Download Networked production

The HOMAG Group on the way to Industry 4.0.
The HOMAG Group already fulfils many of the criteria of the Industry 4.0 vision. In recent years, our
customers in the furniture industry have implemented a number of networked production concepts. This has
enabled furniture manufacturers in trade and industry to produce millions of furniture designs and minimize
delivery times using our fully networked and highly flexible batch size 1 systems. Looking to the future, it
is clear that the level of networking will continue to grow until the Industry 4.0 vision is achieved. With this
in mind, all companies within the HOMAG Group are working hard with partners, suppliers and customers
to harmonize interfaces and enable end-to-end communication. At the same time, the HOMAG Group is
lending its experience and expertise to a wide range of research projects established by the German federal
government to make the Industry 4.0 vision a reality in the near future.
Tangible benefits:
•Productivity increased by up to 30%
•Modular solutions of any size
•Complete modular system of software
modules
•Rapid response to new trends and
customer requirements
•Less capital commitment
•Reduction in revolving stock
•Less space required in production
•Efficiency and transparency in data
structures and sequences
•Efficient machines, efficient sequences,
efficient software, efficient production!
You can find more information at:
networked.homag.com
A video on the topic:
www.homag-group.com/networked
Albert Nopp,
Technical Manager, Hali Office Furniture
“We are running an unmanned production process in
batch size 1 with the shortest changeover gap in the
world. Our production process is label-free and we
have seen a 30% increase in capacity while still
deploying the same workforce. When it comes to
machine technology and software, we have a
partner who can achieve anything; a partner that
implemented everything we had hoped for, and
ensured that the solution worked. We are proud of
this achievement.”
MARTINI-werbeagentur.de 05/2015
Networked production
Dr. Rolf K. Hallstein,
Managing Director of Sedus Systems
“We need to move away from mass production and
towards the manufacture of products that meet
individual customer requirements and I think
networked production will really help us to make
this transition.”
Manfred Schwellinger,
Member of the ALNO Management Board
“Companies who do not implement this concept of
networked production in the future will face a
significant competitive disadvantage. The benefits are
not just apparent in industry, but in trade too. The fact
that customer requirements are increasing while the
pool of skilled professionals is constantly shrinking
means that this sector needs to completely rethink the
way it works. Entering the world of networked
production is the key to ensuring success in the future.”
Furniture production on
the way to industry 4.0
HOMAG Group AG
72296 SCHOPFLOCH
GERMANY
www.homag-group.com
Individual customer requirements
Digitization
Industry 4.0 — A vision becomes a reality.
Web-based sales solutions
The Internet of Things
Digitization and networking of production even beyond the boundaries of companies and
countries — this is the core idea behind the Industry 4.0 vision. The aim of the fourth industrial
Virtual reality
revolution — after steam engines, conveyors and automated production lines — is to enable a
Partners
wide range of units to communicate with one another in the future and, eventually, even organize
themselves. Today, machines in fully networked production already know precisely where each
component is required at a specific point in time, how the component is to be processed, what
Machine manufacturers
the quality standards are and where bottlenecks may occur in storage. For this to work, all
components involved in the production process, including machines, units, handling systems and
Suppliers
storage systems, independently communicate with one another via sensors and networks.
Intelligent factory
Production locations
Market
Industry 4.0: All areas involved in the process are interlinked
globally via standardized interfaces.
The factory of the future
Fully networked production around
the world means that production can
respond to changes in the market,
customer requirements and external
influences in an extremely flexible
manner — constantly interacting with
suppliers, partners, sales departments
and customers.
How can companies produce in a more
energy and resource-efficient way?
Where can raw materials be purchased
for a low price and where could
delivery bottlenecks occur? Networked
production systems, while responding
to the results of these questions, also
continuously optimize products on the
basis of customer feedback and adapt
them to requirements.
Industry 1.0
The mechanical
weaving loom, water
and steam power.
1784
2
HOMAG Group Networked production
Industry 2.0
First production line.
Mass production
using electrical
energy.
1870
This constant exchange of information
creates a production process that
continuously organizes and optimizes
itself, with intelligent products, machines
and resources controlling each other. In
this kind of process, consistent interfaces
and standards for the exchange of data
are essential.
With these measures in place, the
fusing of the digital world and real world
become reality: Industry 4.0 is born.
Industry 3.0
First programmable
logic controller (PLC).
Use of electronics and
IT for further
automation.
1969
Industry 4.0
Based on cyberphysical systems
(linking real objects
with informationprocessing/virtual
objects and
processes via
information networks
[e.g. the Internet]).
Today
Networked production
Fully networking mechanics, electronics
and data means that end products can
be highly individual — and therefore
meet customers’ continuously changing
requirements — in a cost-effective
manner and in batch size 1. A change
requested by the customer can be
implemented even during ongoing
production — without the process being
slowed down.
Increase
efficiency
• Energy and resource efficiency
as decisive competitive factors
Networked production
© HOMAG Group
It is already apparent that the trend
toward individual living spaces as a
place of relaxation will continue to
grow in importance. In particular,
furniture manufacturers are focusing
their production more heavily on the
individual home requirements of end
customers. The following pages give an
insight into what awaits us and what is
already possible today with networked
production by the HOMAG Group.
