Digital Production & Engineering: Glossary

Cyber Physical Systems

Due to a lack of focus, a generally accepted definition has not yet been possible. A 2014 research agenda characterizes "Cyber Physical Systems (CPS) [...] by linking real (physical) objects and processes with information-processing (virtual) objects and processes via open, partly global and at any time interconnected information networks" (1). However, the English word "physical" indicates that the term is primarily concerned with the physical, analog world. In the very latest descriptions, the analog/digital non-specific English word "asset" is used (4) In the context of current discussions, these characteristic properties have been expanded to the extent that they "exhibit a much higher local intelligence and ability to adapt to changing environmental conditions and requirements". These environmental conditions include the crossing of system, organizational and domain boundaries - also by means of human-machine interfaces, which is of elementary importance for the interaction between physical and digital world (2) - so that their heterogeneous composition and structure can be dynamically changed during operation time to support highly model-based engineering processes. This is one of the reasons why they are always mentioned in the context of "embedded systems", since CPS is also controlled by such a system. By extension, CPS were classified as Smart Systems in 2015, "typically composed of autonomous 'embedded systems' with hardware and software components". Also, the aspect of higher local intelligence was extended to an intelligence of its own (3). The potential of Cyber Physical Systems here, however, lies less on the pure digitization, but rather in their characteristic as "continuous platform-based networking of integrated sensors and actuators through local or global networks with other CPSs", so that it practically represents a "System of Systems". A special form of CPS is that of the CPPS, which describes the description of a production system.

(1) VDE, 2013: Cyber-Physical-Systems. Opportunities and benefits from the perspective of automation, Düsseldorf. (2) WGP, s.a.: WGP-Standpunkt Industrie 4.0, Darmstadt. (3) Njah, Amin, Funk, Klaus, Schölly, Reto et al., 2015: Opportunities for Microsystems Technology in the World of Cyber Physical Systems, s.l. (4) Birgit Boss, Bosch GmbH and Plattform Industrie 4.0; AK Industrie 4.0 - Interoperability of BITKOM, June 2019

Digital Transformation of Industry

The platform understands the above-mentioned term to mean the sum of mutually conditional changes affecting industry in technical and social terms as a result of digitalization. Influencing factors are those from increasingly volatile markets, those from technological innovations and those from people. The consequences include far more collaboration with people and assistance systems, as well as those of professional collaboration such as agility and temporary semi-autonomous groups, leadership, and changes in organizations. Soft factors are increasingly appearing in job descriptions, system coaches and architects are desperately sought, lead wolves tend to take a back seat due to the overflowing complexity. Employees undergoing change will need more time for further training than ever before.

Digital Shadow

The ZD.B understands the Digital Shadow as a Digital Twin Light. According to WPG (1), the Digital Shadow in the field of action of Industrie 4.0 is a "sufficiently accurate" image of the processes in production, development and adjacent areas, i.e. also of the physical products." The purpose is to have a "real-time capable evaluation basis of all relevant data, including data formats, data selection and granularity." It thus does not include algorithms and leaves open whether external data is included to the system. The concept of shadow is thus similar in essence and name to IT, which as a digital shadow refers to the totality of data. In our opinion, the programmed functionality (as designed) belongs to the Digital Shadow. In the classical "analog" world thus the digital shade corresponds to a product or process characterization. The direct use of the digital shade is a better transparency of the entire parameter set, which leads to a simpler diagnostic or also anticipatory analysis of deviations (disturbances like also product changes), as long as this is known theoretically or from the history. Also, adjustments and configuration work can be done prior to delivery of customer equipment, which can drastically reduce time-consuming and expensive field installations and qualifications. First the Digital Twin extends the shadow to a "living" counterpart of the cyberphysical system, which reflects disturbances and intentional, i.e. also unanticipated changes true to reality in the virtual world. (1) Scientific Society of Production Engineering: Viewpoint Industry 4.0, June 2016

Digital Twin (Digital Twin)

The "Digital Twin" is the digital, virtual model of a physical system, for example a product, a plant or entire factory, or even a production service, and reflects its status and properties in real time. In doing so, the Digital Twin integrates real-time data relevant to the machine with stored specifications and functionalities as well as with information from connected information systems and manually fed data. This allows not only to monitor the system, but also to simulate different scenarios in real time, to optimize operation / usage and to make well-informed strategic decisions. In particular, disruptions, i.e. deviations from the normal state, can be functionally simulated. On the timeline, the Digital Twin is created with the product idea, typically in R & D, and persists throughout the product lifecycle of the system until its rededication, remanufacturing and disposal.

