Industry Smart Content. INTEGRATING INSPECTION WITH DR. THOMAS WENZEL YXLON INTERNATIONAL GmbH

Connect your company with the Industry 4.0 market that is projected to reach $152 billion by 2020. For more information, visit www.i40today.com. Welcome to Issue 5 of i4.0 Today i4.0 Today is a new platform dedicated to the concept, technology & future of Industry 4.0. We are not just another publication we are an interface for sharing all Industry 4.0 news, research and development within electronics manufacturing. Our mission is to Lead the industry 4.0 movement, and give an insight into the concept, technology and future of Industry 4.0 Leading the Industry 4.0 Movement In today’s fast paced and extremely competitive market, every second saved in the workplace saves not only time, but revenue. Using Industry 4.0 technologies to increase productivity and reduce risk is the number one priority emerging with every industry and sector. What to expect from us... • Opportunity to hear industry • Established quarterly publication leading speakers • Industry 4.0 technology events • Dedicated Industry 4.0 website around the world www.i40today.com • Sponsorship opportunities • Global digital campaign Magazine Contacts Editorial & Advertising Enquiries EDITOR DIGITAL MARKETING To enquire about available advertising Wendy Tindle Cameron Shaw opportunities, please contact: [email protected] [email protected] [email protected] GLOBAL SALES WEB & MARKETING Andrew Carpenter Gordon Brown www.i40today.com [email protected] [email protected] NEXT ISSUE 6 CONTENT DEADLINE EVENTS & SALES DESIGN & MARKETING Q3 2nd August 2019 Stacey Bonnar Lorna Hull [email protected] [email protected] 2 An insight into Industry 4.0 May/June 2019

Inside this issue... 4 YXLON, from the 19th Century to i4.0 Yxlon 8 The Digital Twin in Electronics Industry Siemens 14 Interview with Ranjan Chatterjee of Cimetrix – Connectivity Cimetrix 16 Reduce Costs or Delight Customers? You Don’t Have to Choose. Aegis Software 20 Extending the ‘Golden Hour’ in your Assembly Line: To Repair or Not? Koh Young Technology 24 Easy on the Open: New Amaray Packaging Line Has Stacks Of Potential Sumitomo Shi Demag 30 How New Sensor Technology Opens Up For Smarter Presence Detection Jon De Tech 32 What is Optimised Buildings providing that others in the market aren’t with their ‘Bureau’ services? Optimised Buildings 34 How Industrial IoT is Revolutionizing Manufacturing Tempo Automation 36 Would Brits embrace working with a robot? OnBuy.com PUBLISHED BY ALL RIGHT RESERVED GET IN TOUCH The content of i4.0 Today is protected by copyright law, full details of which i40 Today Ltd, 1 Dow Road, are available from the publisher. While Prestwick International Aerospace Park, great care has been taken in the receipt Prestwick, Ayrshire, UK, KA9 2TU and handling of material, production Tel: +44(0)1292 834 009 and accuracy of the content in this Email: [email protected] magazine, the publisher will not accept any responsibility for any errors, loss or omissions which may occur. i40today.com 3

YXLON, from the 19th century to i4.0 An interview with Dr Thomas Wenzel, President of Yxlon International GmbH YXLON International GmbH designs and produces x-ray and CT inspection systems for numerous high technology applications. Whether in aviation, aerospace, automotive, or electronics industries, their customers are among the largest manufacturers in the world. The Yxlon product portfolio comprises of x-ray and CT systems for the inspection of castings, tyres, scientific and historical specimens, including mummies and fossils up to 3D-printed and fibre-reinforced components of F1 racing cars or aircraft. Automated Defect Recognition (ADR) for quality assurance in production processes plus accurate dimensional measurements of inner material structures during research and development belong to their core competences, providing both standardised and customised solutions. 3D CT Volume of a complete chip. Electronics is a major and growing market sector Q. Thomas, welcome, we understand that for Yxlon where their market-leading Cougar and you’ve been President of Yxlon, the X-Ray Cheetah EVO inspection systems have become Systems division (IXS) of the Comet Group, the global benchmark. They are trusted by most of since last December. Are you enjoying it so far the biggest names in the industry to help ensure and how do you plan to further strengthen the the quality and reliability of their end products. company moving forwards? The company is headquartered in Hamburg, A. It is indeed a pleasure and an honour to be in Germany having sales and service locations in this position and to be able to shape Yxlon’s future Japan, the United States and China, as well as a in the x-ray business. Having my background in strong distribution and service network in more computer science, I definitely want to increase our than 50 countries. YXLON is a local brand for footprint in the digital world. Connected machines customers all over the world and has been a and sensors are more and more the essentials in member of the Comet Group since 2007. a smart factory environment. Contributing to it will only be possible if we understand our machines Our i4.0 Today Team recently had the pleasure of and systems as the sensor with the highest catching up with recently appointed President of information density available on the production Yxlon, (IXS), Dr Thomas Wenzel. floor. We will go beyond the best image, which is and always will be a key element, and extract the necessary information from it, which is needed to improve our customer’s production process. I’m very much looking forward to add the capability to “inspect” a process to our current strength of inspecting specimens. This will create an added value for our customers since it enables yield improvement. Q. Yxlon has a very long history with its roots dating back to the discovery of x-ray in 1895 and the development of the first x-ray tube in 1896. That means that you have most profound knowledge about x-ray technology, and also decade-long experience in CT technology. In your opinion, what are the main challenges that today’s electronics customers face, and how does Yxlon help to solve them? 4 An insight into Industry 4.0 May/June 2019

