Industry 4.0: The Future of Indo-German Industrial Collaboration

Industry 4.0 can be described as the fourth industrial revolution, a mega- trend that affects every company around the world. It envisions interconnections and collaboration between people, products and machines within and across enterprises. Why does Industry 4.0 make for an excellent platform for industrial collaboration between India and Germany? The answers lie in economic as well as social factors. Both countries have strengths and weakness and strategic collaboration using the principles of Industry 4.0 can help both increase their industrial output, GDP and make optimal use of human resources. As a global heavy weight in manufacturing and machine export, Germany has a leading position in the development and deployment of Industry 4.0 concepts and technology. However, its IT sector, formed by a labor force of 800,000 employees, is not enough. It needs more professionals to reach its full potential. India, on the other hand, is a global leader in IT and business process outsourcing. But its manufacturing industry needs to grow significantly and compete globally. These realities clearly show the need for Industry 4.0-based collaboration between Germany and India. So how does Industry 4.0 work? In a first step, we look at the technical pers- pective – the vertical and horizontal integration of Industry 4.0 principles in enterprises. Vertical integration refers to operations within Smart Factories and horizontal integration to Smart Supply Chains across businesses. In the second step, we look at manufacturing, chemical industry and the IT sector as potential targets for collaboration between the two countries. We use case studies to illustrate the benefits of the deployment of Industry 4.0. Potential collaboration patterns are discussed along different forms of value chains and along companies’ ability to achieve Industry 4.0 status. We analyse the social impact of Industry 4.0 on India and Germany and find that it works very well in the coming years. Germany with its dwindling labor force might be compensated through the automation. This will ensure continued high productivity levels and rise in GDP. India, on the other hand has a burgeoning labor market, with 10 million workers annually entering the job market. Given that the manufacturing sector will be at par with Europe in efficiency and costs by 2023, pressure on India’s labor force will increase even more. Even its robust IT sector will suffer fewer hires because of increased automation. Rapid development of technologies – for the Internet of Things (IoT) or for connectivity like Low-Power WAN – makes skilling and reskilling of the labor force critical for augmenting smart manufacturing. India and Germany have been collaborating at three levels relevant to Industry 4.0 – industry, government and academics. How can these be taken forward? The two countries have a long history of trade. The Indo-German Chamber of Commerce (IGCC) is the largest such chamber in India and the largest German chamber worldwide. VDMA (Verband Deutscher Maschinen- und Anlagenbau, Mechanical Engineering Industry Association), the largest industry association in Europe, maintains offices in India. Indian key players in IT, in turn, have subsidia- ries in Germany and cooperate with German companies in the area of Industry 4.0. Collaboration is also supported on governmental level. As government initiatives go, India has launched the “Make in India” initiative and the “Make in India Mittelstand! (MIIM)” programme as a part of it. The Indian Government is also supporting “smart manufacturing” initiatives in a major way. Centers of Excellence driven by the industry and academic bodies are being set up. Germany and India have a long tradition of research collaboration as well. Germany is the second scientific collaborator of India and Indian students form the third largest group of foreign students in Germany. German institutions like the German Academic Exchange Service (DAAD) or the German House for Research and Innovation (DWIH) are working to strengthen ties between the scientific communities of the two countries, and between their academia and industry. What prevents Industry 4.0 from becoming a more widely used technology? Recent surveys in Germany and India show that awareness about Industry 4.0 is still low, especially among small and medium manufacturing enterprises. IT companies, on the other hand, are better prepared. There is a broad demand for support, regarding customtailored solutions, information on case studies and the willingness to participate in Industry 4.0 pilot projects and to engage in its platform and networking activities. We also found similar responses at workshops conducted with Industry 4.0 stakehold- ers in June 2017 in Bangalore and Pune and in an online survey. What can be done to change this? Both countries should strengthen their efforts to create awareness for Industry 4.0, especially among small and medium enterprises. Germany should also put more emphasis on making their Industry 4.0 technology known to the Indian market. India’s IT giants, on the other hand, should make their Industry 4.0 offers more visible to the German market. The governments should support the establishing of joint Industry 4.0 collaboration platforms, centers of excellence and incubators to ease the dissemination of knowledge and technology. On academic level, joint research programs and exchange programs should be set up to foster the skilling of labor force in the deployment of Industry 4.0 methods and technologies

A framework for effective management of condition based maintenance programs in the context of industrial development of E-Maintenance strategies

CBM (Condition Based Maintenance) solutions are increasingly present in industrial systems due to two main circumstances: rapid evolution, without precedents, in the capture and analysis of data and significant cost reduction of supporting technologies. CBM programs in industrial systems can become extremely complex, especially when considering the effective introduction of new capabilities provided by PHM (Prognostics and Health Management) and E-maintenance disciplines. In this scenario, any CBM solution involves the management of numerous technical aspects, that the maintenance manager needs to understand, in order to be implemented properly and effectively, according to the company’s strategy. This paper provides a comprehensive representation of the key components of a generic CBM solution, this is presented using a framework or supporting structure for an effective management of the CBM programs. The concept “symptom of failure”, its corresponding analysis techniques (introduced by ISO 13379-1 and linked with RCM/FMEA analysis), and other international standard for CBM open-software application development (for instance, ISO 13374 and OSA-CBM), are used in the paper for the development of the framework. An original template has been developed, adopting the formal structure of RCM analysis templates, to integrate the information of the PHM techniques used to capture the failure mode behaviour and to manage maintenance. Finally, a case study describes the framework using the referred template.Gobierno de Andalucía P11-TEP-7303 M

