REALIZING THE DIGITAL FACTORY VISION WITH MENTOR - A SIEMENS BUSINESS Featuring:- AUG/SEP 2018 | i40today.com Koh Young, Europlacer, Saline Lectronics, YXLON,PVA, Aegis Software & more...

Connect your company withthe Industry 4.0 market that isprojected to reach $152 billionby 2020. For more information,visit www.i40today.comWelcome to Issue 3of i4.0 Todayi4.0 Today is a new platform dedicated to the concept, technology& future of Industry 4.0. We are not just another publication we arean interface for sharing all Industry 4.0 news, research and developmentwithin electronics manufacturing.Our mission is to Lead the industry 4.0 movement, and give aninsight into the concept, technology and future of Industry 4.0Leading the Industry 4.0 MovementIn today’s fast paced and extremely competitive market, every secondsaved in the workplace saves not only time, but revenue. Using Industry 4.0technologies to increase productivity andreduce risk is the number one priority emerging with everyindustry and sector.What to expect from us... • Opportunity to hear industry leading• Established quarterly publication speakers• Industry 4.0 technology events • Dedicated Industry 4.0 website around the world www.i40today.com• Sponsorship opportunities • Global digital campaignMagazine Contacts...Editorial & Advertising EnquiriesTo enquire about available advertising opportunities, please contact:[email protected] www.i40today.comNEXT ISSUE Deadline for content:Jan/Feb 2019 7th December 20182 An insight into Industry 4.0 August/September 2018

Inside this issue... 4 Industry 4.0: Maximizing your Productivity with Smart, Data-driven Analytics Koh Young Technology 8 Joining the New Industrial Revolution. Blakell Europlacer 10 How these 6 types of engineers make electronics come alive Saline Lectronics 14 I4.0 for Inspection, where are we today? Yxlon International GmbH 18 PVA’s World - Class Dispensing, Coating and Custom Automation Help Customers Advance to the Next Level PVA 20 Latest i4.0 News Keep up to date with the concept, technology and future. 28 Industry 4.0: Build vs Buy? Aegis Software Corporation 32 Evolution of Intelligent buildings and the role of the IT Architect Blended Technology Ltd 34 Tips for Auditors Looking for Industry 4.0 Ready EMS Partners KIC Europe 38 Smart Manufacturing in the Electronics Industry—Realizing the Digital Factory Vision Mentor- A Siemens BusinessEditorial director contacts All right reservedWendy [email protected] SMT Today Ltd, 1 Dow Road, The content of i4.0 Today is protectedPublished by Prestwick International Aerospace Park, by copyright law, full details of which Prestwick, Ayrshire, UK, KA9 2TU are available from the publisher. While Electronics Beyond Content great care has been taken in the receipt Tel: +44(0)1292 834 009 and handling of material, production Email: [email protected] and accuracy of the content in this magazine, the publisher will not accept Wendy Tindle, Editor any responsibility for any errors, loss or Email: [email protected] omissions which may occur. Skype: wendy-smttoday Call: +44 1292 834009 Andrew Carpenter, Global Sales Email: [email protected] Call: +44 (0)7535 645205 i40today.com 3

Industry 4.0:Maximizing yourProductivity with Smart,Data-driven AnalyticsBy Jenny Yuh, Marketing Assistant, Koh YoungTechnology and Brent Fischthal, Sr. Manager,Americas Marketing, Koh Young AmericaThe electronics industry is acutely aware of the challenges manufacturers are facing dueto a chronic shortage of workers with the necessary skill to fill needed manufacturingpositions. Job hopping and employee misalignment lead to high turnover, which furthercompounds the shortage challenge. While leading industry organizations like IPC andSMTA are tackling the issue with education programs and training initiatives, it is notenough. Equipment suppliers like Koh Young Technology are working diligently to expeditethe adoption and implementation of communication standards between equipmentsuppliers to help the situation.The machine to machine (M2M) communication Koh Young Technology has overcome this challengestandards, guided in part by Industry 4.0, are quickly by using true 3D technology for all component typesaltering the manufacturing process by improving metrics to extract their bodies. [Image 1] In the Koh Younglike first pass yield and throughput by implementing Technology Zenith 3D AOI, true 3D measurement isautonomous process adjustments. Far beyond a processed by a revolutionary parallel computing engine.simple product changeover across equipment in the While 2D inspection technologies are combined withline, this two-way communication with suppliers allows real-time PCB warp compensation to offer accuratethe equipment to automatically adjust production inspection data, the Zenith platform goes much further.parameters to increase board quality and lowers costs Using patented shadow-free 3D technology, the Zenithby eliminating rework and scrap. As part of this mission, provides superior results by measuring every aspect ofKoh Young Technology dedicates to its newly developed the component and solder joint in accordance with thesmart factory solution suite called KSMART, which is IPC-A-610 standard. Koh Young’s ability to generaterevolutionizing process optimization. a significant set of reliable measurement data givesMeasurement-based Inspection rise to industry-leading measurement-based KSMARTProcess optimization is desired by every manufacturer, analysis and optimization solutions.as well as equipment suppliers, including automatedinspection providers. However, it has been difficult to Fig. 1, Koh Young’s approach to mapping body by usingrealize due to the limitation of two-dimensional (2D) true 3D measurement technologyimaging, which was the de facto standard for the Ground-breaking Transparencypast 25 years. Not only it is difficult for 2D Automated In this hyper-competitive world, manufacturers placeOptical Inspection (AOI) systems to identify defects ever-challenging demands on process solutions.on curved and reflective solder joint, 2D AOI systemsdo not generate reliable data. Every aspect of the 2Dinspection process relies on contrast, not quantitativemeasurement. As such, 2D AOI users must either scrapor repair defective boards, which increases costs andeliminates process improvement opportunities.The introduction of 3D imaging to the inspectionmarket solved some of the problems. By measuringcomponents and solder joints, and then offering criticalheight information to the inspection algorithms, userscould locate errors like pad overhang and insufficientsoldering. However, the validity of the measurementdata remained questionable as most of the 3D AOIsystems use “blob detection” to find the componentbody; however, this technique is susceptible to externalfactors like board warpage and component proximity.Since finding the component body is the critical firststep in the inspection process, it can negatively affectthe whole inspection sequence if inaccurate.4 An insight into Industry 4.0 August/September 2018

Manufacturers want to monitor and adapt the process can tighten the tolerance to prevent future escapes. Theto achieve zero defects by accessing all the data at measurable data helps improve the process.anytime, anywhere. They must also cope with shorterlife cycles, so inspection solutions should be able to Fig. 3, X-bar chart for thickness of R1005 partcollect and analyze of a large amount of data to produce In the meantime, operators can load and debug identifiedtraceable results. defects with accumulated historical real data fromLikewise, the Koh Young KSMART analysis solution all lines on OLD@KSMART (Offline Debugging). Thiscollects all inspection and measurement data from all application simulates the results of any adjustmentsequipment with its KSMART hub, and then provides the without affecting production. Again, KSMART ensuresdata anywhere within the network with an intuitive user reliability by allowing users to verify if the adjustedinterface on a web-based application. The beauty of setting is “suitable.” Then, optimized programs andthis powerful analytical tool is traceability. Big Data is inspection conditions are deployed to all productiona foundation for Industry 4.0, so advanced inspection lines seamlessly with LM@KSMART (Library Manager).systems must evolve from simply judging “Pass/Fail” These iterative actions can achieve continued processtools into highly intuitive, dynamic decision making optimization based on objective, real measurement data,systems, which emphasizes the need for reliable, not merely by a user’s experience. Moreover, KSMARTtraceable data. KSMART ensures the highest levels applications shows the proof of process improvementof transparency by showing all conditions of the lines,including machine configuration and software version,while providing the required documentation for changesto the job file, package, part, and more.Users can quickly verify whether all lines are withinthe ideal conditions. If a variance occurs, the user caninstantly upload optimized programs and inspectionconditions without fine tuning with LM@KSMART(Library Manager) [Image 2]. The software moduleprovides a complete central management solution forcomponent libraries, programs, inspection conditions,and more. LM@KSMART combines all equipment intoa single centralized library. All changes are traceableand manageable by user level Identification (ID). Suchcontrolled data management allows continuous analysisof the raw data and helps guide experts towards theright direction.Fig. 2, LM@KSMART module on web interface with statistics and charts. The benefits are real. WithEliminates the Bottleneck the use of OLD@KSMART, user could achieve a 98Of course, maintaining quality, repeatable measurement percent of false call reduction.data is not enough to realize a Smart Factory. Instead, The line performance can be monitored in real-timeanalyzed data needs to be instantly visualized with using RTM@KSMART (Real-time Monitoring). Therelevant indicators like yield rate, NG analysis, PPM software module tracks various machines in the factory,analysis, Gage R&R, offset analysis, and more to allow as well as the best performing machine yield and topusers to compare board performance and identify process five defects list, plus charts reflecting yield, availability,deviations. Using real-time SPC@KSMART (Statistical X-bar, and sigma all in one page. As a case in point,Process Control), users can identify the exact defect origin RMS@KSMART has helped significantly reduce falseby checking false calls and NG parts from the dashboard, calls and eliminate unnecessary handling, while enablingas well as evaluate, and optimize default settings. one operator to monitor multiple lines and dozens ofFor instance, if the thickness was the major problem machines, which allows operators to focus on otherin worst case part, users can click the part to view critical line task.analysis result and find the root cause. X-bar chart of Connecting Big Datameasured thickness of the part will be shown across A single inspection system has limits and cannot managetime with average, minimum, and maximum values, plus and optimize a complete line while in isolation. Knowingtolerance levels. [Image 3] If values frequently deviated this limitation, Koh Young Technology has been workingfrom average values and tolerances are too tight, users with printer and mounter partners to achieve totalcan adjust the tolerance levels to minimize false calls. communication and streamline the surface mount lineOn the other hand, if the process was stable, operators to realize a zero-defect future. Working with its KSMART i40today.com 5

CFeoanttuinreued... partners, Koh Young has leveraged the true power of KSMART Process Optimizer (KPO) is a key deliverable connectivity. Its M2M connectivity solution optimizes from the collaborative projects with its KSMART partners. the process by exchanging real-time measurement The software suite includes three interlinking modules data from SPI and AOI systems with every machine that exercise complex algorithms to develop closed- on the production line. Koh Young systems feed real loop print process recommendations. Powered by its measurement data such as offset, volume, height, area, Intelligent Platform (IP) for adaptive learning, KPO has and warnings to other systems, while analyzing trends evolved far beyond its roots as a simple closed-loop for process optimization and traceability. Combining option that continuously monitors and adjusts processes KSMART modules provides unsurpassed performance. to maintain a target value. For example, when Link@KSMART, which connects all The enhanced KPO solution, comprised of three the inspection systems within a line, is combined with interlinking software modules, actively optimizes M2M@KSMART they help define correlations between the printing process by combining real-time printing distinct processes. information with SPI measurement data. Print Advisor Using this advanced communication, the Koh Young Module (PAM) automatically performs DOEs designed Zenith 3D AOI can feed correct mounting position values to perform a detailed SPI result analysis using advanced to mounters, which ensures components are mounted diagnostic algorithms and noise filtering models, and in the targeted position. This feature improves process then recommends the ideal print parameters. Printer repeatability by automatically adjusting component Diagnostic Module (PDM), the second module, uses placements and catching the shifting trend to make multiple anomaly detection algorithms to actively further position corrections. Koh Young is aggressively optimize the print process and further reduce false calls. The final module, called POM (Printer Optimizer Module), uses the Koh Young adaptive learning engine to generate models and fine-tune process parameters. While each module provides inherent standalone process benefits, the combined power of KPO and the three modules ensures the highest process reliability and production flexibility without dedicated resources and expertise. Increased Efficiency, Reduced Costs Fig. 4, The only solution, KSMART, for Smart Factory There is always a drive to improve profitability. For realization to all the process information based on the discussion, assume a typical manufacturing scenario true 3D measurement data produces 1 out of 2,000 defective boards (before line working with others like MPM and EKRA to empower optimization) every day at a cost of $200 per board. M2M connectivity and realize a Smart Factory. The associated scrap or repair costs of $43,200 can Autonomous Process Optimization be eliminated by removing certain portion of defective Understanding the increasing importance of networked boards after identifying the root cause and implementing intelligent systems in the Smart Factory, Koh Young has process improvements with KSMART solution. been continuously testing its modular platforms with its The return on investment (ROI) costs can be further KSMART partners. The modular platform is designed reduced with LM@KSMART as it deploys stored program for future growth and expansion from KSMART. When and eliminates the fine-tuning that typically is required Koh Young releases new modules, a manufacturer can when changing over to a new system. Assume there implement the upgrades within KSMART as needed. will be 240 changeovers every year at cost of $300 per Harnessing the power of the Koh Young Intelligent changeover (plus 60 minutes of fine tuning per product). Platform (IP), KSMART extends beyond automated LM@KSMART can reduce the $72,000 in changeover adjustment towards a comprehensive infrastructure costs by eliminating fine-tuning time. Moreover, for autonomous process optimization. Indeed, a operators will not be required for fine-tuning or process Smart Factory is within reach with the Koh Young monitoring each line, and can be reallocated. Instead of KSMART solution. having five operators for five SMT lines, one operator can handle multiple lines through the use of RMS@KSMART remotely; which saves an additional $96,000 assuming their monthly salary at $2,000. In total, the company could save more than $134,000 annually with KSMART, which means more than one million dollar to be saved over ten years. KSMART offers tangible benefits that real-world businesses are asking for. Conclusion While the lack of skilled resources remains a challenge, Industry 4.0 and its associated benefits will help advance the industry. Koh Young Technology is focused on developing KSMART as a primary vehicle to enable the future of electronics manufacturing. As the absolute No.1 market and technology leader, Koh Young is using its IP (Intelligent Platform) to achieve its vision with a focus on next-generation cooperative efforts that expand process capabilities and factory performance. To this end, the company has established three additional R&D centers worldwide to facilitate a quantum leap in technological leadership and competitiveness. Koh Young can apply the IP to its current areas of expertise while paving the way into new markets and industries beyond SMT. www.kohyoung.comFig. 5, ROI Cost Savings After Process Optimization with KSMART6 An insight into Industry 4.0 August/September 2018

