HELLO INDUSTRIE 4.0 Smart solutions for smart factories.
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HELLO INDUSTRIE 4.0 Smart solutions for smart factories.
HELLO INDUSTRIE 4.0
SMART SOLUTIONS FOR SMART FACTORIES
A simple “Hello“ can change
a million things ...
Page 4 Ready for the next industrial revolution
Long-term transformation of our global perception
of industrial production
The best of different worlds
Prepared for the challenges of Industry 4.0
Page 12 Human-robot collaboration, smart platforms, mobility
The revolution is light, sensitive and has seven axes
Introduction to safe human-robot collaboration
Architectures that master the unknown
Smart platforms
New mobility concepts
Page 26 In the driver’s seat of tomorrow
The Internet of Robotics
Generation “R”
Trend towards customization and demographic change
Industry 4.0 needs strong alliances
3
HELLO INDUSTRIE 4.0
READY FOR THE NEXT INDUSTRIAL REVOLUTION
» INDUSTRY 4.0 HAS THE POTENTIAL TO RESHUFFLE
THE CARDS IN INTERNATIONAL COMPETITION.
WITH DECENTRALIZED, NETWORKED INTELLIGENCE
IN MANUFACTURING AND SELF-ORGANIZING
PRODUCTION PROCESSES, THE FACTORY OF
THE FUTURE WILL PERFORM A QUANTUM LEAP –
IN PRODUCTIVITY, FLEXIBILITY AND EFFICIENCY.
THIS EVOLUTIONARY STEP CAN ONLY SUCCEED,
HOWEVER, IF WE FINALLY BREAK DOWN THE
BARRIERS BETWEEN THE DIGITAL WORLD AND
THE REAL WORLD. THIS IS PRECISELY WHERE KUKA
HAS BEEN SETTING STANDARDS FOR DECADES. «
DR. CHRISTIAN SCHLÖGEL CHIEF TECHNOLOGY OFFICER KUKA GROUP,
MEMBER OF THE BOARD KUKA ROBOTER GMBH
4 5
HELLO INDUSTRIE 4.0
READY FOR THE NEXT INDUSTRIAL REVOLUTION
WHAT IS CALLED FOR HERE IS NO LESS
THAN A LONG-TERM TRANSFORMATION
OF OUR GLOBAL PERCEPTION OF
INDUSTRIAL PRODUCTION.
Smart Production, Internet of Things or Why then, applying the same principle, should
Industry 4.0. Even if the names and terms factories not also be made more intelligent,
used vary from one country to another, they more efficient and smarter? For example, by
all share the same goal: the creation of making universally applicable machines, such
elementary competitive advantages – at both as robots, able to communicate with other
company level and in global competition. cyber-physical systems (CPS) such as intelli-
Work on the factory of the future is thus in gent workpieces, other machines, systems or
full swing worldwide. This involves intelligent, factories and the Cloud. Or by making systems
networked industrial production and logistics in the production process able to respond
processes on the basis of cyber-physical autonomously to customer requirements, the
production systems (CPPS). Or, to put it simply: availability of resources, energy prices, and
ON THE WAY TO INDUSTRY 4.0
factories that, by means of advanced network- much more besides. And all this with decreas- KUKA Toledo Production Operations.
ing, respond intelligently to changing tasks ing logistics costs. As far back as 2006, during construction of
and continuously reconfigure themselves. the body-in-white plant for Wrangler body
shells, KUKA opted for highly networked
Industry 4.0 thus responds to a whole range systems and architectures. 259 robots in
The basic idea is relatively simple. Devices of of factors that define the framework for a the plant communicate with approximately
all kinds, from smartphones, gadgets, tele- future-proof production environment. These 60,000 other devices and machines. Linked
to back-end monitoring systems and a
visions and watches to household appliances, include the need for resource-saving manu- higher-level data management system, this
are becoming ever more flexible and intelli- facturing and the call for maximum flexibility “in-plant Cloud” brings an enormous boost
gent. They are increasingly able to communi- and customization of industrial production to productivity in the production facility.
cate with other devices or data sources via in order to satisfy the manifold requirements
the Internet. According to the forecasts of the of markets and customers directly and across
analysts at Gartner, 26 billion “things” will the board.
be connected to the Internet in the year 2020.
FIRST MOVER INDUSTRY 4.0-READY
It was back in the 1990s that KUKA recognized the With the systematic orientation towards mechanical
potential to be gained by combining IT with conventional systems, electronics, sensor systems and software, as
automation technologies. KUKA was also the world’s first well as its highly specialized know-how in automation,
robot manufacturer to develop open, interoperable and KUKA is on a perfect footing in the major areas of expertise
flexible systems on the basis of standardized mainstream required for Industry 4.0. Current technologies, products
technologies and to make them ready for the market. and solutions from KUKA thus have one thing in common:
they are already Industry 4.0-ready.