Industry 4.0

Many standpoint definitions of Industry 4.0 exist! The terms Industrie 4.0, Digital Production or Smart Production, Digital or Smart Factory, 4th Industrial Revolution are often understood as synonyms. The federal German platform Industry 4.0 published the following key points (1): Industry 4.0 refers to the intelligent networking of machines and processes in industry with the help of information and communication technology. There are many opportunities for companies to use intelligent networking. The possibilities include, for example:

• Flexible production: In the manufacture of a product, many companies are involved that contribute step by step in the creation of a product. Digitally networked, these steps can be better coordinated and the utilization of machines better planned.
• Convertible factory: In the future, production lines will be built in modules. They can be quickly assembled for a task. Productivity and profitability are improved, individualized products can be manufactured in small quantities at affordable prices.
• Customer-centric solutions: Consumer and producer move closer together. Customers themselves can help design products according to their wishes - for example, elements of sneakers can be self-designed and adapted to the individual foot shape. At the same time, smart products that have already been delivered and are in use can send data to the producer. With the usage data, the producer can improve its products and offer the customer novel services.
• Optimized logistics: algorithms calculate ideal delivery routes, machines independently report when they need new material - the smart networking enables an optimal flow of goods.
• Use of data: Data on the course of production and the condition of a product are combined and evaluated. Data analysis provides information on how a product can be manufactured more efficiently. More importantly, it is the basis for completely new business models and services. For example, elevator manufacturers can offer their customers "predictive maintenance." Elevators are equipped with sensors that continuously send data about their condition. Wear and tear can be detected and remedied before it leads to elevator failure.
• Resource-saving circular economy: Products are considered in a data-driven manner over their entire life cycle. Already in the design it is determined in which form the materials can be recycled

All of them have in common the overriding objectives of (a) optimization (often related to productivity and costs) and (b) flexibilization as entrepreneurial added values to be achieved with Industrie 4.0. The coexistence of value chains and life cycle thinking underline the holistic approach and bring sustainability into the equation. Technical characteristics at the core of the concept are: (1) The networking of cyber-physical systems in terms of data and processes (Internet of Things, Internet of Things), the (2) real-time capability, the (3) adaptive, self-learning human-machine interfaces, (4) the capability of automated single or small series production and the network structure of decentralized things, information and decisions. The classic automation pyramid is increasingly being dissolved. Beyond production technology and organization in a value chain, many today refer to (5) value-added oriented digital business models, (6) the use of data-driven analytics to predictive and automated controls that make their own decisions, and the integration of (7) cloud- and service-based operated platforms as the core of Industry 4.0. The Internet of Things is being extended with and synchronized with the Internet of Services. At second glance, one recognizes the transformable, highly flexible and automatable value creation systems as the potential of complexity reduction. Early on, the fathers emphasized the inseparability of production from engineering. The (8) pervasiveness of data from digital development tools as well as the importance of digital twins as a value-enhancing, because development-accelerating simulation tool and thus at least an integral part of the product is becoming generally recognized only in recent years. The latter is measurable in the company values, which are created by knowledge work in comparison to classically produced products. Taylor's separation of executive work and knowledge work (blue color workers / white color workers, direct costs / indirect costs) as well as clocked manufacturing are largely eliminated. Internationally, Germany is considered an Industrie 4.0 pioneer. China emphasizes scaling effects more than Germany. The USA emphasizes the importance of software services. Sources: Wissenschaftliche Gesellschaft für Produktionstechnik WGP e.V.: WPG Standpunkt Industrie 4.0, Plattform Industrie 4.0 (https://www.plattform-i40.de/PI40/Navigation/DE/Industrie40/WasIndustrie40/was-ist-industrie-40.html; download from 18.7.2019)

Internet of Things / Internet of Things (IoT)