Partners Welcome to SMTA International Booth#: 815 www.kohyoung.com i40today.com 7

Joining the NewIndustrial Revolution.The Europlacer Journey towardsIndustry 4.0 by adopting CFX.By David Fenton, Group Customer SupportManager, Blakell EuroplacerDavid Fenton has taken on the challenge of driving Blakell Europlacer towards Industry 4.0integration, initially through the adoption of the IPC’s CFX (Connected Factory Exchange)standards. Here he describes the facets of that relatively short but rewarding journey.For quite some time we’ve seen some of our competitors would usually result in the need for bespoke softwareand strategic business partners in the surface mount development, which is rarely cheap: it’s not easy andelectronics assembly sector claiming to be ‘Industry 4.0 it takes time to implement.ready’, and advertising as much. To us at Europlacer, For a long time, the twin goals of the EMS industrythat seemed rather odd. We’re by no means outsiders have been speed and a low cost of manufacture. Anin this market sector. So we have a clear perspective electronics manufacturer can only go so far towardof the historic and emerging needs of the prospective those goals before it becomes evident that you have toend users of Industry 4.0-compatible assembly be smart to get there, and ‘smart’ is where standardssystems: businesses such as OEMs and CEMs/ that make Industry 4.0 a viable prospect would deliver.EMS Providers, a fair few of whom are Europlacer (or Light at the end of the tunnelSpeedprint) customers. At the beginning of 2018, our focus turned to theThe question that kept popping up was how can anyone newly-proposed CFX standard, championed by Aegisclaim to be Industry 4.0 ready, when there is no standard Software and adopted by the IPC. Little more than ato be ready for? That couldn’t be right. We knew that we month before the APEX Expo in San Diego, Michaelneeded to be involved in the movement but elected to Ford of Aegis presented CFX as part of a Factory 4.0keep our eye on this nebulous ball and investigate every initiative to the management team at Europlacer. It waspotential solution or worthy contribution to the goal as a convincing talk that centred on creating a live demoeach arose. As with all attempts to create a standard, of connected equipment at the exhibition.there are many competing ideas, each of which has its Lots of things fell into place, and we collectively realisedbenefits. Choosing one too early felt a lot like taking a that this was something that made sense. We could seegamble. Someone needed to find an edge; something an achievable standard emerging. With the support ofthat would make the decision more certain. Aegis Corp, it was evident that the standard was beingWhat’s the background? put together by people who know the industry. AfterThe issue with compatibility between assembly at least a year of looking at the ball, we finally saw aequipment from different suppliers goes back a long reason to participate in the game.way. Very often, a manufacturer will have systems from We see Factory 4.0 as a subset of the broader aimsa variety of vendors; it has always been a challenge to of Industry 4.0. But it is the subset that’s critical to ourmake these products work well together. Mechanical business at Europlacer in creating and delivering ‘smart’interfaces for machines at each step of the assembly assembly products. Factory 4.0 is essentially aboutprocess have long been defined. But information digitising the manufacturing process. Achieving thatcompatibility between them suffered from data formats can take many forms, but one essential part is to knowthat engineering development teams typically defined what’s happening in your factory and then be able toyears ago. respond to changes quickly. At Europlacer, we realise that the Pick & Place machine – our core product – is These formats work often at the heart of the assembly process. We also know just fine within the that to maintain efficiency and productivity, process confines of each managers need to understand what’s happening in individual system and around that machine at any time. or platform. But Like every other equipment manufacturer, Europlacer has interfacing that data been providing this information for years – but generally between adjacent in a proprietary format, which suits our placement process in a line machine yet is generally unreadable by other systems. and, worse yet, That had to change if we were to collaborate effectively. across a production Fortunately, that proved to be straightforward. floor, demanded After Michael Ford’s presentation, it was evident that a collaboration between suppliers (who are sometimes competitors) and8 An insight into Industry 4.0 August/September 2018

great deal of expertise and resource had already been When will customers tell us?deployed in an attempt to create a valid standard. Since the APEX event, it’s fair toWith the creation of a CFX software development kit say that interest has grown. Wespecifically for the proposed live demo, the Aegis team received many more instanceshelped streamline our participation. Our R&D team of positive feedback fromused the simple instructions and methods provided Nuremberg. And, obviously,to achieve a conclusive test on the Aegis server in just more again in the contained48 hours. Messages from our software were being environment of our Technologyprocessed and returned accurately. Over the next few Day where Michael Ford ofdays, our machine software was re-engineered, to the Aegis again gave a series ofpoint that we could run through the live demo. All this, presentations to a packedin just one week. seminar room. Visitors wereAt the APEX event, Europlacer participated in the live impressed. So it would appeardemo from two placement platforms we exhibited: our that electronics manufacturing professionals are alreadynew high-speed atom4 machine and our best-selling warming to the Factory 4.0 notion, and are increasinglyiineo+ machine. Both streamed live data to the CFX cloud curious about the implementation options – includingservicer at the show. In turn, exhibition visitors could view CFX.that data on a smartphone app. We repeated the demo That said, it is still predominantly us telling them aboutat the SMT Nuremberg show in early June. And then the future. We are pushing CFX, not simply becauseran our placement systems with the CFX demo being Europlacer has committed to it, but because we believedisplayed on our own dashboard during a Technology in what it can deliver. In my view, there is more workOpen Day held at Europlacer HQ in mid-June. needed by the IPC, Aegis and all CFX collaboratorsWhat adoption will demand to promote the benefits rather than the technology.I believe a key part of a test for any standard is the speed Ultimately, end users don’t care how it works. But theywith which it can be embraced and implemented. On will care about what CFX and Factory 4.0 can do forthat measure, our experience with CFX was very positive their businesses. As Europlacer and other manufacturersindeed. Within a month, our R&D team went from a begin to promote their capabilities, we need to clearlyposition of no knowledge of CFX to a fully-operational articulate the tangible benefits of why we’re doing it.model. That’s why we think it’s the right path, despite But for now, we are the visionaries. Though I do not thinkthe existence of other standards contending to achieve it will be long before those tables turn. I fully anticipatethe same goal. a time in the not-too-distant future when our customersIt could be the wisdom of industry experience from Aegis start to ask us what we can do for them. That couldthat made a difference. It is certainly true that adoption even happen this year.is far more likely if it’s made easy for manufacturers likeEuroplacer to get on the first rung of the ladder. The Where is this all heading?Aegis SDK, hand-holding assistance when needed, and At Europlacer, we quickly recognised the benefits ofwell-thought-out documentation for our programmers CFX as a viable path to Factory 4.0. As a result, we areassured that. It turned out to be easy to get messages committed to implementing it on all our platforms andwritten and coded. equipment in the future. The first step in taking CFXGetting nearer the light seriously was to not miss an early opportunity to beMake no mistake, we’re still in the tunnel. The reaction seen to participate in the live demo at APEX. We wereto the live demo at APEX was mixed. Muted, even. keen to demonstrate a willingness to invest our R&DNo one was getting particularly excited. But I expect into new ideas. That proved to be very fruitful and lessthat’s due to it not being at the forefront of people’s challenging that we dared imagine.minds. Did show visitors even realise that the live CFX But where next? Not wishing to lose momentum,demo they witnessed was arguably the beginnings of Europlacer has signed up to be a member of thethe next industrial revolution in action? Probably not. IPC Technical Review Board that assesses eachTo many people, Industry 4.0 is still a buzz word – a new message proposal that comes up for inclusion.future promise that has no visible manifestation. Yet! It’s heartening to learn that the IPC is collaboratingFor now, I think CFX and Factory 4.0 garners more with the Hermes Standards Committee, rather thatexcitement amongst those of us who want to develop treating it as a rival. With Factory 4.0 mostly aboutand implement it, rather than our customers who will communication, is it not somewhat poetic to see aultimately end up using and benefitting from it. It’s body like the IPC communicating with exponents ofcertainly a great opportunity for equipment integrators, alternative propositions? Such inclusiveness soundsas it will eliminate the need to develop proprietary like a recipe for success rather than a battle to create ainterface protocols. A common protocol makes all the loser. Goodness knows: we really could find ourselves atdifference when it comes to the holy grail of seamless the threshold of the next industrial revolution – Industrialintegration between every process in a surface mount Revolution 4.0!assembly line – from screen printing through to final www.europlacer.comproduct testing, taking in intelligent lineside storageand robotic handling on the way. i40today.com 9

How these 6 typesof engineers makeelectronics come aliveBy Matthew Vande Bunte, MLive andDavina McDonnell, Saline LectronicsFor the end customer, the world’s first robotic frozen yogurt vending kiosk is pretty cool.You order by touchscreen, which triggers an animated video and launches a robotic armthat takes a cup, fills it with froyo and lathers it in your favorite toppings.You’re going to start seeing lots of Reis & Irvy’s robots As former NASA engineers, Potter and fellow co-founderin shopping mall food courts, movie theater lobbies, Aaron Hulse are working to commercialize the kind ofhospital cafeterias and other venues all across the technology they worked on in the space program. TheyUnited States. know what they’re doing when it comes to robotics.“The show is a big part of the appeal,” said Elliott Potter, They know how to program the touchscreen interface,co-founder of Houston-based Rethink Motion, which for example, and they know how to design the printeddesigns the robotic arm that powers the Reis & Irvy’s circuit boards that control the robotic arm’s motorsmachine. “There’s always a line of people watching the and sensors.robot do its thing.” But even though Potter and Hulse can design theWhat the customer doesn’t know is that it takes a lot products and make them work, they aren’t experts onof engineering expertise to make a cool gadget like a how to make the circuit boards inside those productsrobotic froyo kiosk into a viable commercial product inexpensive and efficient to mass-produce. So,that operates at a price point people are willing to pay. they turn to Saline Lectronics, a leading electronics contract manufacturer (CM), with a deep pool of its own engineering expertise for help.10 An insight into Industry 4.0 August/September 2018