6 7
HELLO INDUSTRIE 4.0
READY FOR THE NEXT INDUSTRIAL REVOLUTION
HUMAN
IN THE FACTORY OF THE
REQUIREMENTS FUTURE, THE FOCUS OF
THOUGHT AND ACTION
WILL SHIFT TO HUMANS
WITH THEIR CHANGED
REQUIREMENTS, DESIRES
AND CAPABILITIES.
WORKER
REQUIREMENTS
BY COMBINING THE BEST CUSTOMER
OF DIFFERENT WORLDS, FACTORIES
ARE INDEED BECOMING SMART. ERGONOMICS
INDIVIDUAL
PRODUCTS
The image of automation and robotics has changed considerably since the 1970s. While they were
reviled back then as job killers, it is meanwhile apparent to all that robots not only create and
secure jobs, they are also a prerequisite for the modern products in our world today. Without even
thinking about it, we routinely use smartphones, navigation devices and the Internet. We rely
on electronic assistants when parking vehicles and entrust them with tasks such as the energy
management of houses or simple jobs like mowing the lawn. All these products and services
have one thing in common: they contain components built by robots and would not exist at
all without automation technology. Not one of them can be manufactured purely manually. HIGH
SPEED
Robots not only broaden our productive capabilities, however, they are also the most flexible
and versatile machines that mankind has ever come up with. It is their flexibility and their
generic properties that make an autonomous, self-organizing production unit – and thus the
n=1
dynamic value-creation chain of Industry 4.0 – possible in the first place. For this reason, all
the experts are agreed on one point: in the factory of the future, the robot will be at the center
of the digital supply chain as a core component.
HIGH
With safe human-robot collaboration (HRC), KUKA is taking a further decisive step forward,
PRECISION
however. If we focus our thoughts and actions on humans, we realize that robots have improved
the world of work in many different ways. They handle heavy loads, carry out activities that ROBOT AS
are not ergonomic or are simply too dangerous for people and perform tasks that require levels ENABLER
of precision or speed of which humans are not capable. Until now, however, conventional indus-
trial robots have always worked separated from their human colleagues. This means that positive
effects in the working environment of the operator were always indirect and never direct. It is
precisely this barrier that KUKA has broken down with the implementation of safe human-robot
QUALITY
collaboration. This milestone opens up previously inconceivable possibilities for production in the IN THE SMART FACTORY
smart factory. HRC thus combines the best of two worlds: humans with their superior creativity OF TOMORROW, THE
and cognitive abilities and the robot with its greater repeatability, strength and precision. ROBOT WILL BE AT THE
CENTER OF THE DIGITAL
SUPPLY CHAIN AS A
CORE COMPONENT.
8 9
HELLO INDUSTRIE 4.0
READY FOR THE NEXT INDUSTRIAL REVOLUTION
KUKA – OPTIMALLY PREPARED FOR
THE CHALLENGES OF INDUSTRY 4.0.
As Europe’s leading supplier of industrial For KUKA, Industry 4.0 does not represent a
robots and automated production solutions, “Big Bang” or a mere trend, but a long-term
KUKA is directly involved in the fourth indus- investment in the future. Strictly speaking,
trial revolution with its products and services the road to Industry 4.0 already began for
as an integral part of Industry 4.0. And this KUKA back in the 1990s. KUKA was the first The fourth industrial revolution – Industry 4.0
is not just because robots are the central robot manufacturer in the world to recognize or short – is not yet a standard or even
element providing flexibility at the interface that interfaces based on mainstream a clearly defined term. Instead, it is a
between the real production world and the IT technologies are indispensable. In order paradigm that describes the factors that will
digital one, but primarily also because the to be able to respond with great flexibility characterize the factory of the future. KUKA
KUKA Group is exceptionally well equipped to industry requirements and to network is playing an active role in shaping this image
for the future with its key technologies and digital controllers of a wide range of systems of the Smart Factory.
highly specialized automation expertise. efficiently with one another. To this day, all
innovations and developments from KUKA
consistently adhere to this basic principle of
open communication and simple integration.
Only in a different dimension – already geared
towards the Cloud and its potential services.
For smart, networked products and solutions
that will already link automation technologies
with services and databases on the Internet
in the foreseeable future.