YXLON headquarters Hamburg A. Within today’s electronics manufacturing, interpretation of anomalies seen in the data is key there are really two main areas which present and will be in the main focus for the upcoming years. challenges for x-ray technology. First is the continuing miniaturisation which gives us smaller Q. The i4.0 e-smart factory movement came and smaller features to image, increased packing out of Germany. How is Yxlon embracing this density and less dense structures which are much new and exciting concept? harder to image. Therefore, we need improved tube and detector technology and also more A. We understand the need for much better sophisticated software to process these more machine-to-machine communication and are complex images. working with several strategic partners to improve the quality and yield of production Having my background lines both for SMT and Semicon. Currently most in computer science, of our x-ray systems are not an integral part of the production line and they are designed to I definitely want to increase perform high-quality inspection. By putting our our footprint in the systems closer to the line (at-line concept) they can perform a very valuable role in process digital world. Connected improvement through interlinking them directly to machines and sensors the in-line inspection systems, either AXI or 3D are more and more the AOI. This allows the Yxlon systems to perform a essentials in a smart verification role, making decisions on defects factory environment. which could not be fully resolved by the in-line equipment. Interfacing with other machines, Then we have the opposite set of challenges interchanging information like defect locations in which come from power electronics, including order to directly access the region of interest and IGBTs, automotive and batteries. These also returning detailed results is our answer to i4.0 in demand high resolution but have large heat the electronics industry. planes and other dense materials which make it hard to generate good x-ray images. Add to this Q. Please give me some instances where this the need for better and more sophisticated void technology has advantages? calculation and automated inspection routines and you can see that we have to keep developing A. In-line x-ray systems are under growing to stay ahead of the competition. pressure as line speed, packing density and component complexity increase. This can lead For both areas, automation plays a major role. to a higher ‘false call’ rate. By using our systems Since the amount of structures per area is rising to recheck these issues we can give a definitive as well as the complexity of these structures, a result allowing for improved SPC and also much manual interpretation of the image and volume higher yields and reduced costs. data is not feasible. Automatic detection and The better inline 3D AOI systems can perform very accurate z-height measurements of bottom terminated devices, they are however unable to check joint quality on these components. Our systems can check any components that fail the z-height measurement inspection, again giving a definitive result to the question, ‘is it good or bad?’ This helps the technicians to fine-tune the process parameters using the results of our inspection. This leads to improved first-time pass results and faster, more cost-effective manufacturing. The next step is to automatically optimize the i40today.com 5

process based on our input; a great way to further We understand the need increase the value of our equipment. for much better machine- to-machine communication Q. What do you believe makes Yxlon the best supplier in electronics x-ray inspection? and are working with several strategic partners A. We listen to our customers and work closely to improve the quality and with key players in the industry, sharing our yield of production lines roadmaps and working to overcome the next both for SMT and Semicon. generation of challenges as soon as we become Currently most of our x-ray aware of them. This approach meant that we systems are not an integral were the first manufacturers of high-resolution part of the production line x-ray systems to embrace i4.0. and they are designed to perform high-quality inspection. Head in Pillow 2D Image 9 A. Just recently we launched a range of 3 high- end systems to overcome some of the inspection Q. Yxlon is well known for their customer challenges which the semiconductor back-end support. What do you do to keep ahead of the companies are facing. These systems are able to other companies in this industry? image features that are much smaller than could be seen previously, have many technological A. We supply high-technology equipment which advantages over the competition, and directly is key to producing quality products at our address the needs of our customers. I’d like to customers. At Yxlon, we fully understand this and point out that one of the outstanding features is do all we can to keep our systems running at their the 3D capability to image details in multilayer best, and on the rare occasions of a failure to get objects like TSVs without a superposition from them up and running as quickly as possible. Our neighbourhood structures in breath-taking global support team can use remote access to resolution. As this market is even more demanding the systems and make our customers feel that we than the SMT area, this technology will form the are just an arm’s length away. basis for some of the advances which will quickly filter through into the SMT area. Q. Can you share with our readers any new or upcoming technological advancements that www.yxlon.com you will introduce to the market in the coming year or two? 6 An insight into Industry 4.0 May/June 2019

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The Digital Twin in electronics industry By David Rogers, Global Account Manager, Siemens Digitalization changes everything, everywhere. It is inevitable, new business drivers are forcing the electronics industry to rethink every element of their business. Virtually every company is talking about innovation and digitalization, with one of the major drivers being the so-called Digital Twin. According to Gartner’s technology trends, the latest technologies that will impact companies each year - besides Autonomous products or Augmented Analytics - has been reported as the Digital Twin. This has now been highlighted as a technology trend for 2019 for the 3rd year in a row1. To gain a better understanding of the Digital helps to design, simulate and verify products Twin we should look into its origin. The original digitally. While CAD only involves a design, twin concept was firstly mentioned by Grieves in the Twin includes mechanics, multi-physics 20022. The shown concept was not called Digital electronics and management of the software, Twin, but included all elements of the Digital Twin: which allows testing of physical models based Real Space, virtual space and the data link which on an aggregation of the data. This feature feeds data from real space to virtual space and allows us to develop a prototype and test e.g. vica versa which is shown in Figure 1. Ideally, the heat spot simulations of a PCB until a degree is provided data of the real space model describes reached, where feasibility is proven, then the first all characteristics, behavior models, and other prototype can be manufactured – with precious properties to mimic a real-life model into the resources and rework cycles done via the virtual model. By copying the real model into a digital twin. virtual world, we are able to simulate the effect of changes in a safe environment without affecting Digital Twin of Production the actual original. Furthermore, the virtual model can be duplicated, or by means of web services, Once a product is designed, from a manufacturing accessed from different locations worldwide standpoint, the question is how to manufacture – the physical presence of a person at the the product. This is done via virtual production real-world object becomes obsolete and allows machine builders or system integrators who are global cooperation anytime, anywhere via the capable to plan, simulate, predict and optimize virtual representation. production digitally. This also includes the generation of controller code to enable virtual The use cases of digital twins allow a wide area commissioning prior to the actual construction of of applications. When it comes to the industrial the machine, eliminating errors in design. space, the use of such models can be shown along the product life cycle of any kind of goods Before a product is from the size of a PCB to a turbine, as shown physically present, a in Figure 1. product idea needs to evolve into a concept which provides the design and functionality of the future product. The Digital Twin of a product helps to design, simulate and verify products digitally. Figure 1: The digital twin reference model Digital Twin of a Product Before a product is physically present, a product Digital Twin of Performance idea needs to evolve into a concept which provides the design and functionality of the The two prior Digital Twins are focused on only future product. The Digital Twin of a product a single discipline - either product or production 8 An insight into Industry 4.0 May/June 2019