“Beyond the bill of materials and “It’s great to have that engineersome basic rules of thumb, it’s to engineer discussion,”hard to know what makes a printed commented Steve Telgen, Pre-circuit board assembly expensive or Process Engineer at Lectronics.cheap, so I rely on feedback from “To have intimate knowledgethe engineers at Saline Lectronics of the design intent allows meto say ‘We can do this, but this to help each of our customersthing that you’ve done adds 30 achieve what they need to with thepercent to the cost of the board,’” design while guaranteeing it’s stillPotter said. manufacturable.”“I definitely rely on them to go over Here’s a look at several differentthe design and say ‘Gosh, the pads types of Lectronics’ engineers:on this sure are small’ or ‘Without • When a CM receives an order, likethermal relief on these pads wemay have assembly issues.’ Their for a PCBA that enables a roboticinput on this is critical in terms of hand to sense when it’s graspingcommercial success.” a yogurt cup, a Pre-Production Engineer reviews the customer’sHow many engineers does it take Reis & Irvy fro-yo station documentation and requirementsto serve a cup of froyo? The question may sound like the during a “pre-release” meeting that involves thebeginning of a joke, but the reality is the more engineering entire engineering team. This meeting should includeexpertise you can devote to solving a problem the better. electrical, chemical and mechanical engineers.That’s especially true for an electronics CM. The CM’s engineers evaluate the documentation — instead of blindly following it — and identify“Our clients want someone who can bring value, so we the unique demands of the PCBA, including anylook at solutions on how we can make our client’s job special processes and potential problems that mighteasier,” said David Amador, Regional Sales Manager arise. Having engineers with excellence in a varietyat Lectronics. of fields enables the CM to develop the optimal manufacturing plan for turning out PCBAs that meetNot every electronics CM staffs the same level of the customer’s needs. Any wonky requirements willengineering knowledge and experience. Some CMs havea greater breadth and depth of engineering talent, and be flagged at this stage, and special processes will be better defined with a clear timeline to ensure thatthat has a big impact both on the customer’s experience everything is prepared for the actual manufacturingand on the quality of the final PCBA or box build. process. Flagged requirements may include a special stencil design for smaller components, pallets for flexPCBAs and other electronic manufacturing projects PCBA’s, or added x-ray images for complex BGA’s.require a team effort between multiple types ofprofessional engineers, who each bring the unique • Once a manufacturing plan with instructions for theperspective of their specialty to the table. Lectronics’ build have been developed up front, a Componentengineering team offers combined experience of over200 years. Engineer reviews the Bill of Materials and works with the Purchasing Department to get all the parts and specialty components necessary to complete i40today.com 11

Feature the PCBA. With many parts in short supply theseContinued... days, some CMs will come back to their customers and say “we can’t find these 10 parts, so please find alternatives.” But it’s a huge time saver for customers like Rethink Motion when their CM has the technical capability to say “we can’t find these 10 parts, so please approve these 10 alternatives.” With the current component allocation situation and lead times exceeding 30+ weeks, recommending alternative components to customers is paramount. • “Given the current allocation situation, especially in relation to ceramic capacitors, it’s been difficult to keep up with the dramatic increase in requests for alternate components,” commented Mark Haavisto, Component Engineer at Lectronics. “For passive parts, if we can get form/fit/function approval for alternates where we are buying to the component’s description, it can save a lot of time and help us secure that available stock before it goes away.” Tony Klavinger, Sr. Test Engineer, peering into the Process Engineer reviewing work instructions on the Thermotron chamber to check-up on the burn-in process production floor. for a military product. • A Process Engineer monitors the manufacturing • An Associate Engineer translates the customer’s process, troubleshooting any issues and finding documentation into the CM’s standardized work opportunities for improvement. This may require instructions that technicians will use to implement support from a chemical engineer for special the manufacturing plan devised in the pre-release processes like conformal coating or potting processes, meeting. The work instructions are standardized for for example, or from a mechanical engineer for manufacturing technicians to be able to efficiently and electro-mechanical box build products. It’s helpful accurately perform the assembly work required in each to have specialty engineering expertise in house area. Once the project is released to the production to oversee manufacturing and communicate with floor, a variety of engineers work with technicians to customers. If a PCBA doesn’t sit properly within ensure the assembly proceeds successfully: the designed mechanical housing, an experienced process engineer will work closely with the customer to find a solution, which may mean re-arranging the box-build configuration or even specifying a better- fitting housing. • A Test Engineer works closely with the customer to develop cost-effective testing that validates the PCBA performs as it should. This can include an In-Circuit Test (ICT), Flying Probe or other functional testing that not only validates the PCBA is assembled correctly, but also helps improve product quality. Some clients don’t have the in-house capabilities to establish a robust test plan, so Lectronics’ test engineers partner with many of these clients to develop the ideal test solution. This effort can include development of the hardware, software, and test protocol for each printed circuit board assembly. • “I have a current client with very limited engineering staff, so we are working with them to develop, write, and publish test procedures. Other CM’s wouldn’t work with them to develop an appropriate test solution,” commented Amador. • A Quality Engineer works on the production floor and watches the entire process like a hawk, taking notes and making tweaks to make sure that the finished PCBA meets the customer’s needs. This engineer also is responsible for documenting compliance with any special certification requirements such as ISO13485, for medical equipment, or AS9100, for aerospace equipment. A diverse pool of engineering expertise is necessary for an electronics CM to optimize circuit board design and the assembly process — so that the manufacture of PCBAs avoids time-consuming inefficiencies and costly mistakes so that products like a frozen yogurt vending machine can come to life. “That’s really a huge added value, not just having these engineers on staff at Saline Lectronics but having them work with me,” Potter said. www.lectronics.netDavid Cusumano, VP Engineering, and Jeff Eisemann, Sr. Process Engineer, troubleshootinga new robotic hand soldering process flow for a new PCBA.12 An insight into Industry 4.0 August/September 2018

Connected Factory bringing electronics to life lectronics.net i40today.com 13

I4.0 for Inspection,where are we today?By Ragnar Vaga, Global Business DevelopmentManager and Keith Bryant, Global Director,Electronics Sales Yxlon International GmbHIn the connected Smart Factory of the future, all machines and systems will becomeessentially smart sensors, collecting all possible data from the production line and fromthe boards themselves, it is obvious that the quality of the raw data is one of the corecomponents.Therefore, the accuracy and sensitivity of those verification costs include labor, capital equipmentsensors is very critical, especially in quality control and other related costs such as maintenance andsystems including AOI and AXI. Without diminishing panel handling.the strong characteristics of thein-line inspection equipment, Each defect reported It is impossible to have athese still need assistive by in line AOI or AXI functioning SPC system if thetechnologies for the verification root cause of failure cannot beof some challenging faults that identified, so false fails becomeappear at the same pace as the must be verified, if the a grey area in the statisticsreported defect turns outminiaturization of electronic where it is not known if the failure is real or what type ofassemblies. failure it is. This is a real issueto be a false alarm, thenWith the drive towards 100% for any company trying toinspection, in line X-ray and its verification effort is monitor and improve its yield,3D AOI are becoming more a cost that could have as lack of accurate data makesfrequently used at the SMT been saved, because the any improvements very difficult.lines. However, both these verification did not create The way forwardtechnologies have certain Smart manufacturing should belimitations that may need any real value. a proactive and independentassistive technologies for the decision-making environmentverification of possible false where connected systems orfaults. The false fault rate ofthe inspection system, oneof the key items of the fault coverage, affects the machines will “talk” to each other. That “discussion” is, however, based onoverall efficiency of defect detection. Simply put, algorithms. By definition an algorithm can givethe more false faults you pass on to a repair stationfor validation the more real defects get missed, false us only one single answer. But does this providefaults also generate costs. Each defect reported by in us the right answer or one from three or four or fiveline AOI or AXI must be verified, if the reported defect alternatives? Will it provide the same response everyturns out to be a false alarm, then its verification effort time or different ones for the same issue? Many MISis a cost that could have been saved, because the systems are not yet ready to manage big data, dueverification did not create any real value. False alarm to the lack of smart analytic tools. Without human intervention to make those critical decisions, based on knowledge and experience, we still cannot talk about completely effective and efficient smart production. Therefore the reliable solution combines human brains and algorithms together, allowing Process Managers to make informed decisions after seeing all the data from the various collection points. Considering all this, an at-line x-ray system should become an additional high-end sensor that can compensate, for example, for the limitations of AXI or 3D AOI. An at-line system is essentially an off-line system that is linked to the production line and placed beside it, allowing real-time response to issues and making the x-ray system a tool of the production and QA teams and not simply a test machine in a lab, used by QA staff. Collected data is relayed to a single screen where they also have historical information and everything needed to make a truly informed decision. This is definitely a14 An insight into Industry 4.0 August/September 2018

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Feature Smart Solution, it is not a “Lights Out” fully automated The connectivity of the at-line system is based onContinued... Smart Factory but it is much better than many factories Internet Protocol (IP) via Transmission Control Protocol today. It allows real time monitoring of production flow (TCP). Further use of data (collation and visualization and the changing of settings and limits to ensure that of results from different inspection systems) depends the product produced remains within the optimum on the end customer’s demands and capabilities. The process window, giving potentially 100% acceptable collected data allows the operator to understand what product coming off the line, at least in terms of assembly happened and make predictive analyses about future defects. It is also a big step towards “full automation” and trends. The general task is to provide a dashboard therefore well worth embracing as a way of improving view to the Process Manager who can track down the yields and reducing costs. possible problem areas and initiate proactive measures This solution is simple to implement and therefore to improve the quality of production, before rejects or reliable, the at-line x-ray can be connected to an in- scrap units are produced. line 3D AOI or in-line AXI inspection system directly where it becomes a smart verification tool where only Added value of the Smart Factory solution An at-line system is The ultimate target for this solution is to increase essentially an off-line production yield and reduce the manufacturing costs, system that is linked to including troubleshooting and rework. the production line and In high-reliability products, including aerospace, placed beside it, allowing military and automotive products, there is no room for real-time response to uncertainties. All possible defects have to be verified issues and making the and reworked if possible. Conventional methods for x-ray system a tool of the troubleshooting are the ICT, microscope, etc. these production and QA teams. are usually quite expensive and should be avoided, if possible. questionable and unsolved faults will be transferred As a reference we can use 700 USD as the hourly cost of for repeat inspection on a high-resolution at-line x-ray the ICT method (incl. technology, labor and overheads). system. The inspection results can be stored on the 400 USD per hour will be an average cost of a PCB system PC, but can also be exported to the customer’s rework. Obviously these numbers vary from country MIS, where it is more useful as it can be shared and to country but should reflect the industry standard. viewed by many engineers. The value of the this technology to the user will be on- demand locations scanned from in line technologies and at line X-Ray, which can be compared side-by-side so that the user can make an informed and conclusive decision on the defect calls. At the moment, the best Smart Factory quality control solution is the combination of human brain and algorithms. www.yxlon.com16 An insight into Industry 4.0 August/September 2018