"By IoT, we mean a network of physical devices, vehicles, buildings and other objects that are able to collect and exchange data with each other thanks to built-in electronics, software, sensors and network connectivity. Concepts such as Smart Home, Smart Cities, Smart Mobile are ultimately all based on the Internet of Things. The more things are linked together, the more data is generated and the more complex the relationships between things and their management become. The Internet of Things therefore requires Big Data technologies and is therefore also a concrete application of Big Data; some analysts even refer to IoT as <> in view of the large number of devices. In the production environment, the term Industrial Internet is used specifically. The things here are people, machines, controllers, field devices and sensors, as well as software services in the cloud that link and support these things. An Industrial Internet system supports intelligent production processes with advanced data analytics technology to fundamentally transform business processes based on it. It is based on the idea of a global industrial ecosystem of advanced computing and manufacturing technology, equipped with extensive measurement and sensor technology and network connectivity available throughout. The control systems are to be interconnected, thus enabling more flexible and faster adjustments in ongoing production. External data from company-wide or also public information sources are to flow more strongly into the control of the production processes, in order to be able to make better and more competent decisions.)"

The platform character superordinate to the pure production orientation is also emphasized by others: The ITU (2) describes"...From the perspective of technical standardization, the IoT can be viewed as a global infrastructure for the information society, enabling advanced services by interconnecting (physical and virtual) things based on existing and evolving interoperable information and communication technologies. Through the exploitation of identification, data capture, processing and communication capabilities, the IoT makes full use of "things" to offer services to all kinds of applications, whilst ensuring that security and privacy requirements are fulfilled. (...) Regarding the IoT, things are objects of the physical world (physical things) or of the information world (virtual things) which are capable of being identified and integrated into communication networks. Things have associated information, which can be static and dynamic. Physical things exist in the physical world and are capable of being sensed, actuated and connected. Examples of physical things include the surrounding environment, industrial robots, goods and electrical equipment. Virtual things exist in the information world and are capable of being stored, processed and accessed. Examples of virtual things include multimedia content and application software" (3) highlights: "The term Internet of Things is often used for different concepts. What is meant here, however, is the ubiquity of information processing known as "ubiquitous computing".  Sensors, processors and actuators are networked with each other and can trigger and control actions. Everyday objects equipped with them are able to pick up environmental information and "act" based on it. "The IOT is "the network of the connection of things" connecting objects to the internet according to agreed protocol through radio frequency identification technology, sensors, quick response code and other information-sensing devices to achieve communication and dialogue among objects and things" (4). Instead of the term "Internet of Things", (5) also uses the "Internet of Everything", which deliberately includes services. However, it also describes the 2014 still very hardware-dominated system world: "...The basis of the next wave of innovation is the Internet of things, data and services, an "Internet of Everything" in which subjects and objects alike can communicate in real time. (...). The starting point of the development are embedded systems, high-performance micro-computers, which can be integrated billions of times into all kinds of objects due to the (...)  exponential development of performance parameters in IT and which became the basic technology with the enforcement of RFID technology. At the same time, these embedded systems are equipped with sensors and actuators.  Such systems can collect, store and process a wide range of data from their environment and, on this basis, influence their surroundings at the same time.  Their development in terms of size and performance is subject to "laws" similar to those of computers. Objects thus become intelligent objects (smart objects), and environments become intelligent environments. Already today, 98 percent of all processors are not installed in computers, but in intelligent objects and increasingly high-tech products." (5). (1) Hübschle, Klaus (2017): Big Data- Vom Hype zum realen Nutzen in der industriellen Anwendung. In: Schulz, Thomas (Ed.) (2017): Industrie 4.0 - Potenziale Erkennen und Umsetzen. Vogel Business Media GmbH & Co. KG, Würzburg. Pp. 189-215, p. 207ff. (2) International Telecommunication Union (ITU) (2012): Overview of the Internet of things. At: https://www.itu.int/ITU-T/recommendations/rec.aspx?rec=y.2060 (last accessed: 23.07.18). (3) Keller, Marco/ Pütz, Stefan/ Siml, Jan (2012): Internet of Things. In: Mehler-Bicher, Anett/ Steiger, Lothar (Ed.) (2012): Trends in IT - 2012. Mainz University of Applied Sciences, Mainz. Pp. 118-122. at: https://trends-in-der-it.de/downloads/Buch%20trends%20in%20der%20IT%20Final.pdf#page=118 (last access: 23.07.18) (4) Chang, YaPing/ Dong XueBing/ Sun, Wie (2014): INFLUENCE OF CHARACTERISTICS OF THE INTERNET OF THINGS ON CONSUMER PURCHASE INTENTION. In: SOCIAL BEHAVIOR AND PERSONALITY, 2014 (42). Pp.321-330. (5) Bauernhansl, Thomas/ ten Hompel, Michael/ Vogel-Heuser, Birgit (2014): Industrie 4.0 in Produktion, Automatisierung und Logistik - Anwendung, Technologien, Migration. Springer Vieweg, Wiesbaden. P. 604ff