prior to operation. Once the product is in In the manufacturing disciplines, the product operation, by collecting real-time data, we can twinning is not of much interest. However, with gain insights by different means and interpret the digital twin of production there are still so it. This is called the Digital Twin of Performance many opportunities to improve operations. and allows continuous feedback of the operation data to earlier stages, but also optimizing The traditional concept of putting into practice current operations via data analytics. Figure 2 means a process which includes the following illustrates the three different Twins throughout steps: End users provide functions to their the product lifecycle. knowledge and a specification of the further ...the Twin Figure 2: The Digital Twins throughout the Product Lifecycle includes mechanics, multi-physics electronics required functions. This needs to be put into and management of the a feasibility study by a mechanical concept, software which allows designing the process of manufacturing with testing of physical models current accessible technology. Once this is based on an aggregation finished, the mechanical concept will be designed with the available technology put together via of the data. CAD. This concept needs an electric wiring scheme and furthermore all the tools which allow all the electrical components to work and operate through the automation software and tools, aiding a start-up of more complex items. Once the operational properties are complementing each other, the machine can be assembled, tested and set up and finally put into operation. The construction of a machine is a time-intensive process and traditionally follows a sequential process shown in Figure 3. Figure 3: The traditional process of constructing a machine i40today.com 9

The two prior Digital Twins Apart from significant time savings, testing the are focused on only a production machine in the virtual world also single discipline - either allows machine builders to verify the design with the customer virtually without building a mock-up product or production prior of the machine. Furthermore, it eliminates errors to operation. Once the in the process, where for example, the robot product is in operation, arm collides with another part of the machine or by collecting real-time other conceptual errors, prior to actual assembly. This allows to virtually commission the machine data, we can gain insights without any time constraints on delivery time of by different means and components, or any other critical paths in the interpret it. real world. Ultimately, the actual assembly and commissioning time is reduced since every item is tested beforehand. The described scenario is not a vision that becomes reality way in the future, but is actually applied with several customers now. As one of those customers are in the electronics industry, Siemens worked with Chinese manufacturer Bozhon, who understand this difficult market and are highly familiar with challenges faced by its customers. Figure 4: The Digital Twin of Production By leveraging the Digital Twin of Production, the sequential way of building a machine can be changed by combining electrical design, The traditional concept of automation and CAD with machine properties putting into practice means together in the virtual world. This meshed system allows to test the sequences of the a process which includes machine with a behavior model based on the the following steps: End physics of each component including sensors users provide functions and actuators and a collision model. But a virtual to their knowledge and a instance is more than a physical model since this specification of the further would only be an animation of paths of an item proving the execution of the process. With the required functions. actual electrical datasheets of components and programmed automation, software is integrated The project both companies had in mind sounded into the physical model so that we have a real- a little unusual at first: In Germany Siemens world simulation of a machine which allows us created a digital twin for a machine that was being to verify robot paths, process sequences, the manufactured concurrently in China. It involved mechanical concept – every step which is needed an assembly cell with robot arms, and it was used in the actual operation early on in the process. at a trade show to demonstrate how the front and The respective model can be seen in Figure 4. back of a cell phone housing are joined together. Siemens provide here a complete toolset to design and configure a complete Digital Twin of Production: NX as the underlying CAD software, MCD (Mechatronic Concept Designer) for adding the physical model to the CAD model, TIA Portal to generate the controller code and PLC SIM to simulate the code. 10 An insight into Industry 4.0 May/June 2019

Via utilization of the Digital Twin of Production, Looking into the last Digital Twin - the Digital the end user achieved 30% in time savings by Twin of Performance - after the commissioning improving engineering efficiency, accelerating of the machine, it will be put into operation development, delivery, and commissioning of and it generates data. Every sensor, whether it new machines at the customer site. tracks current, voltage, temperature or vibration, provides information in accordance with the The digital twin was a fully detailed representation motion part of the machine. This information of the actual prospective machine that would alone is isolated, but if it is correlated with ambient allow its sequence of movements to be temperature, or similar machines in a machine simulated. The outcome: the entire value chain fleet park, then the data can be interpreted. At was comprehensively represented, tested, and this time if we are looking at a simple item from optimized in digital form - from product design through planning and designing the machine itself, all the way to the production process and performance. For the customer the development of a digital twin was the correct course to pursue, as explained by the CMO of Bozhon: “The development of a digital twin enabled us to meet the demand for simulations. We expect digital twins to include more functions in the future and therefore further enhance companies’ long-term competitiveness.” the outside, a locomotive is generating around 1 million data points per day – local data storage is costly and makes comparison of similar types difficult. By utilizing cloud services, it is possible to aggregate this information or pre-process it via edge computing, sending only significant data to the cloud. The premise of cloud services is the unlimited power to compute, so this is where data analytics can help users to utilize prediction of the machine downtime, optimizing the process flow or even optimizing resources - such as power consumption, air usage and more. A typical architecture is shown in Figure 6. Figure 5: The end result of Digital twin (left) and actual machine (right) with a Chinese machine manufacturer showcased at Hanover Fair 2018 i40today.com 11