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PVA’s WorldClass Dispensing, Coating andCustom Automation Help CustomersAdvance to the Next LevelBy Kerstin Jakiela , Marketing &Communications Manager, PVAHeadquartered in Upstate New York, with regional sites stationed throughout North America,Europe, and Asia, Precision Valve & Automation (PVA) is a global supplier of conformalcoating systems, innovative fluid dispensing solutions and precision valve technology.PVA is globally recognized as an industry leader in closed-loop servo controlled process that proved bothfluid dispensing and spray systems for adhesives, accurate and rugged. In October 1994, Invotronics insealants and coatings. The company is a specialty Canada became PVA’s first selective coating systemmanufacturer of automated and manual dispensing customer. Local, national and industry accolades soonequipment, spray coating equipment, pumps and followed as PVA’s reputation grew as a serious contendervalves. Its selective conformal coating systems combine in the fluid dispensing market.closed-loop process control, high levels of accuracy Manufacturers rely on PVA’s conformal coating systems,and repeatability for use in moderate to high-volume fluid dispensing solutions and custom automationmanufacturing environments. products. For more than 25 years, PVA has beenPVA was founded in 1992 by president Anthony Hynes, making manufacturing easier with customer-drivenwhen he began selling dispensing valves for automated solutions used throughout numerous industries. “Fromand manual dispensing applications out of his home. benchtop equipment to inline conveyer systems, weLater that year, PVA moved to Rensselaer Polytechnic evaluate each opportunity independently, and withoutInstitute’s (RPI) Incubator Center where it began building limitation, to ensure our customers make the mostXYZ robots to automate its growing valve technology. reliable product possible,” said Frank Hart, PVA’s SalesOn October 26, 1992, PVA sold its first automated & Marketing Manager. “Throughout the changing globaldispensing system. After that, PVA’s dispensing valve manufacturing landscape, we remain committed toproduct line grew rapidly to include superior technology providing customers with exceptional products andfor accurately applying conformal coating materials. In industry-leading global support.”1994, PVA debuted a selective conformal coating system More than world-class coating machines, PVA’sthat would later become the PVA2000, which improved customer-driven solutions are used worldwide in manyon existing XYZ plotting systems by introducing a18 An insight into Industry 4.0 August/September 2018

industries. Its technology, knowledge and flexibility allow • General Packaging: Combining flexible customthe company to work with customers to customize their solutions with diverse application expertise, PVA isprocesses to best fit their requirements. All systems are a valuable source for dispensing hot melt adhesives,backed by a 24-hour global service network, including doming materials, sealants, epoxies and spray coatregionally trained technicians for fast response times. finishing.PVA serves many industries with a range of applications PVA’s products include selective conformal coatingincluding adhesives/sealants, automated dispensing, systems, automated dispensing, meter mix dispensingcoating, curing, custom automation, manual dispensing, equipment, surface mount adhesives, valves, coatingmicro dispensing and SMT/semiconductor dispensing. inspection, inline curing ovens, optical bonding, boardThe goal is to provide the best technology for each handling, valve controllers, manual dispensing/coatingcustomer within the following industries: systems, material delivery tanks/pumps, coating &• Electronics: Used in manufacturing everything dispensing options, dispensing consumables,from smart phones to LCD displays, the company’s programming software and fume extraction/filtration.automated and manual solutions provide accurate, “From modest beginnings in Upstate New York, to areliable dispensing of materials such as solder pastes, 105,000 sq ft facility in Cohoes, NY, with regional sitesadhesives, silicones, sealants and cyanoacrylates. stationed throughout North America, Europe, and• Aerospace: Precision and reliability are crucial in the Asia, PVA has a long history of providing innovationmanufacturing of aircrafts and their parts. Leading and expertise in dispensing, coating and custommanufacturers rely on PVA for accurate dispensing of automation,” concluded Hart.lubricants, solvents, sealants, adhesives and pastes. PVA has stayed true to its small-town roots, earning• Automotive: The diverse automotive industry presents it more than a reputation for technological innovationnumerous dispensing opportunities from selective spray but also as a community leader. Through its Fast Breakcoating to potting, gasketing and bead dispensing, Fund, the company contributes monies and resourcesincluding applying adhesives and lubricants. to developing educational programs that provide• Medical Device Manufacturing: The company’s children with the resources necessary to succeedsolutions assist in this industry from the handheld academically and athletically. The program providesprototyping phase all the way through to large-scale sports summer camp scholarships to children fromproduction. PVA systems are used in applications such families with low incomes and sports clinics to childrenas bonding of plastics, glass and metals, lubricating with developmental disabilities.equipment, coating, dispensing UV adhesives for Halfmoon Works evolved from the Fast Break Fund.bonding canulas, catheters, and other plastic, glass Many of the Fast Break children have grown up andand metal components. are young adults facing the challenges of our complex• Military/Defense: The military market is known for high- world. Taking personal development beyond sports,mix/low-volume applications, as well as nontraditional Halfmoon Works provides a fully equipped 3,000 sqboards. PVA’s machine flexibility and patented 4-axis ft facility and woodworking workshops to these andoption, has made them a valuable partner in the military other young adults with special needs, allowing themmarket. to create and sell quality wood products.• Renewable Energy: The company’s systems are used PVA strives to provide the technological innovation itsin numerous applications to ensure reliable products customers need while giving the care and concern thatin the solar assembly process including solder paste its community deserves.dispense, edge/frame sealing, junction box potting & www.pva.netattachment, thin film backside coating, and electricalconnection sealant/grease. i40today.com 19

Latest i4.0 NewsKeep up to date with the concept,technology and future. of their advances in digitalization and being potential sources of best practices. The UAE, Colombia, Malaysia and Vietnam were selected for representation of key emerging economies from Latin America, South-east Asia, and the Middle East.AUTOMATION AND EDUCATION HAVE TO GO According to the report South Korea, Germany andHAND IN HAND Singapore are the world’s top-ranked nations in their preparations for smoothly integrating intelligentAdvanced automation can mean better, more automation into their economies. Other countries thatmeaningful jobs for workers. A concerted round out the top 10 in ranked order are: Japan, Canada,approach to education and training is needed to Estonia, France, the United Kingdom, the United Statesfully embrace the opportunities being created and Australia.by today’s rapidly developing automation There is not a single industry today that has not beentechnology. ABB’s Automation Readiness Index touched by some form of automation. Yet the studyhighlights the need for education and ranks 25 found that many countries worldwide are not preparedcountries on their readiness to apply the latest to fully embrace the opportunities and challenges beingtrends in automation. created by today’s rapidly developing automation technologies. The ARI report lays out the importance ofWe are no longer gearing up for a future of automation, we training programs that equip current and future workersare living it. The development of very smart technologies to operate in increasingly automated workplaces.such as robotics and those based on artificial intelligence The report recommends that even for countries at(AI) now undertake more than simple assembly-line the top of the list, they still “must develop even moretasks. Factories are being run more efficiently with effective education policies and training programs, asadvanced automation technologies such as predictive well as place a new emphasis on continual learningmaintenance and collaborative operations. ABB for over the course of a career.”example developed a smart sensor technology for The fact that the unemployment rate in South Korea,low-voltage motors, pumps and most recently also for Germany and Singapore are below global averagesbearings, reducing the unplanned still stand times of show that the adaption of automation does not leadfactories by 70 percent. This has an impact not just on to job losses. Experts in the ARI study say the use ofa factory but on society as a whole! A ground-breaking automation in performing repetitive tasks will createreport from ABB and The Economist Intelligence Unit more meaningful jobs for humans, thereby increasingfinds that even the large economies of the world already job satisfaction.embracing the future of work still must rethink how to As a pioneering technology leader, ABB has been atprepare the workforce for tomorrow. the forefront of developing products and services thatThe report “The Automation Readiness Index (ARI): WhoIs Ready for the Coming Wave of Innovation?” ranked25 countries on their readiness to successfully put intouse intelligent automation – machine-learning and AI-assisted automation – in existing industrial operations.The expert panel selected the largest economies ofthe world (G20), comprising a majority of high-incomecountries (ten), upper-middle-income countries (seven),and two lower-middle-income countries (India andIndonesia). These are considered to be more exposedto the changes brought about by automation and,consequently, more likely to be developing innovativepolicies and best practices. Additional countries wereselected in consultation with the expert panel on thebasis of relevance and geographic representation.Estonia and Singapore were selected on the basis20 An insight into Industry 4.0 August/September 2018

have spurred business productivity in power grids, from all systems and uses the data to make the rightelectrification products, industrial automation, robotics decisions, such as when the robot has to set off toand motion. The company’s cross-industry portfolio of deliver the material to the production station on time.digital solutions for monitoring and controlling automation Current machine states are also monitored: Can thesystems, ABB AbilityTM, is helping manufacturers shape system accept material right now? Or when does it needfactories of the future by allowing customers to know new material? This is all mapped by the ASYS Materialmore about their data and manage it efficiently. Manager, which independently coordinates production.Another example is ABB’s cross industry YuMi® robot, More projects are scheduled to be completed in thewhich represents a paradigm shift in robot and human course of the year.collaboration. YuMi’s flexible dual arms, along with the We are ahead of the game with this approach. ASYS isnew single-arm YuMi increase manufacturing flexibility the only company that can offer such a comprehensivethrough human robot collaboration while unlocking the solution from a single source. Our proximity to customersfull potential of the digital factory. means that we have been able to develop this practicalABB technology is helping companies around the world solution and we will now be continuously developingto take full advantage of automation. ABB is committed it. We have already completed our first projects withto address the opportunities and challenges of artificial customersintelligence and industrial automation. Augmenting To establish autonomous production in the long term,human potential with technology, in a responsible way, there are often extensive requirements to be met, whichwhile providing ongoing education and training, is an take time. This is where ASYS steps up for its customers.opportunity to drive prosperity and growth for everyone. Production tasks can initially be semi-automated. “Inwww.abb.com the next step, it is then very easy to ramp up to the fully automated solution. This means that we can walk inASYS DELIVERS END TO END SOLUTIONS step with our customers on the long road to the smartMonitoring machine availability while keeping an eye factory and deliver the right degree of automation foron material flows and ensuring that product stations each implementation phase,” Ritter sums up.are supplied with material at the right time – these www.asys.deare the challenges that production managers faceon a daily basis. ASYS now provides end-to-end BOSCH LAYS FOUNDATION STONE FOR FACTORYmaterial logistics solutions that network all of these OF THE FUTUREelements and automate the supply of materials. • Key technology: semiconductors for automotiveASYS has made a name for itself in the automation ofproduction lines. “It was a logical step for us to look technology and the internet of thingsat the processes away from the line to implement the • Expansion of manufacturing capacity: more andnecessary automation measures there as well. We havefocused on the material flows in production, which have more chip applicationto run smoothly at all times to meet production targets,” • Ten-figure sum: high-tech factory to employ 700explains Florian Ritter, Unit Director Software Solutions • Artificial intelligence: Quality assurance through& New Business. The overall goal of material logisticsis to automate all material flows within production. connected manufacturingThat means all types of production materials should • Bosch board of management member Hoheisel:be transported autonomously, from trays, magazines,raw materials and component reels to other process “Semiconductors pave the way for better qualitymaterials, such as soldering pastes, adhesives and of life.”cleaning rollers. Essential support is provided by AIVs • Federal and state officials emphasize contribution(autonomous intelligent vehicles) which transport to Germany’s competitivenessmaterials autonomously from A to B. These smart The foundation stone laid recently in Dresden is a keyproduction transport systems are self-organizing.Fleet management is designed so that each robot isassigned a task that it can complete most quickly andeffectively. As smart systems, they automatically detectand avoid obstacles, navigating the shortest path totheir next point of work.End-to-End SolutionsBut ASYS does not just supply autonomous robots formaterial logistics – it provides an end-to-end solutionthat includes machinery, AIVs and software and networksall elements for maximum profitability. “We are seeing atrend for processes within a line to be separated fromeach other. This is partly due to the different cycletimes. Separating the production line into standaloneproduction centers creates new transport routes formaterials. This is where we bring in material logistics,”says Ritter. Higher-level software provides a virtualmap of the production line, even where processes arephysically separated. At ASYS, this is all done by theASYS Material Manager (AMM). It collects information i40today.com 21

