR/DR- Multimodal
Assistance in Human-Machine
Complex Work Interaction
Processes
Location-based
Maintenance and
Planning
Assistance
© W. Wahlster
App Stores for the Smart Factory

© W. Wahlster
Location-based Industrial Assistance Systems in
Smart Factories for Resource Efficiency Improvements

© W. Wahlster
Advanced Industrial Assistant Systems Based
on Augmented Reality Technologies

Industrial Environment Industrial Worker Tools

with Google Glasses
Mobile, Interactive and Situation-Aware
Tutoring

© W. Wahlster
Look-Through Technology Used in the
Smart Factory

© W. Wahlster
DFKI’s Fembot AILA: Using the Semantic Product
Memory for Adaptive Grasping
Stereo Cameras in the Head and a 3D
Camera on the Torso for Approaching
an Object

Reading Size, Weight and Lifting Points

from the Product Memory with an
antenna in the left hand – the Robot
gets instructions from the product being
produced in the CPPS
© W. Wahlster
Multiadaptive Assembly System for
Highly Flexible Hybrid Job Floors
Nach-
Rewor- Ver-
Pack-
-
Prüfen
Testing
arbeit
king aging
packen o Use of OMM/OMS as a

Variant 1
Nach- Ver-

Schrau-
Prüfen
Active Product

Screws
arbeit

Shellben ben
packen

Schrau-
55Workers
Werker Memory

schaleschale
Unter-
Unter-Lower
o Use of Assistance
Board
Platine Board
Platine
Ober-
Upper-
Shell
schale
Functions in Planning
Platine Platine
Nach-
Ober-
schale
Ver-
and Production
Prüfen
arbeit packen
Nach-
Rewor- Ver-
Pack-
-

Schrau-
Prüfen
Testing
arbeit
king packen
aging

ben ben
Variant 2
Schrau-
Screws
Shell schale
Unter-Unter-
53Workers
Werker

schale
Lower
Ober-
Platine Platine
schale
Upper
Ober--
Board
Platine Board
Platine Shell
schale

Rewor- Pack-
-
Testing
king aging
Variant 3

3 Workers +
1 Roboter Bosch APAS
Upper-
(Automatic Production
Board Board
Shell Assistants)
Automatic Manually Transport

© W. Wahlster
Industrie 4.0: Smart, Green, and
Urban Production

Smart Production
High-precision, superior
quality production of high-mix,
low volume smart products

Urban Production
Green Production Smart Factories in the city
clean, resource-efficient, close to the employees‘ homes
and sustainable
© W. Wahlster
President Obama has introduced the
“re-industrialization” strategy for the US
In the US, the great spike in unemployment over the
past five years was disproportionately due to loss of
manufacturing jobs.

Innovation in Germany builds on legacies: in industrial

specializations, workforce skills, and proximity to
suppliers with diverse capabilities.

The potential of German patterns extends well beyond

defending niches against lowcost competition with
MIT Taskforce on
incremental advances. Innovation and
Production Reports
MAKING IN AMERICA
MIT Press, 2013
They create new businesses, not usually through start-
ups - the U.S. model - but through the transformation of
old capabilities and their reapplication, repurposing, and
commercialization © W. Wahlster
Standardization as a Key Success Factor
for Industrie 4.0
Intefaces between Digital Enterprise
Standardization and Digital Factory Layer
through EN 62264
Semantic Meta Semantic Service Description and
Description Semantic Product Memory 2860
Languages OWL OWL-S OMM++
USDL WSDL

7 SOA Services SoA

Standardization
through
6
OPC UA OPC-UA

5
Interoperability
Communication
4
3
IP TCP/IP 
Standards
2
1
Ethernet RJ45, WiFi… 
Mechatronic
Base Standards HAN-Modular 
© W. Wahlster
The Race for Industrie 4.0 Standards

Competition
for Standards

 Leading Provider  Leading Manufacturing  Leading Provider of

of Internet Hardware, Industries Internet Hardware
Software and General ICT  Leading Provider of  Giant Market for
 No Leading Manufacturing Enterprise Software Manufacturing Industries
Industries

© W. Wahlster
From Smart Factories to Smart Products and
Smart Services based on Smart Data

Smart Smart
Factory Product

BIG DATA Smart Smart

Data Service

© W. Wahlster
Cooperation between DFKI and Basque R&D
for Empowering Industry

Bremen

Berlin
Osnabrück

Saarbrücken Kaiserslautern

© W. Wahlster
The Potential of Industrie 4.0
for the Basque Country

• Bilbao was the center of Basque Country‘s

Bilbao Industrial Revolution during the 19th century.

• Industrie 4.0 is the chance for Basque country

to become again a leader in the fourth industrial
revolution.

• Industrie 4.0 can boost both the production of

next-generation manufacturing tools and smart
services based on digitally enhanced physical
products.

• Industrie 4.0 will create new jobs since mass

customization needs the collaboration of skilled
workforce and next-generation lightweight
robots.
© W. Wahlster
 Thank you very much for
your attention.

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