By exploiting all these characteristics we establish a Digital Twin of Performance, which not only allows us to predict the behavior of current versions and correspond to actual operations, but also to feedback future optimizations into the next versions. Real time data is no longer unemployed but can be exploited and even allow new business models to thrive e.g. usage-based pricing and more. By leveraging the Digital Today we have the computing power to establish Twin of Production, the one incorporated model instead of several sequential way of building isolated ones. Incumbents and also new market a machine can be changed entrees want to join the IOT movement. The by combining electrical Digital Twin will be one of the key technologies leveraging Digitalization or Industry 4.0 and design, automation disrupt current markets of machine builders, end and CAD with machine users and contract manufacturers. properties together in the To distinguish from the competition, it will be virtual world. necessary to embrace new technologies and be an early adopter rather than be at the outer edge. Conclusions It has never been more important to stay ahead of technology than it is today. The Digital Twin has Digital Twins are powerful tools to optimize offline reached a maturity where proven concepts, tools and online. However, with over-engineering, it is and domain knowledge exists, and it is possible important to only take the relevant data to predict to implement within a reasonable time frame and behavior in the virtual representation, rather than provides companies a competitive edge. over-complicate the model. Apart from this, it also allows us to collaborate on a global scale, which References was only possible previously locally, or by flying in the experts in a certain discipline. 1. Gartner Technology Trends 2017, 2018, 2019 2. Grieves, University of Michigan, 2002 (add conference report or weblink indicating source) www.siemens.com Figure 6: Digital Twin of performance architecture 12 An insight into Industry 4.0 May/June 2019

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 13

Interview with Ranjan Chatterjee of Cimetrix – Connectivity By Philip Stoten, SCOOP In this interview Ranjan Chatterjee talks to our i4.0 editor about connectivity, drawing on his considerable experience in the semiconductor sector. Connectivity is the foundation for smart manufacturing and the key to digital transformation of every industry and every process. Q. Ranjan, there’s so much talk about they are very expensive lines and machines, they connectivity, it seems to be one of the key need to be connected. It’s not an option for them, topics relating to industry 4.0 and smart they need to monitor machines because they are manufacturing. You’ve got so much experience their biggest investment. of this from the semiconductor industry and so much knowledge to bring to the SMT sector. Cimetrix have used the same technologies in There are some fundamental differences, but Semiconductor and SMT and integrated 24 there are similarities as well, aren’t there? factories, 20,000 SMT machines, almost a decade back. The thing is that once you use a A. We do have had a lot of experience in connectivity standard, and it’s very well thought connecting in the semiconductor sector. Because out and it works in a very capital intensive industry, it is easy to digitize at scale because the standard and the process have been debugged, the semiconductor has invested an enormous amount of money to make it work. For a standard to get adopted, you must have rigorous testing and you must reference implementations. You must have a minimum critical mass. Once those things exist, then it can happen. Other sectors can then benefit from their efforts and investment. If you look at the PCB industry - which is probably one of the least sophisticated and spends the least amount of money (they invest even less than the SMT sector) - they have adopted the semiconductor standard, the GEM standard. One of the reasons is that having looked at everything and they said, “Instead of trying to figure out a new standard of their own, which could take a while to get adopted, and if it did get universally adopted, it takes a while to get deployed.” To get it done quickly, they chose GEM. Nowadays, data is data. The machines are all similar, they have similar operating systems. The heart of the machines are similar, they all run Windows, most of them have similar motion, vision, and other technologies. Q. If I look at an EMS company in Tier 1, or Tier 2, upwards of a dozen factories, and as you say, literally thousands of machines and many different equipment sets, some legacy, some that they’re currently investing in. What I’d want, if I were them, is something that gives me the fastest solution to digitize my ecosystem, but also, economic. If I’ve got 10,000 machines, I don’t want it to cost me a $1,000 a machine, because that’s $10 million. A. Yes, that’s right. Some EMS companies have 90 factories, to them, if you’re just monitoring one line or a few lines in a few factories, that doesn’t give them what they need. If you are try to do 14 An insight into Industry 4.0 May/June 2019

OEE (Overall Equipment Efficiency), you want to A. Yes, something that can be done immediately, Nowadays, data is data. connect across the board, across all the factories, and then we can move the discussions to the The machines are all every single line. If you can’t do that, you don’t higher level, like what do you do with that data get the benefits. You can end up dwelling in a and how to actually process it. You need to similar, they have similar prototype purgatory. collect, you need to analyze, and you need to operating systems. The act! We need to get to the act part as soon as heart of the machines Q. A lot of these bigger EMS companies now possible. If you are at the collecting data stage are similar, they all run are selling on manufacturing agility. We have and it’s taken you months and months, you’re Windows, most of them all these challenges with wanting to produce not really getting any return on your investment. product as close to the end user as possible, The data collection should happen across all 90 have similar motion, but also trade wars and tariffs has made people factories for a large EMS, so they can get to the vision, and other rethink where they produce. The companies “analyze and act” as soon as possible. That’s technologies. that can move manufacturing quickly definitely where the real value comes. have an advantage in the market. Having an equipment set that is compatible, the ability to About Ranjan Chatterjee: move quickly, the ability to benchmark one line against another, is hugely valuable, not just in Ranjan Chatterjee is Vice President and General their internal business, but also in their ability Manager of Cimetrix, where he oversees all to engage with certain OEMs. aspects of business strategy and execution for the Smart Factory business. His focus is on extending A. Yes, absolutely. You’re also seeing that some of and introducing standards and platforms into the OEMs and EMS companies are not doing one Industry 4.0 and Industrial Internet of Things (IIoT) thing anymore. A semiconductor wafer fab will initiatives by interfacing manufacturing equipment often do packaging. They may not like it because with big data and embedded analytics tools. it has lower margins, but they must do it because that’s what customers are demanding. EMS With nearly 25 years of experience across companies are moving into packaging or OSAT the cloud, mobility, networking, security and territory. So, connectivity needs to be something collaboration markets, Ranjan joined Cimetrix that works across the supply chain. It’s not just from Motorola. At Motorola, Ranjan was General moving production from one facility to the other. Manager of the Software Solutions group that When you send a wafer, you must send a wafer pioneered disruptive, game-changing software map that can be handled by an SMT machine. technologies that dominated the market in mobile platforms, cloud networking and cloud services In the semiconductor back-end there is a lot solutions. Ranjan has held positions of increasing of discussion around whether to standardize responsibility at Motorola in various divisions on the material handling systems. Not just the including Semiconductors, Mobile phone, communication systems, but the material handling Automotive and Public Safety, bringing significant itself. In semiconductor, when they went from experience in strategic planning and execution, 200mm to 300mm wafers, they went through organization development, and incubating and a huge transition to standardize on the material scaling new businesses. handling systems. That transition is going on in the semiconductor back-end, which is morphing Ranjan led the development and deployment of into the SMT front-end. a standards-based factory control systems for Semiconductor, SMT and assembly factories, Q. I guess in summary, I look at what’s going on which encompassed multiple factories around with the discussion about CFX, about Hermes, the world, and connected thousands of pieces about different standards, the bottom line is of equipment. Ranjan has a M.S. in Computer we need to get stuff connected, we need to get Science from Carnegie Mellon University. it all digitized. We need to stress a little less about standards and just actually get on and www.cimetrix.com find the right solution. i40today.com 15