CFeoanttuinreued... milestone in the construction of the Bosch Group’s chip manufacturing process, working to plan, manage, state-of-the-art wafer fab. Construction is scheduled and monitor production. This also includes modifying to be completed in late 2019, when installation of the the production processes and evaluating the data from production machinery will start. Dresden in Bosch’s global manufacturing network. “Bosch’s decision is an important milestone. The Saxony as a business location: driving Europe’s construction of the new wafer fab here in Dresden will microelectronics industry create many other attractive jobs, strengthen Saxony’s In his address, Peter Altmaier, the German Federal reputation as a location for technology and business, and Minister for Economic Affairs, underlined the central is good for Germany and Europe as well. This project importance of this Bosch investment: “We are today will play a decisive part in securing a leading role for taking an important step toward securing the future European industry as a whole in the technologies of the competitiveness of Germany as an industrial location. future,” said Michael Kretschmer, the Minister-President The research community in Germany and Europe is an of the state of Saxony. “This investment in such a excellent one, but we cannot afford to rest on our laurels. major project is a sign of confidence in Saxony, in its In the field of microelectronics, we also need engineering people, in the research and industrial network that has skills and know-how, and especially industrial-scale become established here, and in its innovativeness.” In manufacture and application, in Germany and Europe its search for a new location, Bosch considered several ceremony is an important step on this route.” As a cities around the world. In Hoheisel’s words, “Dresden supplier of technology and services, Bosch is investing is an excellent microelectronics cluster.” He added that roughly one billion euros in its new location in the Saxony the city’s infrastructure is excellent: everything is easily state capital. The first associates are due to start work accessible, and the transportation connections are in the new plant in early 2020. good. The cluster also includes automotive suppliers After Reutlingen, the Dresden plant is the Bosch and service providers, as well as universities offering Group’s second wafer fab in Germany. With it, the technological expertise. As Hoheisel pointed out: “We company aims to expand its manufacturing capacity, want to work closely with semiconductor companies and thus to boost its competitive edge in global markets. and universities to increase semiconductor technology’s Semiconductors are finding their way into more and competitive edge – not only in Germany, but across more applications relating to the internet of things and Europe.” mobility solutions. According to the market research Semiconductors: key technology for the internet company Gartner, semiconductor sales around the of things world rose by some 22 percent in 2017 alone. Otto Graf, Manufacturing semiconductor chips always starts with who will manage the new plant, said: “Construction is a silicon disc, or wafer. The bigger the wafer’s diameter, proceeding right on schedule. “During the construction the more chips that can be made per manufacturing phase, we will move some 7,500 truckloads of earth, cycle. This is one reason why the new Bosch factory lay about 80 kilometers of piping and ductwork, and will focus on the production of 300 mm wafers: mix more than 65,000 cubic meters of concrete – 8,000 Compared with conventional 150 and 200 mm wafer concrete mixers-worth.” Following a rollout phase, pilot fabs, 300 mm wafer technology offers greater economies manufacturing operations are expected to start at the of scale end of 2021. The plot of land – measuring some 100,000 Semiconductors are extremely small integrated circuits square meters, or roughly 14 soccer fields – will also with structures measured in fractions of a micrometer. be home to a nearly 72,000 square-meter multistory Manufacturing them requires a highly automated and building housing offices and production space. Up to complex process consisting of several hundred individual 700 associates will be involved in the highly automated steps over several weeks. It takes place in clean-room conditions, as even the tiniest particles in the ambient air can damage the delicate circuits. Connected manufacturing: 22 metric tons of data a day for higher quality Wafer production is one of the forerunners of connected manufacturing. The Dresden plant is expected to generate production data equivalent to 500 text pages per second – written out on paper, that would be more than 42 million pages a day, weighing 22 metric tons. This is why artificial intelligence will play a special part in chip manufacturing in the factory: the highly automated production facilities analyze their own data in order to optimize their processes. As a result, the quality of the chips rises while production costs go down. Furthermore, planning and process engineers can access this production data at any time to accelerate the development of new wafer products or minimize tolerances early on in the manufacturing process. “We need creative minds for our connected and automated manufacturing operations – particularly experts in wafer technology, like process engineers, mathematicians, or software developers,” Graf said. Many new associates have already been hired for the Dresden plant, he added, and there has been no drop in the number of applications. Leading semiconductor manufacturer with 45 years of experience For more than 45 years, Bosch has been making semiconductor chips in various forms, above all as22 An insight into Industry 4.0 August/September 2018

application-specific integrated circuits (ASICs). At itswafer fab in Reutlingen, Germany, Bosch currentlymanufactures ASICs, power semiconductors, andmicroelectromechanical systems (MEMS). BoschASICs have been used in vehicles since 1970. Theyare customized to individual applications, and essentialfor functions such as engine management or airbagdeployment. In 2016, every car rolling off the productionlines worldwide had on average more than nine Boschchips on board.www.bosch.comBOSCH AND DAIMLER SELECT NVIDIA AI of experience to the development of functional safetyPLATFORM systems. To achieve maximum safety and reliability, the necessary computing operations are done by a• Bosch and Daimler to source Drive Pegasus number of circuits in parallel. In the unlikely event of a platform AI processors and software supplied by malfunction, the results of these parallel calculations the U.S. AI computing company Nvidia can be accessed in a flash. ECU network to be integrated into battery cells’• Systems architectures for fully automated cooling circuit and driverless urban driving must be versatile, The high computing capacity and the huge number of redundant, and fail-operational. operations to be performed mean that the ECU network needs to be cooled. Bosch and Daimler developed an• Bosch and Daimler machine-learning methods efficient concept based on liquid cooling. In this jointly will generate vehicle-driving algorithms. developed system for highly automated and driverless driving in cities, Mercedes-Benz intends to deploy• ECU network for automated urban driving handles battery-powered vehicles. These cars have a cooling hundreds of trillion operations per second. system on board, so engineers can make the most of this legacy technology by integrating the ECU networkStuttgart – Automated vehicles are complex computers into the battery cells’ advanced cooling circuit.on wheels. And they need even more computing power Bosch and Daimler staff working side by sideif they are to negotiate city traffic automatically, with In April 2017, Bosch and Daimler announced they wouldinput sourced from an array of disparate surround be joining forces in an effort to put highly automatedsensors. In their alliance to put highly automated and and driverless vehicles on city streets. This alliance isdriverless vehicles on urban streets, Bosch and Daimler developing a driving system for use in vehicles that willhave specified the computing power needed for their be able to maneuver through city traffic driverlessly. Theprospective system. The two companies have selected technology is to be ramped up for mass production byand signed an agreement with the U.S. AI computing the beginning of the next decade. Bosch and Daimlercompany Nvidia as a supplier for the artificial intelligence are working together in the greater Stuttgart area and(AI) platform they need. AI is an important building block in Silicon Valley. The two companies’ personnel arein fully automated and driverless vehicles’ network of co-located, working practically at adjacent desks. Thisseveral individual ECUs (Electronic control units). Under allows them to quickly and efficiently share informationthis contract, Nvidia will provide its Drive Pegasus across disciplines and to make decisions fast.platform powered by high performance AI automotive www.bosch.com | www.daimler.comprocessors along with system software that will processthe vehicle-driving algorithms generated by Bosch and HP AND SIEMENS EXPAND 3D DESIGN ANDDaimler using machine-learning methods. As a result, ADDITIVE MANUFACTURING INNOVATIONthe ECU network will reach a computing capacity of Recently at Siemens PLM Connection Americashundreds of trillion operations per second. This is akin to 2018, one of the largest events for Siemens’ PLMthe performance delivered by at least six synchronized, software users, HP Inc. and Siemens expandedhighly advanced deskside computer workstations. Bosch their longstanding collaboration to enable evenand Daimler will also be able to tap Nvidia’s expertise more advanced functionality across a broader setto help develop the platform. of Siemens PLM software to change the way usersA versatile, redundant, and fail-operational systems can design and manufacture with HP’s Multi Jetarchitecture is needed to make automated driving in cities Fusion 3D printing technology.a reality The performance bar for the networked ECUs Siemens’ NX and Solid Edge Software deliver supportis no lower, as navigating city traffic is a tremendous for Full-Color 3D Printing Capabilities through HP Multiamount of work Jet FusionSensor data processed within fractions of a second With the latest releases, Siemens, a leader in digitalThis network handles all the information gathered and innovation software, and HP, the global industry leader intransmitted by disparate radar, video, lidar, and ultrasonic 3D printing, will enable users of Siemens’ NX™ softwaresensors. Just one video sensor, such as Bosch’s stereo and Solid Edge® software to design and produce fullvideo camera, generates 100 gigabytes of data in color 3D-printed parts. HP’s Jet Fusion 3D 300/500just one kilometer. The ECU network combines data series is the industry’s first 3D printing solution for thesourced from all the surround sensors in a process production of engineering-grade, functional parts incalled sensor fusion. Within fractions of a second, itassesses this information and plans the trajectory ofthe vehicle. This is as fast as the sensation of touchthat needs between 20 and 500 milliseconds to reachthe human brain. Bosch and Daimler bring many years i40today.com 23

FCeoanttuinreued... full color, black or white – with voxel-level control – in applications first-hand in a design and manufacturing a fraction of the time of other solutions. showroom environment. The Jet Fusion 3D 300/500 series also supports the Siemens and HP share the objective to accelerate the leading color file formats including 3MF, enabling digital transformation of the manufacturing industry, designers to easily produce the color parts they want providing all of the necessary capabilities, from with a reliable workflow. Users taking advantage of NX generative design for product innovation through 3D and Solid Edge for HP’s Multi Jet Fusion technology will printing for industrial-scale manufacturing. Through have access to 3MF files ready for HP’s entire portfolio generative design, companies can automate innovative of printers including the industrial-grade HP Jet Fusion designs directly from functional requirements which can 4200/4210 and 300/500 solutions. result in enhanced functional performance for parts We share HP’s vision that 3D printing is empowering and products. Using HP Multi Jet Fusion technology, companies companies can manufacture these innovative parts more “Our users will now be able to apply the power and economically at larger production volume. Together, HP’s flexibility of Siemens’ NX and Solid Edge product design 3D printing solutions and Siemens’ technology combine software to HP’s groundbreaking 3D printing technology, in a single integrated solution that enables businesses opening a world of new design possibilities with the to reimagine products, reinvent manufacturing and availability of full-color parts,” said Tony Hemmelgarn, rethink business models. president and CEO, Siemens PLM Software. “We share www.siemens.com HP’s vision that 3D printing is empowering companies to reinvent their product lifecycles to prosper and thrive JABIL SUPPLY CHAIN INTELLIGENCE in manufacturing’s all-digital future. Expanding our End-to-End Capabilities Enable Customers to partnership with HP allows us to continue to elevate Achieve Digital Differentiation, Cost Leadership additive manufacturing for end-use parts at industrial along with Responses to Dynamic Market Changes scale.” and Business Models Jabil recently announced enhancements to its suite The combination of the two leading digital manufacturing of industry-leading procurement capabilities to help technologies dramatically expands the potential global organizations minimize risk, optimize production applications for Siemens’ market-leading digital and achieve cost leadership. Additionally, the company innovation software and HP’s disruptive Multi Jet Fusion introduced its new Radius Digital Strategy Practice 3D printing technology. Customers will have the ability to assist customers in navigating complex digital to quickly and economically prototype and produce new transformations while creating business value and designs and end-part applications with advanced voxel brand differentiation. capabilities. In addition, the collaboration creates new “The digital transformation of manufacturing is causing opportunities to accelerate the adoption of 3D printing a ripple effect worldwide as companies struggle with at an industrial scale for customers and partners that demand and supply volatility, including shifts in supply participate in Siemens’ Additive Manufacturing Network. ecosystems and shortening product lifecycles,” said Don “Adding the full-color capabilities of HP’s expanded Hnatyshin, SVP and chief supply chain and procurement Multi Jet Fusion platform to Siemens’ market-leading officer at Jabil. “Our ability to quickly and effectively design and manufacturing solutions creates an immense address these critical business challenges is bolstered new set of possibilities for products and applications,” by digital supply chain and procurement capabilities that said Stephen Nigro, President of 3D Printing, HP Inc. deliver much-needed visibility, real-time intelligence and “It is exciting to deliver the power of our technologies real-world actionable insights.” to customers large and small, fundamentally changing According to a 2018 digital transformation survey by the 3D printing end-to-end process, from design to Dimensional Research of more than 300 manufacturing prototyping and ultimately manufacturing. This is executives, the quickening pace of digital transformation another pivotal step not just for our companies, but for creates issues despite significant investments. While the entire global manufacturing ecosystem, as together most respondents reported increased funding for with Siemens we change the way the world designs digital solutions, nearly half of the survey participants and manufactures.” acknowledge persistent challenges due to inadequate HP’s Multi Jet Fusion 3D printing technology was also digital expertise and mismatches between existing showcased as a foundational 3D printing platform in toolsets and organizational capabilities. Siemens’ Additive Manufacturing Experience Center in Designing a Digital Future Erlangen, Germany, which invites customers to discover To expedite customers’ digital journeys, Radius the latest additive manufacturing technologies and their Innovation and Development, a Jabil product ideation and development business, has launched a new Digital Strategy Practice. Blending creative, customer-centric insights with quantitative business analysis, Radius answers the questions of “who, what, why, when and how” digital strategies can benefit new or existing businesses. A cross-functional team of experts evaluates various alternatives at any stage of a company’s digital transformation. “Our new Digital Strategy Practice guides customers through the constant cycle of creating, monetizing and defending business value,” said Heather Andrus, Senior Director of Strategic Development at Radius Innovation and Development. “We can enable companies to evolve their products and experiences by adding a digital component, build or expand their digital ecosystems24 An insight into Industry 4.0 August/September 2018