Reduce
time-to-market
• Shorter innovation cycles
• More complex products
• Larger volumes of data
Increase
flexibility
“Failure to implement intelligent, networked
production in Germany means sitting on growth
potential of 20% to 30%.” — Roland Berger,
Strategy Consultants
“Companies who do not keep themselves up to date
with the latest developments in an informed and
active manner may soon be left behind.” —
Dr. Volkmar Denner, Chairman of the Board of
Management, Bosch
“The German federal government is also actively
promoting innovation to equip us for the future.
Industry 4.0 is centered on intelligent processes
and products. It is all about horizontal and vertical
integration in dynamic value creation networks, digital
engineering continuity throughout the entire value
creation chain — in other words, intelligently
networked production.” — Dr. Georg Schütte,
State Secretary at the German Federal Ministry
of Education and Research
Increase
competitiveness
• Customized
mass production
• Volatile markets
• High productivity
HOMAG Group Networked production
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Optimally networked, with people taking center stage.
Networked production means individual production that is as efficient as possible and adapted
to the customer’s requirements. It is essential that all components involved in the production
process communicate with one another. A central production control system organizes and
monitors the flows of information. People are the key success factor: People make sure that
production runs smoothly and bring their experience to the table. People are the only universal
sensor that we know; people are indispensable as decision makers in factories. Not everything
can be automated — and employees continue to be a key part of production.
Sales (point of sale)
Order processing
Production control system
How do you know what a piece of furniture will look
like in your own home before you have bought it?
Using the latest apps and the camera function on
their smartphone, end users can position their
customized furniture virtually in their home, turning
furniture designs into something they can actively
visualize. A quotation for the furniture is provided and
the customer can order the item straight away — all
via the app and the Internet.
Order processing ensures that the furniture or parts
to be manufactured are clearly recorded and defined.
Parts lists, pricing and a description are provided
for this purpose. The quality of the data is critical to
the subsequent processes. All production data is
generated efficiently from the order data, within a very
short timeframe.
A higher-level, intelligent production control
system interlinks planning, production and the
material flow. This means that the correct information
always goes precisely where it is needed,
exactly when it is needed. The production control
system takes over control of the processes and
provides specific and targeted data from the work
preparation stage for the production stage.
Networked production: Already a reality with the HOMAG Group
ecoPlus — Technology that really pays off
Efficient work, increase in productivity, reduction in
the amount of energy and resources consumed —
with ecoPlus, you can save up to 30%.
powerTouch — Machine operation via a
touch screen
Easy to operate — just like a smartphone: The
standardized powerTouch operating system
and powerControl control technology guarantee
an optimum manufacturing process across all
networked machines.
MMR
(Machine Monitoring & Reporting)
MMR is a diagnostic system to analyze and
optimize production (cause and effect relationship).
It supplies evaluations of machine data on all levels:
unit, machine and cell.
The advantages: Increased productivity,
availability and flexibility.
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HOMAG Group Networked production
HOMAG Group Networked production
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Pioneer of networked production.
The aim of networked production is to produce customized furniture on an industrial scale –
in the most efficient way and at a similar cost to that of mass production. With networked
production, the HOMAG Group offers an end-to-end flow of information. In addition, the
intelligent workpiece plays a role, communicating to machines how it is to be processed. For
this purpose, every workpiece is equipped with a digital identity that contains all specifications
and production parameters.
The five fundamental elements of
networked production:
1
2
3
4
5
The digital component
The intelligent machine
Vertical networking
Horizontal networking
The intelligent workpiece
5 The “intelligent workpiece” passes through production bearing
all processing data, for example as a barcode or RFID.
3
3 Vertical networking
Sale
Order
1
The digital component
The digital component is clearly
distinguished by dimensions, color,
shape and processing steps.
2
The intelligent machine
The “intelligent machine” controls,
monitors and optimizes itself. At the same
time, the machine communicates with
the production control system and the
workpieces to be processed.
Data
Vertical networking
4
In the sales area at the POS (point of
sale), the customer’s requirements are
recorded digitally. As part of internal
order processing, this order data is
supplemented with additional production
data via automated guidelines. The
resulting “digital component” is
transferred to the machines in production
via the production control system.
Once there, the component controls
the completion of the customized order.
Working in this way means that errors
as a result of manual intervention can be
almost completely eliminated.
Horizontal networking
From suppliers and tool manufacturers
to subcontractors and partners
along the entire process chain in
furniture production, there is absolute
transparency. The “intelligent
workpiece” passes through production
independently, without any errors,
efficiently and optimized for speed. In
the process, all HOMAG Group units
communicate with one another via
standardized interfaces. The continued
standardization of these interfaces is a
central task in the current developments
underway in Industry 4.0.
Planning
Production control system
4 Horizontal networking
Storage
6
HOMAG Group Networked production
Cutting
Separating
Edge
Sorting
Drilling
Assembly
Packaging
HOMAG Group Networked production
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