Reduce costs or delight customers? You don’t have to choose By Deb Geiger, VP, Global Marketing, Aegis Software Balancing Costs vs. Customers In today’s customer-centered world, meeting the needs of customers is more demanding and business-critical than ever. At the same time, manufacturers struggle to reduce operating costs as margins compress and the competitive landscape intensifies. For many manufacturers, there exists a dichotomy in pressure to “choose” between reducing costs and delighting customers. The tradeoff mindset is apparent in the top While reaching zero-defects and peak pressures reported by discrete manufacturers, performance is crucial, manufacturers also need which are almost exclusively focused on one to reduce recalls, supply chain interruptions, question: How do you deliver higher-quality and downtime to strategically adapt to demand products that delight customers, while still fluctuation, rising expenses, labor issues, ensuring a higher profit? But while these priorities and other costly operational issues—all while appear to be mutually-exclusive, best-in-class complying with regulatory agencies. To ‘do it manufacturers don’t see them as a tradeoff; all,’ manufacturers need to look at a technology In fact, they take a holistic approach to quality solution that doesn’t require them to cut costs at management that allows them to have their cake the expense of quality or prioritize quality at the and eat it, too expense of feasibility and profitability. Traditional Approaches to Forming Quality- Oriented Strategies When balancing the competing forces of cost and customer, manufacturers have traditionally taken one of three approaches when creating cost- effective, quality-oriented strategies for their enterprise. The first one is standardizing quality processes. In a recent 16 An insight into Industry 4.0 May/June 2019

How do you deliver production processes in an attempt to ensure higher-quality products quality at a lower cost. This approach is a that delight customers valuable endeavor that enables manufacturers to transparently gain insights from their operations while still ensuring at any point in the manufacturing process, quickly a higher profit? But recognizing discrepancies in quality. It does not, while these priorities however, provide a framework by which operators appear to be mutually- can report and address quality management exclusive, best-in-class issues. The third approach commonly taken is manufacturers don’t see to ensure collaboration with suppliers across the them as a tradeoff... enterprise. In the same Aberdeen Group research study, 27% of manufacturers attempt to improve Aberdeen Group research study, 63% of collaboration with their suppliers and enhance manufacturers aim to standardize quality communications throughout their enterprise. processes such as compliance and risk-based This tactic aims to ensure that suppliers are controls, quality training, and more. In doing delivering quality products through scorecards, so, their goal is to create a manufacturing high-impact supplier projects, and more, as well environment in which the cost of quality as create a connected environment in which decreases, as excellence becomes standardized. quality data is shared across IT / OT constituents. This approach, however, fails to account for Like the second strategy, these efforts are fluctuating demand and other unexpected valuable but do not provide an actionable or disruptions that must be addressed in a cost- cost-effective system for managing quality. While effective way that also prioritizes quality. The these are three worthwhile efforts to increase second traditional approach is improving visibility quality standards for a lower cost, they are only and traceability. According to Aberdeen Group, stopgaps when it comes to addressing the long- 35% of manufacturers strategically enhance term balance between cost and quality. visibility and traceability controls across Instead of focusing solely on short-term strategies as the three just mentioned, today’s best-in-class manufacturers are taking a holistic look at how quality management fits into their wider manufacturing operations. To do so, they no longer rely on Quality Management System (QMS) technology alone. Instead, forward-thinking manufacturers are leveraging holistic platforms that have a full range of QMS capabilities embedded into their Manufacturing Execution System (MES). i40today.com 17

The Best-in-Class Approach: A Holistic intelligence they need to make real process Perspective improvements. These leading manufacturers also combine quality data with enterprise-wide Let’s now explore four key strategies that leading operational data, creating a single source of truth manufacturers are doing to deliver higher-quality that includes QMS and MES inputs for enhanced products at a lower operational cost. For best- insight, clarity, and functionality factory-wide. in-class manufacturers, delivering top-notch quality for a lower cost all begins with getting In addition to measuring, analyzing, and sharing C-level buy-in on the prioritization of quality data about their own internal performance, management. This executive sponsorship, the third strategy is ensuring that they are also which solidifies the ongoing commitment and doing the same for their network of suppliers. attention of senior management, is crucial. It Additionally, best-in-class manufacturers are sends an enterprise-wide message that higher collaborating with their most robust suppliers on quality, not just lower costs, must be considered product design to improve their performance, in everyday operational decisions. The second establish key processes for automatic quality KPI strategy is that best-in-class manufacturers aren’t monitoring and failure notifications. The crucial just centralizing and sharing best practices for fourth strategy that best-in-class manufacturers cost-effective quality; they are also reporting are doing is turning to automation to standardize real-time measurements of quality and KPI data a framework for high- quality manufacturing at across the enterprise. This data empowers a lower cost. The best of the best-in-class are various constituents to access the actionable automating key manufacturing processes such as change control management, corrective action/ How do you deliver preventive action (CAPA), audits management, higher-quality products dashboards, supplier quality ratings, advanced that delight customers, product quality planning (APQP), and more. This level of automation leaves little room for error while still ensuring when it comes to manufacturing high-quality a higher profit? But products and correcting defects. By using QMS while these priorities functionality and technology and applying it more appear to be mutually- broadly across the execution of manufacturing exclusive, best-in-class processes, these leaders further demonstrate the manufacturers don’t see value of an integrated QMS+MES solution. them as a tradeoff... These leading approaches, leveraged by best-in-class manufacturers, are designed to increase quality while decreasing operating costs and delivering significant ROI. Manufacturing leaders can excel at reducing the cost of quality with a holistic, MES+QMS-oriented approach, which optimizes quality data to be used across the enterprise and made actionable through shared access. www.aiscorp.com/en/ 18 An insight into Industry 4.0 May/June 2019