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CFeoanttuinreued... and explore opportunities to monetize Internet of “Supply chain leaders have always been under Things (IoT) data, while benefiting from cutting-edge pressure to streamline processes, improve quality, keep solutions, including advanced automation, 3D printing inventory low and reduce delivery times while keeping and machine learning.” costs down…Digital technologies are enabling and Procurement Solutions for the Digital Age promoting changes that have a larger impact, greater Effective procurement strategies are essential to unpredictability and increased frequency… Now, more delivering success in the digital economy. Jabil’s than ever, high-tech supply chains require digital skills Intelligent Digital Supply Chain encompasses value- and methods to deliver customer-driven solutions in added procurement insights to address spend visibility an on-demand fashion. across the supplier ecosystem. With its Procurement www.jabil.com Intelligence Platform, for example, on-demand access to Jabil’s global commodity management expertise can alleviate major sourcing problems in the supply network, which is facing the tightest supply conditions in over a decade. With hundreds of procurement experts around GE ADDITIVE UNVEILS ARCAM EBM SPECTRA H the world, leveraging trusted relationships with more GE Additive recently unveiled the Arcam EBM than 27,000 qualified suppliers, and a $15 billion-dollar SpectraTM H, a new metal additive manufacturing plus spend, Jabil helps customers win in the digital system, designed to handle high heat and crack economy by balancing supply assurance and price prone materials. The Arcam EBM Spectra H using advanced analytics and supply trend models. complements the company’s existing electron Together, Jabil’s procurement solutions and Radius’ beam melting systems. multi-disciplinary Digital Strategy Practice empower Unveiled at the RAPID + TCT 2018 show, the new system customers to benefit from: is available to pre-order. It will be manufactured at • Effective digital transformations with accretive Arcam’s plant near Gothenburg, Sweden with expected delivery from Q4 2018 onwards. business value • Unique system designed to handle high heat and • Development of new business models and revenue crack prone materials, such as TiAl and nickel Alloy streams 718 • Faster time-to-market with product innovation • Cost reductions through productivity enhancements. Up to 50% increase in build speed and 39% increase breakthroughs in build volume • Improved customer experiences, increased • End-to-end industrialization – improved power handling, automation and calibration, decreased profitability and stronger competitive differentiation risk of contamination, reduced operator dependency • Flexible and scalable cost models that align with Unique additive production of high heat and crack prone materials changing business needs As manufacturers make significant steps towards serial • Increased supply chain and manufacturing agility, production, they require larger, faster, industrialized solutions and machines that are capable of handling efficiency and cost leadership high heat and crack prone materials, such as titanium John Picard, Vice President, The Ray aluminide (TiAl). Today, electron beam melting remains “As the world’s first regenerative highway project, we the only commercial additive manufacturing method are building connected roadway reflectors designed able to support TiAl production requirements. to improve the health and safety of transportation Initially, the Arcam EBM Spectra H will support both infrastructure across the US, and Radius is our digital TiAl and Alloy 718 and additional Ni-super alloys will partner. By connecting previously analog reflectors and be supported from 2019. GE Additive‘s materials lights through solar-powered sensors to the cloud, we science team is currently exploring future opportunities are creating a platform to make safer roads. Radius’ for a wider range high heat materials, including; nickel expertise has made it possible by assessing feasibility superalloys, tungsten, CoCr, stainless steel and metal and now architecting the digital hardware and software matrix composites. components required to deliver on the vision.” Reducing cost through increased productivity Virginia Howard, Research Director, Supply Chain The Arcam EBM Spectra H incorporates a range of Research Group, Gartner new features and enhancements to drive down cost by increasing the productivity of the system. We remain focused on accelerating innovation across sectors and helping the world work smarter, faster and more efficiently,” said Jason Oliver President and CEO, GE Additive. “It’s great to be able to show the Spectra H here at RAPID and get feedback from across the industry. We have created what we think is an amazing system that demonstrates how Arcam continues to push the possibilities of EBM technology. Spectra H is the result of really hard work by a cross-functional team from across the GE Additive family, supported www.ge.com/additive/26 An insight into Industry 4.0 August/September 2018

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Industry 4.0:Build vs Buy?By Michael Ford, European Marketing Director,Aegis Software CorporationNumerous in-house software systems, which includes externally developed bespokesystems, have become a part of the critical manufacturing support infrastructure in mostassembly factories. These systems are essential components of engineering, quality, andthe manufacturing flows. As factories now face a step-change challenge to move forwardwith Smart digital manufacturing that Industry 4.0 represents, can existing in-housesolutions be adapted, or are digital factory best practices achieved with the introductionof a new commercially developed digital MES solution?Changing Industry Requirement: each other in most factories, after all, if it isn’t broken,In-house “point solution” software applications were don’t fix it. The production models and practicescreated as a result of specific needs within manufacturing, behind point solutions however, as well as legacyoften tied to specific processes or hardware, and are MES (Manufacturing Execution Systems), ostensiblybased on the software technology of that time. Many originated around high-volume mass production. Angenerations of point solutions continue to work alongside isolated set of engineering data for a product that would run steady-state for long periods with a predefined28 An insight into Industry 4.0 August/September 2018

configuration and the push-delivery of material kits the definition of legacy bespoke interfaces created forand resource assignments satisfied requirements. A specific uses, the definition of the data to be exchangedsteadily increasing demand for the factory to produce through the IIoT interface is based on the scope of thea higher mix of products, together with smaller lot device rather than a specific application. Many differentsizes, has put progressively increasing strain on these applications will be expected to use the IIoT data inlegacy solutions, resulting in the need in many cases parallel. As IIoT data will be exchanged between devicesfor urgent “quick and dirty” modifications. Being able to from many different vendors, it is critical that there iscope with changing requirements in production via ever- conformance to a universally agreed data definitionincreasing customizations by the in-house IT department standard. The three ingredients needed for an effectiveis however a long way from providing flexibility in line IIoT standard are the protocol, data encoding, andwith the latest digital best practices. As the industry language definition. Take for example a cell-phone,moves forward toward the ultimate model of flexibility where handsets from different vendors communicate& automatic adaptability that Industry 4.0 represents, in a standard way over a standard network. Telephonemanufacturing is expected to produce each day only calls are however only effective where both peoplewhat the customers want for immediate delivery, without understand a common language. For IIoT systems, theloss of productivity. The goals today are elegant and issue is exactly the same. To date, legacy interfaceautomatic single-piece flow and ultimate configure- standards for data communication in assemblyto-order. Legacy software solutions cannot easily manufacturing, have neglected to fully addresscope with this scenario, this final requirement, andcreating the need for a An isolated set of engineering have not been successful.completely new technologyand architecture. The data for a product that would run By contrast, the new IPCsituation is rather like steady-state for long periods with CFX (Connected Factoryreplacing one’s CD and a predefined configuration and the Exchange) IIoT standardDVD collection with digital consists of a clearly definedmedia streaming services; push-delivery of material kits and protocol (AMQP v1.0),there are fundamental resource assignments satisfied data encoding methoddifferences in supporting (JSON), as well as therequirements. comprehensive definition requirements. of standard content. CFXThe Digital Streaming has been created throughFactory: a collaborative consensus across the industry, as machine vendors, manufacturers and softwareAn Industry 4.0 factory has many things in common solution providers anticipate being a part of the nextwith a media streaming service. Customers are generation of digital factories. The scope of CFX coversexpecting to get what they want, in any quantity they the entire range of assembly factory operations, includingwant, whenever they want, whilst reserving the right to all forms of production assembly processes, test,frequently change their minds and ask for something inspection, supply chain, quality control, environmentdifferent. The Smart assembly factory has to be able and planning. The specific focus of CFX is on theto respond immediately in these situations, without enablement of Industry 4.0 solutions, including provisionthe overhead of a warehouse full of finished goods for Augmented Reality (AR) and Artificial Intelligence (AI)making it appear that the factory can provide flexible technologies which are expected to be common withindelivery. Immediate response in the factory operation the industry over the coming years. Any Smart factoryrequires immediate decision-making across multiple solution being considered needs to have the capacitydisciplines. Whereas traditional factory practice is to and infrastructure to embrace the use of standard IIoTsimulate, plan and optimize scheduled operations technology such as CFX.weeks or even months in advance, plans now needto be created “on the fly”, repeatedly every day, and The challenge for both in-house and the MES solutionsyet, also need to be optimized such that the impact going forward is the ability to work in the real-timeof changeover losses are minimized. The human IIoT messaging environment, rather than theprocess of decision-making, based on discussion, traditional approach of gathering data from specificmeetings, phone calls, emails, and a quick Excel interfaces, some form of interpretation of content,report, is simply too slow to the population of a series ofsupport the Industry 4.0 Customers are expecting to get databases, which then needfactory, never mind provide what they want, in any quantity to be combined somehowthe required optimization. as reporting softwareInstead, relevant data attempts to piece dataabout the progress and they want, whenever they want, together to create actionablestatus of every process and whilst reserving the right to information. For most legacyoperation must be available systems, the use of IIoTcontinuously, gathered and frequently change their minds and data represents a criticalprocessed by intelligent ask for something different. paradigm shift in the waysoftware modules working that they are architected,together across the factory. meaning that significantThe result is the creation of immediate decision- refactoring is required.making support for managers and engineers, and,in an increasing number of cases, automated There is good reason however for the transitiondecision-making. There are two critical technological from legacy manufacturing solution technology, to IIoTelements to the solution, needed irrespective of how based technologies. Rather than a narrowly focusedthe solution will be created, the use of IIoT technology needs-based design, IIoT provides the framework for anyand a digital infrastructure platform. conceivable Industry 4.0 solution idea that comes along. IIoT in itself is the enabler of a rich and diverse range ofThe Reality of IIoT Technology: solutions, as opposed to being a solution in itself. The degree of capability and value derived from IIoT dependsTransfer of data using IIoT technology allows information on how the technology is applied, especially wherefrom any data provider to be available for use at any multiple solutions from a user-perspective, will worktime, by any data consumer. Any provider may also be together seamlessly on a single digital infrastructure.a consumer, as IIoT is bi-directional in nature. Unlike i40today.com 29

Digital Infrastructure Platform: regimes, quality control, conformance, compliance and traceability, together with the introduction of IIoT One of the strengths of MES is the underlying technology, will in all cases mean a complete paradigm infrastructure that models the manufacturing operation change. Faced with outdated software systems, the most and provides the underlying structure on which MES common decision will be to recycle the accumulatedFeature functions work. This becomes very much more critical manufacturing knowledge, but none of the code. A cleanContinued... in an Industry 4.0 environment, where changes sweep and unencumbered start will be an attractive need to be executed urgently whilst bearing in option, utilizing the latest software technologies mind any constraints, consequences and loss of and standards such as CFX. The in-house team production optimization. will get the opportunity of Product assignments to line The challenge for both in-house seeing and understanding configurations should be the exact new requirements reviewed, including process and the MES solutions going and needs of manufacturing. engineering data creation, forward is the ability to work as well as the availability in the real-time IIoT messaging Getting up to speed of materials, tools and however to build a risk-free other key resources. solution internally, with the Decisions in the Industry required infrastructure to 4.0 environment need to environment, rather than the provide advanced, real- be taken quickly. The whole traditional approach of gathering time decision-making manufacturing operation functionality, will take a great needs to seamlessly data from specific interfaces... deal of time and investment. transition from a current plan to a new plan. The The delay until return on that investment is achieved may run into several common digital infrastructure that inter-connects years. Maintaining professional grade internal processes and functions is absolutely mandatory. resources for such projects is a major expense The scope of decision consideration may also for a manufacturing company, which adversely affects extend to interact with machine vendors’ Industry business performance metrics. 4.0 environments, which also adapt and optimize accordingly. Within the MES industry, unfortunately, the majority of solutions will face similar technical issues as the The connection and integration of all of the elements in-house system developers. Whether the legacy MES within manufacturing is a fundamental difference from infrastructure of each solution can be adapted to work the way in which the majority of legacy point solutions in the digital IIoT environment will vary from case to have been developed. Even legacy MES providers case, but many compromises can be expected as a are significantly challenged, as many are made up of result. The effectiveness of systems in such cases will different historical components linked together, with be difficult for customers to immediately understand bolt-on applications that are not fully integrated. This until the solutions have been deployed and in use for scenario may have been a reasonable compromise some time. Many functions appear to look similar across for legacy production practices, but fails to provide solutions but in fact are often completely different in support for the latest and future generations of digital the way that they work and the values they create. In manufacturing with Industry 4.0. terms of business risk, having a solution on-hand, having been developed and tested professionally, in use at Build vs Buy: other customers, and being immediately available for installation however, represents a lower business risk, a For an in-house software development team, the shorter time to value and a quicker return on investment, realization of the infrastructure required relating to work- with little effect on the fixed costs of an operation as orders, shift patterns, machine and line configurations, compared with a dedicated software team. engineering data, work assignment, tools, maintenance www.aiscorp.com30 An insight into Industry 4.0 August/September 2018