Modular supervisory controller for complex systems

Automation for the oil and gas industry is driven by the need to improve efficiency, productivity, consistency, and personnel safety, while reducing cost. Fully automated systems alleviate the physical toll on human operators and allow them to focus on monitoring unsafe well events and machinery maintenance. Complex systems like drilling rigs and snubbing units require supervisory controllers that can safely coordinate equipment and processes, overcome interoperability challenges and allow for functional scalability without sacrificing safety, security, and consistency of operations. The primary objective of this report is to explore the feasibility of developing a modular supervisory controller architecture which addresses these concerns by modifying and extending existing architectures. Such modifications include the use of non-homogeneous models in sub-system modules, including discrete event models for control and physics-based models for collision avoidance, addition of a system compilation module (Meta Module) to identify simple design errors, and implementation of an algorithm for synthesis of modules and filters to replace missing sub-systems. This report discusses the implementation results of the modular supervisory control architecture (modMFSM) on a simplified two-machine drilling system for assessment of design practices. Simulations for three test cases were executed to assess the ability of the controller to correctly perform error-free operations, detect and react to possible collisions, and adapt to missing equipment. The report then discusses the possibilities of extending the modMFSM architecture to control large complex systems such as drilling rigs, using snubbing operations as an example.Mechanical Engineerin

Towards an Open-Source Industry CAD: A Review of System Development Methods

Due to the industry knowledge barrier, general computer aided design (CAD) software cannot do everything in digital manufacturing by itself, and industry CAD, therefore, occupies a crucial position in the CAD industry. To develop industry CAD smoothly, open-source is the best choice. We analyzed recent examples of industry CAD development and divided the development methods into four types: development based on the graphics development environment, development based on geometric modelling kernel, secondary development based on general CAD, and hybrid development. We analyzed the characteristics of various methods and believe that the method based on the hybrid development of the geometric modelling kernel and the graphics development environment is the best open-source industry CAD development method. We proposed a system architecture of open-source industry CAD for reference and conducted a preliminary exploration of the reference architecture to verify its feasibility

Improving interoperability on industrial standards through ontologies

Interoperability refers to the effective exchange of information and understanding to collectively pursue common objectives. System developers commonly use ontologies to enhance semantic and syntactic interoperability within this context. This work aims to evaluate the contribution of ontology in making explicit the meaning of the entities described in a Piping and Instrumentation Diagram (P&ID) model and to provide an architecture that allows the representation of a P&ID in ontological knowledge bases. To understand the semantics of the P&ID entities and relations, we map each class of the P&ID to the corresponding entity of the Offshore Petroleum Production Plant Ontology (O3PO). The ontology describes the definition of each vocable associated with the axioms that clarify and regulate the meaning and utilization of this vocabulary. We intend to guarantee that the integration of P&ID with other models respects the original semantics and avoids unintended data exchanges. We follow this ontological analysis with a case study of a model that conforms to the Data Exchange in the Process Industry (DEXPI) specification, intended to provide homogeneous data interchange between CAD systems from diverse vendors. The ontological analysis of the DEXPI P&ID specification, to build a relation with a well-founded ontology, raises a set of desirable properties for a model intended for use in interoperability. While achieving technical interoperability between DEXPI P&IDs and ontologies represented in OWL is evident, we identified several challenges within the realm of semantic interoperability, specifically concerning clarity/intelligibility, conciseness, extendibility, consistency, and essence. These issues present significant hurdles to achieving seamless systems integration. Moreover, if the DEXPI standard were to evolve into a de facto standard for representing P&IDs across a broader range of domains than initially intended, these highlighted issues could potentially bottleneck its adoption and hinder its integration into different systems.Interoperabilidade se refere à troca efetiva de informação e entendimento na busca por objetivos comuns. Neste contexto, desenvolvedores de sistemas comumente utilizam ontologias para aprimorar a interoperabilidade semântica e sintática. O objetivo deste trabalho é avaliar a contribuição da ontologia para tornar explícito o significado das entidades descritas em um modelo de Diagrama de Tubulação e Instrumentação (DTI) e fornecer uma arquitetura que permita a representação de um DTI em bases de conhecimento ontológicas. Para entender a semântica das entidades e relações do DTI, mapeamos cada classe do DTI para a entidade correspondente da Ontologia de Planta de Produção de Petróleo Offshore (O3PO). A ontologia descreve a definição de cada vocábulo associado com os axiomas que esclarecem e regulam o significado e a utilização desse vocabulário. Pretendemos garantir que a integração do DTI com outros modelos respeite a semântica original e, assim, evite trocas de dados não intencionais. Seguimos essa análise ontológica com um estudo de caso de um modelo que se conforma à especificação "Data Exchange in the Process Industry" (DEXPI), destinada a fornecer uma troca de dados homogênea entre sistemas CAD de diversos fabricantes. A análise ontológica da especificação DEXPI DTI, para construir uma relação com uma ontologia bem fundamentada, levanta um conjunto de propriedades desejáveis para um modelo destinado a ser usado na interoperabilidade. Embora a conquista da interoperabilidade técnica entre DTIs DEXPI e ontologias representadas em OWL seja evidente, diversos desafios foram identificados no âmbito da interoperabilidade semântica, especificamente em relação à clareza/inteligibilidade, concisão, extensibilidade, consistência e essência. Essas questões representam obstáculos significativos para alcançar uma integração de sistemas perfeita. Além disso, se o padrão DEXPI evoluir para um padrão de facto para a representação de DTIs em um conjunto mais amplo de domínios do que inicialmente pretendido, essas questões destacadas poderiam potencialmente atrasar sua adoção e dificultar sua integração em sistemas diferentes