Your Connection to Measurable Industry 4.0 Benefits A dynamic and holistic MES platform, FactoryLogix® rapidly connects your factory to greater efficiency, productivity, and profitability. Built for today’s converged manufacturing reality, it links all of your business-critical systems, processes, and people, unleashing the factory-wide data insights needed for Industry 4.0 transformation. 30% 10% Reductions Improvement in Assembly in OEE & Average Re-Work Time Productivity 75% 85% Decrease Reductions in ECO & NPI in Manual Data Entry Time *Derived from Aegis Customer Case Studies 90% Less Work Instruction Creation Time Manufacturing Execution & Operations Solution for Factory-Wide Connectivity • DME—Digital Manufacturing • QMS—Quality Management System Engineering • Regulatory & Customer Compliance • Manufacturing Intelligence • Manufacturing Process Execution • Active Rules Engine • RMA/MRO—Returns & Overhaul • Connectivity (IIoT Edge & Business • Lean Materials Management • Adaptive Planning Systems) Learn more at www.aiscorp.com i40today.com 19

Extending the ‘Golden Hour’ in your assembly line: To repair or not? Jenny Yuh, Marketing The first hour after the occurrence of a traumatic injury, or the “Golden Hour”, Assistant, Koh Young is considered by trauma surgeons to be the most critical time for successful Technology, Inc. Seoul, Korea emergency treatment. It may not be the same life or death situation, but it is similar in an SMT assembly line, where a few minutes of downtime can cost millions of Brent Fischthal, Sr. dollars. Yet the Golden Hour concept does exist in the SMT production process. Manager, Americas Marketing, Koh Young It is widely recognized that over 70 percent of Koh Young Technology America, Inc. soldering defects are associated with the solder are working diligently paste printing process.1 These defects pose to extend the “Golden serious concerns to the industry, especially with Hour” well beyond its the component miniaturization trend and the limit by implementing 0201M microchip emergence. Manufacturers new innovations like cannot scrap the board and the microchip, due to procurement challenges and component costs. integrated tools to However, if the manufacturer does not repair the repair defective issue quickly, the whole board is susceptible to failure. Leading inspection suppliers like Koh solder depositions. Young Technology are working diligently to extend the “Golden Hour” well beyond its limit have advantages, as well as limitations. As shown by implementing new innovations like integrated in Figure 1, needle-based dispensing is suitable tools to repair defective solder depositions. for many package types, including Ball Grid Array (BGA) packages. However, the system needs Need for the Correct Solder Volume to maintain a constant z-axis distance between the substrate and needle tip. An inconsistent What is ideal amount of solder to deposit? It distance reduces repeatability and accuracy. may be different for too much solder paste will Non-contact jetting, another relatively new cause solder bridging, whereas insufficient solder method, has superior dispensing speed but, it is paste may result in printing defects like bridges, less flexible due to the limited number of certified tombstones, and more. With the widespread use solder paste for jetting. of leadless packaging, insufficient solder volume is an increasingly frequent defect occurring, because solder paste tends clog smaller apertures and cannot be released onto the pad. Rework innovations can help solve insufficient solder issues. Rework Applications The rework application can be categorized into two types: traditional, needle-based contact dispensing and non-contact jetting. Both methods Dispensing 01005 0201 0402 CSP CSP Jetting (0402mm) (0603mm) (1005mm) 0.3mm 0.4mm          Figure 1: Recommended deposition method based on package type2 1 Mitch Holtzer, Karen Tellesfen, Westin Bent, Predicting Solder Paste Transfer Efficiency and Print Volume 2017 2 Fernando Coma, Jeffrey Kennedy & Thilo Sack. (2015) Deposition of Solder Paste into High Density Cavity Assemblies [PowerPoint slides] Retrieved from https://www.smta.org/chapters/files/April-2015-Kennedy.pdf 20 An insight into Industry 4.0 May/June 2019

Volume Sigma (%) Area Sigma (%) 35 35 30 30 25 25 20 20 15 15 10 10 55 00 1 Test 2 Test 3 Test 4 Test 5 Test 1 Test 2 Test 3 Test 4 Test 5 Test (50 times) (50 times) (50 times) (50 times) (50 times) (50 times) (50 times) (50 times) (50 times) (50 times) Figure 2: Koh Young’s Volume & Area Repeatability Results (each test was run independently 50 times) Automated Dispensing with Advanced Accuracy The Koh Young Auto Repair system replaces Today’s production environments need equipment that is both flexible and easy to use. Koh Young mechanical height meets the industry’s needs by adding a new sensors with a laser “Auto Repair” dispensing system to its high- sensor to accurately speed KY8030-3 3D SPI (solder paste inspection) measure the z-axis platform. The Koh Young Auto Repair system distance and overcome replaces mechanical height sensors with a laser sensor to accurately measure the z-axis distance the challenge of and overcome the challenge of traditional traditional dispensing. dispensing. This innovative sensor method provides excellent Gage R&R capability. (Figure 2) and increases nozzle longevity. It also significantly extends the service interval to upwards of seven The Koh Young 3D SPI system can accurately days. When cleaning is needed, the syringe holder inspect and identify solder defects, thanks in part, incorporates a one-touch release for fast and to its precisely engineered mechanical structure. easy replacement. These minimal maintenance Unlike other 3D SPI systems that move during the requirements improve the Return on Investment measurement process, the Koh Young SPI uses (ROI) by reducing labor and material costs. “stop and shoot” technique. Unwanted vibration and image stitching is eliminated. Auto Repair, Superior Flexibility when added to the high-speed KY8030-3 is truly the solution for production today and in the future. Does the Koh Young Auto Repair system offer other benefits? Yes. The design is highly flexible Minimal Maintenance Koh Young has examined system maintenance and usability during the Auto Repair system development. The Koh Young Auto Repair system, unlike other dispensing technologies does not use a plunger to dispense solder paste. The plunger can crush the solder particles and clog the nozzle. Instead, the integrated Auto Repair dispenser uses air pressure, which reduces wear 0201 CSP (0603mm) 0.3mm 0201 0201 0201 0201 (0603mm) (0603mm) (0603mm) (0603mm) Volume: 5.57% Volume: 62.79% Volume: 58.92% Volume 89.21% Area: 16.25% Area: 95.9% Area: 86.54% Area: 73.66% Figure 3: Before and After Comparison of the Koh Young Auto Repair System i40today.com 21