Manufacturing Agility, Evolved.Adaptive, modular FactoryLogix, a uniquely adaptive manufacturing executionMES, built for an and operations solution, drives enterprise-wide compliance,Industry 4.0 world. quality, and efficiency. Designed for today’s manufacturing reality, it connects business-critical systems, processes, and people— unleashing the transformative benefits of Industry 4.0. Delivering Industry 4.0 Benefits Reduce Costs | Increase Revenues | Optimize QualityAchieve Compliance Requirements | Improve Customer SatisfactionHolistic. Modular. Adaptive. Proven.• Digital Process Engineering • Quality Management System (QMS)• Manufacturing Execution System (MES) • Tactical Production Planning & Scheduling• Warehouse Management System (WMS) • Industrial Internet of Things (IIoT) Engine• Manufacturing Intelligence • Workflow & Rules Engine & Big Data Analytics Learn more at www.aiscorp.com i40today.com 31

Evolution of Intelligentbuildings and the roleof the IT ArchitectBy John Coulter, Managing Director,Blended Technology LtdBlended Technology specialise in the design and commissioning of Intelligent BuildingNetworks and associated technologies. We provide consultancy to the building industryallowing information technology to be at the heart of the building from its very conception.This allows systems such as CCTV, BMS and access control to seamlessly integrate intothe fabric of a building. We create a secure independent platform for each system whilemaintaining the ability to interconnect systems where required. This allows unprecedentedcommunication enabling the potential of a “Smart Building” to be realised.Intelligent buildings have evolved dramatically with only fuelled a greater need for building IP networks. Theincreased demands on connectivity and the integration pace of development in IP networking within the buildingof autonomous systems. In the beginning control of industry has continued to grow exponentially causingbuilding services was accomplished by a multitude of a knowledge gap in the providers of these systems. ITcommunication methods and proprietary languages. managers and technical specialists associated with theAs these systems developed it became apparent that building user have become reluctant to permit suchsome form of inter system communication would be equipment to connect to the corporate network. As anecessary. IP (Internet Protocol) became the standard result service contractors are forced to provide multiplehowever language and other elements remained communications networks for their systems with varyingproprietary. Over time standards developed and the true levels of success and little or no best practice. This hasbenefits of the connected building environment began highlighted a need for the development of a specificallyto emerge. Systems continued to evolve with more designed network to support these systems.components adopting IP and Ethernet as the standard In order to facilitate this need around the buildingcommunication method. Other systems such as CCTV management portfolio, the network must deliverand access control moved to IP based solutions. This32 An insight into Industry 4.0 August/September 2018

functionality in a number of key areas. Firstly to the manufacturing process. As this technologyhave a high level of availability and resilience. This develops over the coming years augmented realityis achieved by utilising features of industry standard and voice interactive technologies will bring newnetworking, this allows and exciting developmentsresilient connectivity aided Service contractors are forced to to the area of smart factoriesby uninterruptable power provide multiple communications and manufacturing. Utilisingsupplies for equipment. networks for their systems with this technology can bringSecondly systems such significant cost savings andas CCTV may need priority benefit to a manufacturingover network resources. varying levels of success and business. It does howeverBy implementing quality of little or no best practice. This also come with a numberservice across the building has highlighted a need for the of challenges. The mainnetwork we can prioritise technical challenge revolvetraffic and eliminate development of a specifically around the security andexcessive network latency, designed network to support resilience of the networka problem common to infrastructure in commonpoorly installed network with existing smart buildingsolutions. In addition these systems. networks. By providing awe need to provide a tailored network solutionconnected frontend interface to the multiple services these challenges can be addressed to provide asuch as CCTV, lighting and HVAC control. This secure and stable platform to support any futureprovides secure access to control systems both application.within the building and remotely across the internetgreatly enhancing the flexibility to support these systems. This increased reliance in data acquisition means thatElements can communicate in a controlled manor information technology should now be at the heart of newenabling the full potential of a connected intelligent building design. Traditionally IT decisions and designsbuilding infrastructure. These dedicated solutions have tend to be first conceived quite late in the building designuntil now been resigned to larger more prestigious process, at stage 4 of the RIBA’s construction workbuildings with appropriate budget to match. However plan. This is usually associated with the developmentas more building systems move to IP connectivity, of the mechanical and electrical engineering design andhaving a building core IP network has now become encompasses data cabling and telecommunicationsa necessity rather than an optional requirement. This room design. By engaging an IT architect at the conceptpresents a major problem for architects and contractors and early design phases a more holistic approach towho need to provide this specialised IT infrastructure the buildings technology can be adopted. This wouldoften beyond their skills portfolio. Blended Technology involve areas such as audio visual systems, networks,can provide turnkey solution to suit any size and type and wireless provision to name but a few. The IT architectof building infrastructure. This dedicated network should act as both project manager and technical designinfrastructure provides high bandwidth and availability authority for the duration of the building project. Thiswithin a secure cabled environment. Utilising the latest should include managing the relationship between keytechnologies we provide a future proof solution capable IT sub-contractors, the building contractor and mostof being upgraded throughout many years of service. importantly the client. By following sound best practice and recognised project processes, the IT architectThe concepts of data analysis in building and facilities can take much of the ambiguity out of technologymanagement has dramatically altered over the past 20 provisioning and requirements. This results in lessyears. These new developments are often referred to as changes in scope and subsequent increases in costs.“Big Data”. Big Data is an extremely large data set thatmay be analysed computationally to reveal patterns, So as we move into this new and exciting time, the needtrends, and associations, especially relating to human for imbedded information technologies shall continue tobehaviour and interactions. In addition the development become a greater part of the building design process.of connected sensor networks and pervasive computing, Architects and facility providers shall need to embraceoften described as the Internet of Things (IoT), has these technologies and build them into the very heartadded new dimensions to the applications of Big Data of their buildings. With this in mind the IT architect rolewithin building management solutions. The IoT can be should only grow within the building industry.defined as network connectivity embedded in physicalobjects – from motorway signs to refrigerators. These www.blendedtechnology.co.ukare linked through wired and wireless networks, oftenusing the same Internet Protocol (IP) that connectsthe internet. The emergence of the IoT through datagenerating networks in everyday objects coupledwith Big Data analysis gives way to the collection ofan immense amount data to create “smart” buildingsand interconnected cities. This new urban environment,that’s designed for performance through Informationand Communication Technologies (ICTs) heralds afundamental change in the design and managementof both commercial and domestic property.This expansion of big data leads nicely into thedevelopment of Industry 4.0 and beyond within thecontext of “Smart Factories”. Industry 4.0 is seen asthe 4th industrial revolution and is the introductionof real time monitoring and decision making basedon highly connected manufacturing environments.Key principles in the development of these smartmanufacturing solutions are interoperability and thetransparency of information between systems. Thisallows for the revolutionary transformation of real timemonitoring and automated decision making within i40today.com 33

Tips for AuditorsLooking for Industry 4.0Ready EMS PartnersBy Vitor Barros, General Manager, KIC EuropeOver the last few years I’ve talked to many people about Industry 4.0: the trend, thechallenges, the hype and, more recently, the reality. We finally appear to be in a phasewhere, while there’s no silver bullet, there are numerous solutions available that claim tobe Industry 4.0 ready or compatible. Perhaps the recent work done on standards or justthe way technology has advanced is the reason for this but, whatever it is, it’s a welcomechange as we move from theory towards reality.We now are seeing the topic become increasingly and the eventual consumer. An Industry 4.0 strategyimportant to EMS companies large and small, but must start with objective. The ‘why’ must lead to themore significantly to the OEMs or brands that are ‘how’ when it comes to smart factory applications.considering it when selecting their EMS partners. Some Hence, the objectives should define the plan.companies, particularly in high-reliability markets like An Industry 4.0 Ready Environmentautomotive or medical, now expect some degree of If the goal of Industry 4.0 is factory-wide intelligence,Industry 4.0 readiness from their entire supply chain then the foundation should be connectivity first andand are beginning to audit for connected, digital or data management second. We found OEMs keensmart factory elements. This comes up repeatedly as to understand if the manufacturing environmentOEMs ask for thermal process data and traceability, has only elements that are Industry 4.0 compatible.often insisting that their vendors use specific solutions By “manufacturing environment,” I don’t mean justlike the ones we provide at KIC. the SMT line, but rather the entire factory includingWithout clarity around Industry 4.0 parameters, auditing discrete manufacturing processes. The manufacturingcan be a challenge. We’ve spoken to some companies environment also may include multiple factories into ask what they’re looking for and auditing against. different locations.While the answers varied considerably, most are looking So, what is an Industry 4.0-ready environment? It’s anfor certain criteria to be met. Based on the feedback environment that has infrastructure in place to connectwe’ve had from OEMs in various industry sectors, here every machine, where data is extracted, shared andare our tips for those auditing smart factories, and for used. Some auditors mentioned looking for machinerythose being audited. that can ‘read, record, relay and react.’ These fourIt Starts with Strategy Rs are the fundamentals of Industry 4.0 readiness,While it is difficult or probably impossible to audit a ensuring that each part of the ecosystem can read thestrategy, we found that most OEMs are keen to know data that comes into it, record everything that happensthat their vendors are on the path to Industry 4.0 and on it, including process parameter details, relay thathave a plan. This means showing a strategy with a real data to a system or another machine, and then reacttimeline as well as a clear idea of what they expect to to incoming data.achieve. Complete TraceabilityMuch has been spoken about Industry 4.0 and how it For considerable time now, the top priority for auditorscan be achieved, however little has been said about the has been traceability, and this remains the case. Thereal benefits it offers the manufacturer, their customers34 An insight into Industry 4.0 August/September 2018

What is your PCB profile now? ...and now? Automate Profiling – Traceability – Dashboard – Data Sharing kicthermal.com kic.cn• Consistent quality • Improved productivity• Reduced production cost • Connected reflow process i40today.com 35