10 11
HELLO INDUSTRIE 4.0
HUMAN-ROBOT COLLABORATION, SMART PLATFORMS, MOBILITY
» CYBER-PHYSICAL PRODUCTION SYSTEMS
CONSTITUTE THE BASIS OF INDUSTRY 4.0 –
BUT THE IDEA BEHIND THE NEXT INDUSTRIAL
REVOLUTION IS MUCH GREATER. IT NETWORKS
HUMANS AND MACHINES IN PRODUCTION AND
REQUIRES MAXIMUM FLEXIBILITY OF SYSTEMS.
KUKA IS THUS ACTIVELY DRIVING AND SHAPING
INDUSTRY 4.0 IN THE THREE FUTURE-ORIENTED
FIELDS OF HUMAN-ROBOT COLLABORATION,
SMART PLATFORMS AND MOBILITY. «
D R . M I C H A E L H A A G S E N I O R V I C E P R E S I D E N T R E S E A R C H & D E V E LO P M E N T KU K A R O B OT E R G M B H
12 13
HELLO INDUSTRIE 4.0
HUMAN-ROBOT COLLABORATION, SMART PLATFORMS, MOBILITY
HUMAN-ROBOT COLLABORATION –
THE REVOLUTION IS LIGHT,
SENSITIVE AND HAS SEVEN AXES.
Industry 4.0 is characterized by decentralized intelligence. All parties can communicate with
one another – workpiece with machine, machine with machine or with higher-level processes.
Until recently, by contrast, the barriers to human-robot collaboration were highly visible
and weighed tonnes: stable metal safety fences all around the robot and equipped with highly
sensitive safety systems. The role of the human was essentially limited to monitoring his
robotic colleague – productive teamwork, but at arm’s length.
With the LBR iiwa, KUKA has laid the foundation for an entirely new human-robot relationship:
direct and safe collaboration – with no safety enclosure whatsoever. Where there is no fence
restricting freedom, the way is open for new, highly efficient and far more flexible production
processes. As a component of the Smart Factory, the LBR iiwa is able to learn from its human
colleagues thanks to its sensitive technology. Connected to the Cloud, it can independently
check, optimize and document the results of its own work. The feedback provided by the robot
to the networked data traffic ensures maximum transparency within the production processes.
A NEW ERA OF SENSITIVE EN ISO 13849
ROBOTICS The safety functions of the LBR iiwa meet the requirements
40 years after the first industrial robot was used, KUKA of Performance Level “d” with structure category 3.
is opening a new chapter in the history of industrial This enables safe human-robot collaboration. Guaranteed.
robotics with the LBR iiwa. “LBR” stands for “Leichtbau-
roboter” (German for lightweight robot), “iiwa” for
“intelligent industrial work assistant”.
14 15
HELLO INDUSTRIE 4.0
HUMAN-ROBOT COLLABORATION, SMART PLATFORMS, MOBILITY
WITH THE INTRODUCTION OF SAFE
HUMAN-ROBOT COLLABORATION,
KUKA HAS REDEFINED THE WORD “UNIVERSAL”.
Human-robot collaboration still seems like a lightweight robot for industry, this univer-
vision of the future to many. However, small, sally applicable robotic colleague is now
specialized service robots have long since available. Moreover, it proves that the
established themselves in our everyday lives. visions of Industry 4.0 can be implemented
They are generally to be found as assistants in reality. Robots are already working hand
at home – vacuuming, cleaning windows and in hand with humans and expanding their
mowing the lawn. These robots, usually limit- range of capabilities, enabling them to work
ed to a single activity, may be a far cry from more efficiently and ergonomically, and
the universally applicable robotic colleague with greater precision and concentration.
required for Industry 4.0, but they do demon-
strate one thing: cooperation between humans The properties incorporated into the collabo-
and robots works. rative robot as an “intelligent work assistant”
open up a whole new spectrum of possibilities
This is also necessary: in a time of rapid in an industrial setting. Thanks to its sensory
demographic change in the industrial nations, capabilities, it can intuitively learn new tasks
characterized also by ever shorter product on an ad hoc basis, simply by being guided
cycles in manufacturing and ever greater by the operator. It is able, for example, with-
diversity of variants, the challenges facing out vision systems and complex grippers,
the production of the future are enormous. to insert rubber plugs, install non-rigid parts
This applies in equal measure to human work- or precisely adjust workpieces. In the context
ers and robots. Genuine teamwork between of this robot class, the term “universally
the two opens up an opportunity to support applicable” needs redefining. The range of
the worker, make his work easier and extend possible applications in the factory of the
his human capabilities. With the LBR iiwa, the future is virtually infinite.