and considers many production variables. For start, so there may not be anything to repair. Will example, imagine a hundred different board manufacturers still need an Auto Repair system? layouts with different components - each The answer may be “yes,” as this is not going to component type requires a unique solder paste happen in near future. Indeed, the smart factory amount. The Auto Repair system can be an will not replace rework applications, instead it will effective solution, especially for small BGAs enhance the functionality. Auto Repair powered and microchips. (Figure 3) It can dispense by AI may be able to recognize complex patterns solder to repair insufficient errors to a wide of solder pads, synthesize information, draw range of component sizes, including 0402M conclusions, and provide recommendations to microchips with a pad-to-pad distance over optimize the solder paste printing process. 100um. Additionally, Dynamic Z-Axis Tracking automatically adjusts the distance between Conclusion the head and the board surface to maintain the ideal focal range and prevent false calls due The printing process is one of the most critical to PCB warp. Such flexibility allows users to steps in the SMT assembly line, because it is readily improve yields and efficiency in their the origin for most of the process defects. The assembly lines. benefits of readily repairing printing defects extend far beyond the cost savings from Smart Factory Future eliminating cleaning, post-reflow rework, and scrap. As rework costs and complexity increases, Looking forward, Industry 4.0 is rapidly gaining the ability to extend the “Golden Hour” with traction among manufacturers. The factory is Auto Repair system will increase line productivity not a static place, it is a dynamic zone where and yield. machines work together to execute complex tasks. In fact, the Koh Young’s Auto Repair system As the absolute No.1 market and technology already addresses Industry 4.0 in many aspects. leader, Koh Young has been developing By integrating 3D inspection and repair, it innovative solutions to overcome industry establishes a closed-loop process and eliminates challenges, expand process capabilities, and unnecessary board cleaning or scrap. Additionally, boost factory performance. To this end, the it integrates a real-time process dashboard, so company has set up three additional R&D centers operators can quickly verify rework performance to facilitate a quantum leap in technological and make the right decisions by comparing with leadership and competitiveness. Koh Young previous results. continues to integrate AI advancements in many of its systems, while overcoming Golden Hour What is next for the Auto Repair system in a future challenge and paving the way for new markets smart factory? In the ideal future the a connected and industries beyond SMT. systems should remove inefficiency from the www.kohyoung.com/en 22 An insight into Industry 4.0 May/June 2019

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Easy on the open: New Amaray packaging line has stacks of potential By Kevin Heap, UK Packaging Expert, Sumitomo (SHI) Demag With more than 320 packaging patents to its name, applying ingenuity to enhance the customer experience continues to define Amaray’s success. Most recently, the Corby-based injection moulding facility in partnership with Sumitomo (SHI) Demag, Waldorf Technik and Roth Werkzeugbau unveiled a pioneering, fully automated In Mould Labelling (IML) production line that’s repeatedly manufacturing, stacking and wrapping over 7,500 easy open, fully decorated rigid wipe lids per hour. Figure 1: Amaray’s pioneering packaging The push button lids, cleverly designed for a major possibly the most sophisticated packaging line comprises a 12+12 stack mould, blue chip personal care client, have proven to be production line in the world today, Rick credits the producing 7,500 fully decorated rigid a feat of functional engineering several years in dedication of the entire team to delivering such a wipe lids per hour for a leading blue chip the making. Yet, the project may not have got off pioneering project. personal care customer. the ground or have been quite so cutting-edge or financially viable without the cooperation of Taking centre stage on the line is Sumitomo (SHI) such forward-thinking machinery and equipment Demag’s ultra-high speed 580-tonne El-Exis supply partners, claims Rick Ormerod, Head of SP, fitted with a multi-cavity 12+12 stack mould. Technical at Amaray. An integrated high speed IML Waldorf Technik robot places each label into the mould, and then Believed to be Europe’s first ever installation removes and closes each of the 24-hinged lids as of a 12+12 stack packaging mould, and quite soon as they are extracted from the mould. This has to be done swiftly while the polypropylene Figure 2: Partnering with Sumitomo (SHI) is still malleable. Each lid is then placed on the Demag, Waldorf Technik, Roth Werkzeugbau conveyor where they are each quality checked by and Mevisco, Amaray believes it to be the most a camera. A robot then stacks 38 lids, passing to a sophisticated packaging production line in the binder, at which point nine stacks are fed into an world today, integrating injection stack moulding, automated wrapper to create a brick of 342 lids IML, robotics and vision. for loading onto a pallet. Amaray considered its selection of partners for this new production line long and hard, emphasises Rick. “We intentionally chose suppliers that could bring fresh thinking and were leaders in their respective fields. This was our first UK Sumitomo (SHI) Demag installation to join our fleet of 38 injection moulding machines. The team proved to be a driving force in scoping out the exact machinery specifications needed in order to create a fully automated, streamlined packaging production line. “Through an open dialogue we were able to arrive at a cohesive direction together that would enable Amaray to achieve the best design, in the most productive and cost effective way possible,” adds Rick. Pushing the design envelope The wipe lid builds upon Amaray’s media market domination. “It ties in very closely with manufacturing hinged casings to protect DVDs, computer games and videos,” comments Rick, who has extensive personal experience in moulding and IML. “All of this expertise melded together very well,” he highlights. 24 An insight into Industry 4.0 May/June 2019