Smart Factory

"Smart Factories are adaptive production systems networked by software systems with an interlocking of the value creation networks. The timely distribution and provision of information plays a key role here" (1). "At its core, the smart factory is about networking machines and systems with the help of software so that they communicate intelligently with each other and coordinate their work steps in an automated manner. This networking takes place both within a factory, but in the future primarily within production networks and entire ecosystems. These networks usually consist of several plants of an industrial company as well as the production sites of its suppliers and service providers and increasingly also of its customers. The smart factory requires a number of basic technologies such as computing power, storage power, broadband Internet as well as the cloud for the development and provision of digital solutions and platforms in manufacturing. It also requires key networking technologies such as cyber physical systems, embedded systems, M2M, actuators and sensors, and standardized communication protocols" (according to (2)). Similarly, (3) describes it as the "factory whose level of integration has reached a depth that enables self-organization functions in production and in all business processes affecting production. The virtual image of the factory enables intelligent decisions. The goal is to increase efficiency, effectiveness, flexibility and/or adaptability." The basis of the smart factory is so-called cyber-physical systems and the intelligent networking of machines and products. The product itself communicates the information required for production to the Smart Factory. This information is used to control the individual production steps until the desired end result is achieved. In many cases, wireless communication takes place between products and plants. The communication basis is the Internet of Things (IoT).  The most important components and tools in a Smart Factory are: A somewhat broader definition describes (4): "A Smart Factory is a manufacturing solution that provides such flexible and adaptive production processes that will solve problems arising on a production facility with dynamic and rapidly changing boundary conditions in a world  of increasing complexity. This special solution could on the one hand be related to automation, understood as a combination of software, hardware and/or mechanics, which should lead to optimization of manufacturing resulting in reduction of unnecessary labor and waste of resource. On the other hand, it could be seen in a perspective of collaboration between different industrial and nonindustrial partners, where the smartness comes from forming a dynamic organization" (1) Schulz, Thomas (2017): Industrie 4.0 - Potenziale Erkennen und Umsetzen. Vogel Business Media GmbH & Co. KG, Würzburg. (2) Zillmann, Mario (2016): Smart Factory - Wie die Digitalisierung Fabriken verändert. Transformation from the factory floor to corporate management. Lünendonk GmbH, Mindelheim. At: https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=6&ved=0ahUKEwiWvfPa063cAhWjIpoKHatDBcQFghpMAU&url=https%3A%2F%2Fwww.telekom.com%2Fresource%2Fblob%2F323140%2F53ed1330933baaca2da24915b4b7cfce%2Fdl-160620-whitepaper-smart-factory-data.pdf&usg=AOvVaw0Vn48gAVaI_7AYYwz8PnM1 (last access: 20.07.2018). (3) Fraunhofer IOSB (2018): http://i40.iosb.fraunhofer.de/FA7.21%20Terms%20-%20Industry%204.0#smart-factory (last access: 07/20/2018) (4) Radziwon, Agnieszka/ Bilberg, Arne/ Bogers, Marcel/ Madsen, Erik Skov (2014): The Smart Factory: Exploring Adaptive and Flexible Manufacturing Solutions. In: Procedia Engineering 69, 2014. pp. 1184-1190. Can also be found at: https://www.researchgate.net/profile/Marcel_Bogers/publication/275540142_The_Smart_Factory_Exploring_Adaptive_and_Flexible_Manufacturing_Solutions/links/556d84d308aefcb861d80d7f.pdf (last accessed: 20.07.2018)