world’s first series-produced, collaborative
16 17
HELLO INDUSTRIE 4.0
HUMAN-ROBOT COLLABORATION, SMART PLATFORMS, MOBILITY
MAXIMUM
INTEROPERABILITY
THANKS TO
MAINSTREAM IT
INTEGRATION
OF THIRD-PARTY
SOFTWARE
SUPPORT FOR
INTERNATIONALLY
RECOGNIZED
STANDARDS
EXTENSIVE
SOFTWARE LIBRARY
FOR DEVELOPERS
MODULAR CONTROL
ARCHITECTURE
FOR MAXIMUM
SCALABILITY
ANYONE WANTING TO SHAPE THE
SHARED DATABASE
CYBER-PHYSICAL FUTURE NEEDS ARCHITECTURES FOR MAXIMUM
FLEXIBILITY
THAT CAN MASTER THE UNKNOWN WITH AGILITY.
Even if complete implementation of Industry 4.0 takes several years – the first effects of this
great master plan will make themselves felt in the near future. The first quantum leap in produc-
tivity will be achieved when the great idea of networking cyber-physical production systems is
implemented – initially in a defined setting rather than globally. A “Cloud in a box”, so to speak.
The term “box” could refer here to one or more factories, or to a whole company, or even a group
of companies. Once we have managed to network productive systems throughout with flexible
interfaces, and to enrich them with IT technologies, such as Cloud or Big Data, the first step
towards the smart factory will have been taken.
18 19HELLO INDUSTRIE 4.0
HUMAN-ROBOT COLLABORATION, SMART PLATFORMS, MOBILITY
SMART PLATFORMS – For the smart factory of the future, KUKA values and parameters, but can also, in combi-
already has modular software architectures in nation with other standards, define them
DEVELOPED WITH THE ASPIRATION its portfolio, based on mainstream technolo- semantically in a way that is machine-readable.
gies and prepared for the entire evolutionary
OF ACTIVELY SHAPING INDUSTRY 4.0. process of Industry 4.0. In this strategy, all KUKA Sunrise goes one step further. The
building blocks fit together and each individual control technology of the LBR iiwa is based on
one is agile enough to dock proactively onto the object-oriented and platform-independent
the IT systems or standards of future pro- programming language Java. KUKA is thus
duction environments or to integrate them able to benefit, almost automatically, from the
seamlessly. This is a pioneering concept that rapid developments on the IT hardware side.
brings the future closer than you might think. With regard to Industry 4.0, the Java platform
of KUKA Sunrise makes it ideally suited to
If, for example, one takes a closer look at future app-based programs. These are smart
the current KUKA Sunrise or KR C4 controller tools that give robots new capabilities and
KUKA KR C4 KUKA SUNRISE generations, one can see that their systems functions at the click of a mouse. All the user
are already prepared for the modular inte- has to do is enter the required parameters
With the pioneering concept of the KR C4, KUKA has The revolutionary KUKA Sunrise control technology unites
developed a new ground-breaking, clearly-structured safety control, robot control, logic control and process gration of new software components and in the programming.
system architecture that concentrates on open and control of the entire system. Its interfaces, scalability, protocols. Here, KUKA is working on the
powerful data standards. In this architecture, all performance and openness mean that there are virtually
assumption that new standards will become From KUKA’s viewpoint, the step from the
integrated control modules have a common database limitless automation possibilities. In combination with
and infrastructure which they use and share intelligently. the sensitive LBR iiwa lightweight robot, KUKA Sunrise established in conjunction with Industry 4.0, platform-independent modular application to
For maximum performance, scalability and flexibility. constitutes a technology that redefines robotics. ensuring maximum interoperability for the Industry 4.0 is not so much a technical chal-
Today and in the future – and not just for KUKA robots.
customer. One of the most likely candidates lenge as a matter of how quickly the necessary
in this respect is OPC Unified Architecture global norms and standards for the smart
(OPC UA). This protocol not only transfers factory can be drafted and established in
machine data, process values, measured the market.
20 21HELLO INDUSTRIE 4.0
WITH NEW MOBILITY CONCEPTS,
HUMAN-ROBOT COLLABORATION, SMART PLATFORMS, MOBILITY
KUKA IS TAKING FLEXIBILITY IN
PRODUCTION TO A NEW DIMENSION.
Mobility is not just about moving people and
goods from A to B, it also has an enormous
influence on our competitiveness and our
opportunities for growth. One of the main
requirements of Industry 4.0 is providing pro-
duction with long-term flexibility. In addition
to intelligently connected information
superhighways, this will require a new form
of intelligent networking of goods flows
and manufacturing processes. New concepts
for moving products, workpieces or entire
production units or repositioning them in
different locations. In short – we need to
mobilize production to a greater extent
than ever before. For this reason, KUKA is
paving the way for mobile robotics and thus
creating the basis for a new dimension
in flexibility for the factory of the future.