Feature change comes in the level of that traceability, its properties of the oven, but for a solder paste inspectionContinued... granularity, and how extensive the need for that data system or an X-ray machine that may be getting the is. For an auditor, the best part of Industry 4.0 is the right image. real-time nature of the data provided. If you’re auditing A Smart Connected Team a process, the last thing you want hear is that the Industry 4.0 is about more than connecting machines, report you need will take several hours or even days to it is about connecting teams of committed people generate. The best solution is to deliver real-time data working with common goals. The companies that have in simple dashboards or reports that can be reviewed, enjoyed the most success in deploying Industry 4.0 and if data needs further investigation, then drill-down are those that have built the right internal teams and data should be readily available. external collaborations. Traceability should cover as much detail or granularity There are few companies that claim to offer a one-stop as possible, and as much of the supply chain as solution for Industry 4.0, and I suspect that those that possible. In the case of the thermal process, that do are unable to supply everything. For that reason, data often is required to be granular enough to trace collaboration is essential, starting internally. At its heart, a profile to a single board, rather than a batch. It also Industry 4.0 is cooperation between IT and Operations, should be contextual, with the addition of a time stamp, and if both departments are not involved at the start silos the machine used, operator information, recipe can form and connectivity will break down. Establishing information, adherence to established process window diverse multidiscipline internal teams is the start, before and much more. bringing in external experts to create the right connected digital ecosystem. Good Data Drives Good Decisions Software Ecosystem In any audit process, the veracity of data is essential. To turn data to actionable intelligence requires some The adage garbage-in-garbage-out has never been truer form of management software and one of the first things than in a digital factory environment. If decisions are we find auditors looking for is a connected software made using poor quality data, the outcome will likely ecosystem where all the subsystems work in harmony. be wholly inaccurate. Good process control relies on Software is needed at a granular machine level, across good process data, and with so much data flowing into the factory floor, in production planning, across larger an ecosystem, bad data risks contaminating good data. multisite ecosystems and at an enterprise level. At every process, good data comes from vendors Getting the MES, ERP, PLM and whatever other software who can combine their ability to connect to the digital is present working in concert will help deliver a seamless ecosystem with domain expertise to get the right connected solution. Having to move data manually from data quickly and accurately. In our case, the thermal one system to another presents opportunity for errors to occur and that will concern any customer. Pilot Project Can Be Proof of Concept OEMs visiting EMS sites have told us that they have been impressed by companies that have carried out pilot projects or proof-of-concept activities to learn about the deployment of Industry 4.0 in a manageable manner. Where they have seen specific results, albeit in a small part of the process, they have recognized that these companies are ready to deploy Industry 4.0 on a larger scale. Defining the return on investment (ROI) of these pilot projects, creating a team to carry them out with key performance indicators (KPIs), and being able to report on them shows both intent and ability. Industry 4.0 Must Deliver At the end of the day, every investment must deliver, and this one is no different. If it delivers internally, management will want to continue and do more. If it delivers externally, customers will be satisfied and will want to do more business with you. Never undertake such a project without knowing precisely why you’re are doing it. It may be because it delivers efficiency and allows your business to increase margins, something hard to do in the EMS world. It may be that an Industry 4.0 strategy will open opportunities with new accounts in new sectors or industries. It may be to lower the risk of product failures in the field due to poor production quality. Or it may be as simple as keeping your existing accounts happy and maintaining or growing the business you do with them. Whatever the reason for implementing Industry 4.0, it seems clear that it will form a larger part of customer audits in the future. Being ready for the questions, rather than being blindsided, will help make the next audit a simpler, more pleasant process. www.kicthermal.com36 An insight into Industry 4.0 August/September 2018

DFFA-A10222-00-7600 Work open, virtual, and connected Digital workflow with Totally Integrated Automation Portal The Totally Integrated Automation Portal (TIA Portal) increases flexibility for machine builders and plant operators through the use of digital workflows. With flexible cloud solutions, virtual commissioning using a digital twin, and open interfaces for greater connectivity, your workflows are open, virtual, and connected. That makes the TIA Portal the perfect gateway to automation in the Digital Enterprise. siemens.com/tia-portal i40today.com 37

Smart Manufacturingin the ElectronicsIndustry—Realizing theDigital Factory VisionBy Jay Gorajia, Director of Consulting, PCBDesign and Manufacturing Services, Mentor-ASiemens BusinessThe pace of change and complexity of manufactured products continues to increase.The way products are designed and manufactured is causing the global manufacturingsector to have to evolve at a high rate of change. With accelerating global competition,extreme quality measures required by high-tech companies, a need to design anywhereand build anywhere, more demanding consumers, and shortened product developmentlifecycles, a sound digital factory strategy is more important than ever.Technology and society are evolving at a pace that is Uber and Lyft inspired many niche copycats such assimply too difficult for many organizations to keep up HopSkipDrive, Shuddle (both rides for kids), and Wheelizwith. Retiring Cisco CEO John Chambers at the 2017 (wheelchair accessible peer-to-peer car rentals).Cisco Live event delivered a dire prediction: “Forty LEGO and the On-Demand Business Modelpercent of businesses in this room, unfortunately, will The people at LEGO went through a process to reinventnot exist in a meaningful way in 10 years,” adding that the company, which began in 2004 and took 10 years.70% of companies would attempt to go digital but only They launched LEGO Mindstorms, video games, and30% would succeed. If this sounds overly dramatic,consider what ride sharing has done to the taxi businessand to rental-car companies.However, for those who successfully adapt new businessmodels, the future is promising.General Motors and Lyft: New Business Model forJoint DevelopmentAdapting to these changes requires new and innovativebusiness models. One example is the joint developmentof a network of on-demand autonomous vehiclesbetween General Motors and Lyft. This businessmodel leverages GM’s deep knowledge of autonomoustechnology and Lyft’s ability to provide a broad choiceof ride-sharing services. It means that GM can be apreferred provider of short-term use vehicles to Lyftdrivers through rental hubs in various cities in the UnitedStates. Lyft drivers and customers can have access toGM’s portfolio of cars and OnStar services. This createsa richer ride-sharing experience for both driver andpassenger. GM and Lyft also can provide each other’scustomers with personalized mobility services andexperiences through their respective channels.“We see the future of personal mobility as connected,seamless, and autonomous,” said GM President DanAmmann. “With GM and Lyft working together, webelieve we can successfully implement this visionmore rapidly.”Many of the major OEMs also are investing in the ride-sharing business model, including Daimler Investments,RideScout, Intelligent Apps, Moovel, and Car2Go.38 An insight into Industry 4.0 August/September 2018

applications connected to their block systems that are Some smart manufacturing tenants from Industry 4.0 are:more appealing to digitally savvy customers. LEGO • The ability of all players (machines, humans, smartbecame a market-leader integrating physical anddigital play. They pioneered new ways of thinking about factories, partners, etc.) to be connected.digital leadership enterprise-wide. They bolstered the • The ability to collect and analyze data and makeenterprise IT platform. They crowd-sourced innovationand development of LEGO community platforms. decisions in real time (by humans or AI).As companies make these changes, design and • Flexible adaptation of smart factories to changing market requirements.engineering are becoming more interdisciplinary andcollaborative. The way we realize products, or theproduction of products, is also changing. Amazing • The ability of systems to make decisions on their own (product awaretechnologies are emerging in Lyft drivers and customers can manufacturing).automation with AI, additive have access to GM’s portfolio • The ability of machinestechnologies, and robotics. of cars and OnStar services. and humans to interface in aAnd finally, the way we evolve standardized way.products – leveraging major This creates a richer • The ability to build adevelopments in cloud, ride-sharing experience for virtual representation of the realknowledge-based automation both driver and passenger. world (digital twin).and data analytics – ischanging. We use generativedesign to develop productsto be produced by additivemanufacturing that uses advanced robotics – and Infrastructure and Communications for Realizingthen learn from that process with data to make the Digital Factoryproducts even better. The manufacturing industry has a long history of dataWith additive manufacturing, we are printing steel and collection. It includes logging the number of productsare able to create the most amazing constructions. produced at end of every hour or shift, manual loggingWith solutions such as generative design and of down time of machines, and manual logging oftopology optimization, we have adopted nature’s way issues. All this manual collection consumes operatorof “constructing” trees and plants and other living time risk of lack of accuracy, so machine vendors andthings. New cloud technologies allow us to analyze factories started deploying sensors, counters and somedata and gain insights from feedback throughout the progress was made. Then came the age of machineentire process. interfaces such as RS232/RS485 (serial port), parallel ports, and Ethernet (which was originally developed for debugging purposes, but added functionality). This led toIndustry 4.0 Moves Down the Manufacturing Chain a new electrical risk with PCs connections to SMT/PTHThe Industry 4.0 initiative and push for “smart” factories machines, causing electrical discharges, surges, etc.has helped to “democratize” advanced technologyand capabilities, making them more available to Tier Digital communication was the next challenge to2 and Tier 3 manufacturers and scaling manufacturing address. Several standards were attempted 10 to 20capacity and capabilities. years ago such as IBM’s MAP and TOP, CAM (now used in automotive), and GEM-SECS, which became standard in semiconductor industry. These protocolsThe resulting benefits include flexible order processing, standardize infrastructure and control, but not actualefficient resource management, connected and reliable data content (which needs peer-to-peer agreement).production, 100% traceability and quality assurance, The next generation, CAM-X, was network heavy, andself-optimizing manufacturing and production, consistent complex machines were not supported completely.engineering, and digital continuity throughout the The standard was compromised because of the needlifecycle of a product. This digital thread needs to for proprietary customization.include an ecosystem of partners working together toachieve true benefits to cost and quality, while managingschedule risk. Using a standardized communication protocol is crucial to making a smart factory but has particular challenges i40today.com 39

Feature such as machines with different formats, connections, Using a standardizedContinued... and protocols and legacy machines. Different amounts communication protocol is of data are represented in different context, with varying crucial to making a smart factory accuracy and complexity. Machine downtime may be but has particular challenges caused by material load error or parts out, which isn’t such as machines with different necessarily reflected in output. formats, connections, and Smart Factory Infrastructure protocols and legacy machines. A truly smart factory system requires a communication protocol that uses normalized intelligent data. We need to be able to know the status of the operation at any and performance. It collects data from the various given moment, for any given location – OEE, DPMO, stations on the shop-floor as well as peripherals such etc. – and validate that the process runs in line with the as light towers, conveyers, and temperature sensors. plan. We also need to be able to perform root-cause The data is converted into a standard format – the Open analysis – if the actual differs from plan, we need to Manufacturing Language (OML) – making it open to any understand why. We also need to be able to predict how application to subscribe to it. the process will act and proactively make adjustments. The Valor IOT Manufacturing network boxes include Our solution needs to get the data, normalize it, and some built-in KPI dashboards at the machine level, make it easily available. With the Valor IOT Manufacturing line level, and even factory level, for instant visibility platform, we can create a digital twin of production; of the operation. instant out-of-the-box KPI dashboards up to the The boxes don’t only collect data – they can also stop factory level. the machines if the application that consumes the data Industrial Internet of Things decides that there is an error or process failure. The The Valor IOT Manufacturing network platform system boxes include built-in power backup to allow for safe is the gateway that connects the real world to the virtual shutdown and prevention of data loss in the event of world, assisting to create a digital twin of production power outage. They retain three days’ worth of data, so in the event of communication failure, nothing is lost. With this kind of connected system, normalized manufacturing data is available for use by any application – whether it’s the ERP, analytics, PLM, MES, cloud applications, or home-grown applications. The applications simply need to subscribe to the relevant data pipe, and they can get the data – and only the relevant data, so bandwidth usage is optimized. The number of potential uses for this data is limited only by imagination. In Summary Industry 4.0 aims to provide a framework for addressing the challenges now inherent in modern manufacturing. These principles are designed to help a company go from manufacturing in isolated, optimized cells to a fully integrated manufacturing process that carries data and product flows from design conception to delivering products to customers. With its acquisitions, including Mentor Graphics, Siemens is now able to provide the most comprehensive flow for creating today’s technology, from pre-production (design, development, and validation) thorough production planning and execution. This flow will enable small to large manufacturers to move into the digital age together and build smart, connected factories. www.mentor.com40 An insight into Industry 4.0 August/September 2018

Shift ManufacturingKnowledge Into DesignValor NPI shifts manufacturing process knowledge to the leftand into your PCB design process, allowing you to optimizeyour designs for manufacturing the first time.For more information call 1-800-547-3000 or visitmentor.com/valor_npii40today.com 41

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CONNECT in cooperation withFORUM and 6-7th November DoubleTree by Hilton Hotel Newark, Fremont IS IT TIME FOR YOU TO BECOME A DIGITAL CHAMPION? DISCOVER LEARN JOINfuture insights from senior first-hand the experiences, our exclusive network ofmanufacturing executives, challenges and solutions our executives and high profileengineering expertise and industry leaders are taking to exhibitors as we connect you to achieve smart manufacturing the future of manufacturing technology leadersFor more information please contact: [email protected] 43

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