Robots on mobile platforms that can move
autonomously in order to transport things
or machine workpieces. If necessary, finding
their own way around – without floor mark-
ings, induction loops or magnets. They align
themselves with the workpiece with millimeter
precision. Or they simply invert conventional
sequences: for example, the robot moves to
the workpiece rather than the other way round.
Mobile automation solutions from KUKA show
today what the future holds in store for highly MOBILE ROBOTICS FOR THE PRECISION
flexible production. Equipped with pioneering MACHINING OF XXL COMPONENTS
technology and new capabilities, the robot, Large-scale components for ships, aircraft
or wind power plants are difficult or
in its capacity as the world’s most versatile virtually impossible to transport. In any
tool, will throw the door wide open for entirely case, their transportation is extremely
new fields of application in Industry 4.0. cost-intensive. The mobile concept vehicle
“moiros” is able to make the machining
of giant rotor blades for wind power plants
more efficient and cost-effective. Instead
of the workpieces, each weighing several
tonnes, the robot moves itself into the
correct position – with millimeter precision.
22 23HELLO INDUSTRIE 4.0
MOBILE ROBOTICS IS CREATING
HUMAN-ROBOT COLLABORATION, SMART PLATFORMS, MOBILITY
NEW DEGREES OF FREEDOM –
IN EVERY ORDER OF MAGNITUDE.
KUKA makes things mobile, thereby creating
new flexibility in a wide range of applications.
In the highly complex form of human-robot
collaboration, systems are able not only to react
intelligently to their surroundings, but also KUKA Mobile Robotics iiwa
to change location. The KUKA spectrum ranges Industrial manufacturing of the
future will require new, modular,
from lightweight robots that can be moved versatile and, above all, mobile
manually to fully autonomous systems. Their automation concepts. KUKA
ability to interact with people, machines or Mobile Robotic iiwa combines
the sensitive LBR iiwa light-
workpieces in a location-independent manner weight robot with an autono-
means that the application potential of this mous, omnidirectional, mobile
new generation of mobile robotics is virtually platform, thereby opening up
entirely new possibilities in
boundless. Essentially, there are as many direct and flexible human-robot
potential applications as there are ideas for such collaboration.
applications. Mobile robots can already perform
logistics tasks independently, collaborate
directly with humans or quickly take on new
tasks at different workstations. Even deployment
in offices or service departments is conceivable.
KUKA is also eliminating barriers to mobility in
the production environment in another sense.
In the flexible world of Industry 4.0, static
floor markings, induction loops and magnets CarryPick
as orientation guides defining the paths for Designed to be modular and
multifunctional, CarryPick from
mobile systems will increasingly disappear. Swisslog consists of mobile
With intelligent navigation software, KUKA can racks and automated guided
already dispense with them. For example, using vehicles for goods-to-person
picking. Combined with the
the “Simultaneous Localization and Mapping” warehouse management
process (SLAM), mobile platforms can create system WM6, the result is
maps of their surroundings and also make an overall solution that defines
how people, processes and
them available to other units. This results in technologies are integrated
a universally networked, shared “motion and KUKA flexFELLOW into the sequences.
route plan” in which all robot motions are This automation unit can be
moved manually and allows
coordinated. If the production environment an entirely new degree of KUKA omniMove
in the factory or shop changes, the mobile flexibility in the planning The heavy-duty mobile
robots can be adapted to the new situation of systems as well as an platform. Individually or
infinitely variable degree as a fleet, these mobile
in the shortest possible time. of automation. The ideal platforms can effortlessly
combinability of manual move beneath, and lift, loads
and automatic tasks means weighing 90 tonnes or more.
that production can be And move in any desired
optimally adapted to direction from a standing
the required capacity start. With millimeter
utilization. precision.
24 25HELLO INDUSTRIE 4.0
IN THE DRIVER’S SEAT OF TOMORROW
» IN THE NEXT 50 YEARS, ROBOTICS WILL
DEVELOP A SIMILARLY DISRUPTIVE FORCE
TO THAT OF THE INTERNET IN THE LAST
HALF CENTURY. IT WILL PENETRATE AND
ENRICH EVERY AREA OF OUR LIVES. «
D O M I N I K B Ö S L CO R P O R AT E I N N O VAT I O N M A N A G E R KU K A A G
26 27HELLO INDUSTRIE 4.0
WITH THE INTERNET OF ROBOTICS,
IN THE DRIVER’S SEAT OF TOMORROW
KUKA IS CREATING THE BASIS
FOR THE ROBOTICS OF THE FUTURE.
MAINSTREAM When we talk about the future, the situation With the establishment of a standard that is
LOGISTICS TECHNOLOGIES may sound paradoxical: KUKA is already able, valid worldwide, enabling a high degree of
in many areas of manufacturing, to implement system interoperability, KUKA will push ahead
the networking of production and the digital with expansion of the “Internet of Robotics” to
world required by Industry 4.0 – and has long create an “Internet of Automation”. This will be
since been creating automated production a Cloud solution that taps the full potential of
systems of this type worldwide on the basis of the combination of comprehensive production
“Industry 4.0-ready” products and solutions. data, innovative manufacturing processes,
Until now, however, there has been one flexible networking and responsive compo-
limitation: these highly efficient and flexible nents. This step will give rise to smart manufac-
systems are always specific individual solu- turing solutions. One example for a holistic
tions – self-contained systems that are indi- application of this nature is the optimization
vidually adapted to specific customer re- of production capacity utilization on the basis
CLOUD / quirements. The true potential of Industry 4.0 of current energy prices: an automatically
BIG DATA will only unfold when industry manages learning system will analyze order data and
to define open communication and data fluctuations in energy prices, identify room for
standards and to establish them worldwide. maneuver in production capacity utilization
Only then will production be interoperable and autonomously optimize the manufacturing
far beyond the factory gates. sequence of the products in the production
process with regard to energy consumption
To accelerate this development, KUKA is during manufacture. The result for the manu-
working in cooperation with international facturer will be considerable savings potential.
partners from the IT sector on solutions that
will provide this necessary backbone on the The new possibilities created by the Internet
basis of standardized high-performance of Automation will definitively herald the
infrastructures. The goal is to achieve, in arrival of the cyber-physical production
SMART FACTORY / the near future, a springboard – the “Industry systems required by Industry 4.0. On this
CYBER-PHYSICAL 4.0 Cloud” – for further modularization and basis, components of all different kinds will
PRODUCTION SYSTEMS digitization of KUKA automation solutions: enable seamless interaction between
the “Internet of Robotics”. This will already products, solutions and services from
ROBOT AS A CORE enable KUKA to increase the intelligence of different manufacturers.
COMPONENT OF THE robot systems in a sustainable manner over
DIGITAL SUPPLY CHAIN the next few years. This will be achieved
by means of easily implemented app-based
software expansions or Cloud-based
functions, such as predictive maintenance.
28 29HELLO INDUSTRIE 4.0
IN THE DRIVER’S SEAT OF TOMORROW
INNOVATION
IT THINKS AND ACTS IN AN ADVANCED FOURTH ROBOTIC REVOLUTION:
DIMENSION OF INDUSTRY 4.0 – GENERATION “R”. COGNITIVE, sensitive and safe robot-based automation solution
THIRD ROBOTIC REVOLUTION:
MOBILE, sensitive and safe robot-based automation solution
SECOND ROBOTIC REVOLUTION:
SENSITIVE AND SAFE robot-based automation solution
The rapid development of robotics will perma- laptop (mobilization), tablet and smartphone
FIRST ROBOTIC REVOLUTION:
nently change the world, just as the Internet (omnipresence). Endowed with these smart
and information technology have done in all skills, they will accompany us in every area ROBOT-BASED automation solution
areas of life. Today, robots are a key element of our daily lives – both in the workplace and
of Industry 4.0, providing answers, with new at home.
production methods, to the major questions
of our times: global challenges such as Future generations, “robotic natives”, will
shortage of resources, climate change and see robots as the state of the art, as a life-
the consequences of accelerating population style, or quite simply as normal. Generation
growth combined with the aging of society “R” will certainly have no inhibitions regard-
in the industrial nations. ing robots. They will have overcome the old
human versus machine antagonism. It will
Initially designed merely as a universal be a society that not only works differently,
machine to boost productivity, the robot has but also thinks differently. It will see the
increasingly developed, with its ever greater capabilities of robots as universal, network-
sensitivity and mobility, into a colleague that able services that can be requested via the
supports humans in their work. Just as robotic Internet and flexibly adapted to the require-
colleagues have become a matter of course ments and desires of the individual at the
in industrial settings, they will also establish click of a mouse. Generation “R” will think ROBOTIC
themselves as service assistants in many other in an advanced dimension of Industry 4.0.
areas of life in the next few years. If we con- REVOLUTIONS
sider a longer period of time, it is foreseeable
that robots will also become smaller, more
mobile, networked and cognitive, reflecting The transformation of society towards development times for new robot generations,
the development from the mainframe comput- generation “R” is reflected in the “four revolu- this step will also require a radically new
er to the desktop computer (miniaturization), tions in automation technology” postulated approach. The focus in the future will no
by KUKA. Alongside industrial robotics, which longer be on the manufacturing process
will continue to grow strongly with new, net- of purely mass-produced goods, but on
worked manufacturing processes, the area the customized product manufactured to
of service robotics – and ultimately robots – industrial standards – and thus on the
in private settings will become more estab- customer’s requirements.
lished. In addition to ever faster response and
30 31HELLO INDUSTRIE 4.0
IN THE DRIVER’S SEAT OF TOMORROW
TREND TOWARDS CUSTOMIZATION
ROBOFACTURING
AND DEMOGRAPHIC CHANGE –
STRONG DRIVERS OF INDUSTRY 4.0.
The long-term trend towards customization offers traditional industrial nations the chance
to return previously outsourced production capacity to locations in high-wage countries.
This is because Industry 4.0 is creating the conditions for implementing the highest levels of
DESIRE FOR
CUSTOMIZATION customization – all the way down to batch size 1 – within industrial manufacturing: high-quality
single-piece production with the profitability of series production. Conventional manufacturing
CUSTOMIZED is being replaced by “robofacturing”, i.e. highly flexible factories in which humans and machines
PRODUCTION WITHIN
work hand in hand. The ability to design and build these highly efficient manufacturing systems
INDUSTRIAL
MANUFACTURING will enable Industry 4.0 to contribute to the long-term securing of jobs in industrial nations.
Furthermore, growing demand for customized products that can be configured easily via the
Internet will open up entirely new areas of business for industry.
It is also becoming ever more apparent that demographic change will be another strong driving
force behind Industry 4.0. In contrast to the global population growth, the industrial nations
are faced with falling birthrates and increasing overaging of society. In Germany in 2030, of
100,000 employees in the manufacturing industry up to 20,000 will already have retired.
n =1
Newcomers to the job market will be scarce. This challenge can only be met if the remaining
80,000 employees become significantly more productive than all generations before them.
At the same time, the factory of the future must also make it possible for older, experienced
employees to participate in the world of work for longer. Robots that can collaborate with
humans are the only realistic answer to these questions posed by the future. They are able
to make workplaces both highly productive and ergonomic, even for older employees.
Robotics will not only enrich everyday work, however. Everybody wants to stay active for as
long as possible when old. With average life expectancy in 2030 being up to 86 years, service
robotics can help people to prolong their independence and quality of life within their familiar
BATCH SIZE 1
social surroundings. With the aid of intelligent robots, rehabilitation treatment, for example,
will be possible at home. Mobility assistants will help people to remain independent and agile
HOME-ASSISTED into old age, improving the quality of millions of lives.
LIVING DEMOGRAPHIC
CHANGE
ERGONOMIC
WORK
32 33HELLO INDUSTRIE 4.0
IN THE DRIVER’S SEAT OF TOMORROW
26
RELATIONSHIP BETWEEN IOT, Individual production: The trend towards customization will
continue to intensify. Consumers expect products that meet
CPS, CPPS, INDUSTRY 4.0 COMPONENT their personal requirements and wishes – but at terms and
conditions corresponding to those of industrial mass production.
“n = 1” is one of the declared goals of Industry 4.0.
What do these keywords mean and
billion
what are the differences between them?
Thing in the IoT: This refers to a device
that contains a microprocessor and can
communicate via networks. These things According to a study conducted by the analysts
taken as a whole constitute the Internet at Gartner, there will be 26 billion networked
of Things (IoT). devices worldwide in the year 2020 that will
be able to exchange data among themselves
CPS (cyber-physical system): A CPS is a interoperably. In addition to the expected sales
thing in the IoT that offers a service via the revenue of 300 billion US dollars, this also
Internet by linking the real, physical world entails major challenges for processing the
with information-processing processes. THINGS CPS CPPS INDUSTRY 4.0 enormous quantities of data in the Cloud.
IN THE IoT COMPONENT
CPPS (cyber-physical production system):
A CPPS is the application of cyber-physical
systems in manufacturing industry and enables
a complete overview of products, production
MARKET VOLUME FOR CONSUMER GOODS
equipment and production systems, taking
changing processes into account.
BY CONTINENT IN 2013
Industry 4.0 component: This refers to AFRICA:
cyber-physical production systems that have 443 B I L L I O N E U R O
been specified in greater detail with regard CENTRAL AND SOUTH AMERICA:
1,529 B I L L I O N E U R O
to interoperability by Working Group 2 of
the “Industry 4.0 Platform”.
EUROPE:
3,337 B I L L I O N E U R O
BIG DATA
Big Data refers to the fact that enormous quantities of data have to be
processed ever more quickly. In the context of the industrial production NORTH AMERICA: ASIA:
2,954 B I L L I O N E U R O 5,160 B I L L I O N E U R O
of the future, what is important is evaluating and preparing this flood
of data in order to be able to control processes intelligently and adapt
them to changing parameters. SOURCE: FERI; PLANET RETAIL
34 35HELLO INDUSTRIE 4.0
IN THE DRIVER’S SEAT OF TOMORROW
GLOBAL MEGATRENDS
THE DRIVERS OF INDUSTRY 4.0
DEVELOPMENT OF
POPULATION FIGURES
GERMANY WORLDWIDE
NUMBER OF PEOPLE IN MILLIONS
NUMBER OF PEOPLE IN BILLIONS
80 10
World population growth: The growing world population
W O R L D P O P U L AT I O N
is increasing demand for industrially manufactured products. GROWTH
Customization: Consumers expect to be able to configure G LO B A L I Z AT I O N 75 5
products according to their personal requirements
as standard.
70 0
C U STO M I Z AT I O N
Digitization: In the future, ever more products and 2015 2025 2030 1950 1975 2000 2025 2050 2075 2100
services will be provided via the Cloud in digital form. SOURCE: GERMAN FEDERAL STATISTICAL OFFICE SOURCE: UNITED NATIONS
The interoperability of things in the Internet will M O B I L I Z AT I O N
create new business areas.
Mobilization: Smartphones and tablets have made
communications mobile. Robotic solutions are undergoing
the same development. They are becoming smaller and
D I G I T I Z AT I O N
DEMOGRAPHIC
more agile and moving autonomously.
Globalization: The Internet is turning the world into a
CHANGES
single, complex, networked location in which everyone Population in Germany by age group in the years 2008, 2020* and 2060* (in millions).
can trade and communicate with everyone else. In the year 2020, more than half of the German population will be over 50 years of age.
-19.2
30
billion kWh 24.3
NUMBER OF PEOPLE IN MILLIONS
In 2014, 614.0 billion kWh gross of electricity 19.8
20 19.2
was generated in Germany. Compared with the
previous year, power generation thus fell by 15.6 15.5
19.2 billion kWh – corresponding to 3.0%. 14.6
13.6 12.7 12.9
SOURCE: AG ENERGIEBILANZEN E.V.
12.6
11.9
10.1 9.9
10 8.5 9
COMPLEX 6.1
4.1
6
LOGISTICS Due to the boom in Internet trading,
e-commerce parcel deliveries in Germany
are set to double to more than 1.2 billion
between 2013 and 2023.
0 TO 20 YEARS
2008 2020* 2060*
20 TO 30 YEARS 30 TO 50 YEARS 50 TO 65 YEARS 65 TO 80 YEARS 80 YEARS OR OLDER
SOURCE: GERMAN FEDERAL STATISTICAL OFFICE
*Forecast, variant “medium-aged” population, lower limit
SOURCE: OLIVER WYMAN
36 37HELLO INDUSTRIE 4.0
IN THE DRIVER’S SEAT OF TOMORROW
OPEN NETWORKING AND COLLABORATION
ARE THE CORE IDEA OF INDUSTRY 4.0
AND A CHANGE IN PARADIGM THAT IS ALREADY
BEING LIVED BY KUKA.
Industry 4.0 needs strong alliances. This is As one of the world’s leading suppliers in
because no company is now able, independ- the fields of robotics, automation and systems
ently and on its own, to push forward with engineering, KUKA is directly involved in
the required global norms and standards. Industry 4.0 and a sought-after interlocutor
Only by combining their respective competen- for decision-makers in the worlds of politics,
cies can Cloud suppliers and the automation research and business – at both national
industry create the basis for Industry 4.0 and international levels.
and the Internet of Things. As a globally
active automation company, KUKA sees it Our goal is to make a success story of
as its responsibility to form strong alliances Industry 4.0 and to establish KUKA as a leading
and actively shape the factory of the future supplier of innovative technologies and
together with the other key players. That is solutions worldwide.
why KUKA is a member of all major national
and international advocacy groups and
committees, such as the Industry 4.0 Platform,
the Industrial Internet Consortium IIC, the
OPC Foundation, the industry association
VDMA and the associations BITKOM and VDE.
38WWW.KUKA.COM KUKA Aktiengesellschaft Zugspitzstr. 140 86165 Augsburg Germany Phone: +49 821 797-0 Fax: +49 821 797-5213 kontakt@kuka.com
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