Connecting Global Competence November 12–15, 2019 Accelerating Innovation co-located event World’s Leading Trade Fair for Electronics Development and Production November 12–15, 2019, Messe München productronica.com i40today.com 25

Figure 3: In addition to the ultra-high speed 580-tonne El-Exis SP, the Sumitomo (SHI) Demag team supplied fresh thinking to achieve the best design, moulded in the most productive and cost effective way possible. Driven by its underlying principle to make good processing challenge. Sumitomo (SHI) Demag’s things better, the company did extensive and UK packaging expert Kevin Heap explains: “To ongoing market research with parents and carers create the flip-like hinge was challenging in itself, to scope out how they could structurally improve as the tooling needed to accommodate varying upon the rigid pop up lid concept. depths of raw material. Unlike a single face tool, the polymer is injected in the centre between the Rick explains: “Wipes are a classic on-the-go two plates and has to be evenly distributed in all product where convenience and accessibility are 24 cavities.” paramount. During the design and trial phases, users repeatedly emphasised the dexterity Additionally, using a two-face 12+12 stack mould challenges they face when changing or cleaning in conjunction with the IML system means that a wriggling child. Above all else, they desired a 24 cavities are opening at the same time, with a secure lid that stopped wipes from drying out to Waldorf Technik side-entry robot placing labels save on waste, yet could be opened and closed accurately within fractions of a second. “Typically, with one finger.” packaging moulders use a single face mould with a maximum of twelve cavities when integrating To maximise post-consumer recycling efforts, an IML system, so Amaray’s installation doubled Amaray made the intentional decision to the complexity. To insert labels on both tool use polypropylene. “It means that the entire faces required a much larger robotic system,” component - lid and label - can be recycled after emphasises Kevin. use,” says Rick. Multi-tasking robot In order to deliver this uncompromising design, the lid needed to be moulded as a single Given that the El-Exis is the world’s fastest component and decorated and assembled in a packaging machine, robotic speed was equally seamless process. From an injection moulding important. The Waldorf side-entry robot serves perspective, using a 12+12 stack mould although two purposes. As well as inserting the label into more productive, presented a tooling and each cavity before the plastic is injected into 26 An insight into Industry 4.0 May/June 2019

Intelligent Simple Fast Automated Component Counting Key advantages ✓ Drastically reduce line down time ✓ Drastically reduce counting labor ✓ Eliminate counting mistakes ✓ More productive use of manpower ✓ Direct link to factory ERP/MES ✓ Direct link to storage units Counting components shouldn’t require hours of programming. A true Plug-and-Play solution is a machine that doesn’t require libraries, but is based on logical algorithms. Monitoring SMT lines is critical. “Line-Down” due to 27 lack of precise inventory management is wasteful. [email protected] | 1-833-We-Count (932-6868) optical-control.com i40today.com

the mould, it has to retract and then re-enter the the production flow. Utilising the latest Smart moulding area to remove all 24 lids, closing them Factory innovations to ensure full traceability, the before the plastic hardens. checking system monitors and captures the data The robot then manoeuvres around to place the of total parts produced, parts rejected and the lids on a conveyor where the dimensions and reasons for those rejections. label are fully quality checked. The vision system, cameras and software were supplied by Mevisco, Once the full quality check is complete, the lids with Rick hailing their support and commitment are stacked and bound in-line, creating a brick to the project as being excellent. If parts fail to of nine stacks which are wrapped and palletised meet the specified criteria they are rejected ready for shipment. from the line by air blasts without interrupting “For moulders that are seeking to maximise Figure 4: Unlike a single face tool, the polymer is injected in the centre between the two plates and profitability and productivity - particularly for high has to be evenly distributed in all 24 cavities. quality, decorated yet low margin branded lids - stack moulds provide an increasingly attractive option,” notes Kevin. “With a stack system of this scale, moulders can get more production output per square metre, as well as saving on utility and maintenance costs.” “Commissioning the stack mould was a bold move on our part. However, it massively increases our moulding capacity in each cycle,” adds Rick. 100% unique While some moulders might be content following the rules, engineering something that has never been attempted before is always exhilarating, claims Rick. “It requires dedication and open communication, with engagement across all suppliers. For a mega-project like this there were so many aspects to consider. Yet, our uncompromising attitude was worth the effort as we have engineered a new process and technique for moulding packaging lids in high volumes.” During some parts of the process, the tooling and machine was being built in tandem with developing the lid design and consumer focus groups, says Rick. “Creating something new, especially such a revolutionary production line, requires a different mindset. Development is exponential. If you challenge yourself to think differently, you can be more disruptive. It’s only when you start to put the pieces together, adjusting the requirements as the project evolves and consumer feedback is generated, can you really refine the process. Thanks to everyone’s engagement, this project has been an absolute privilege to work on.” The entire Amaray team has closely watched the project unfold, with live production commencing towards the end of 2018. “Such was the excitement among colleagues, we were counting down the days to launch,” exclaims Rick. “There are several examples in Europe of moulders using 8+8 stack moulds for producing IML margarine lids in high volumes,” adds Kevin. “However, using a 12+12 stack mould, Amaray’s line really has pushed the packaging boundaries.” Sitting directly in view of Amaray’s conference suite, visitors to the Corby plant are quick to comment on just how ground-breaking the production line is. “From a functionality and user perspective, the single push button wipes lid is new and innovative. Equally inventive is the process for manufacturing them in such vast volumes,” ends Rick. http://uk.sumitomo-shi-demag.eu Figure 5: In keeping with their ‘Making Good Things, Better’ philosophy, the Amaray wipe lid is uniquely designed and manufactured to be opened and closed with one finger. 28 An insight into Industry 4.0 May/June 2019

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How new sensor technology opens up for smarter presence detection By Anders Jansson CTO, JonDeTech New sensor technology can bring about new and more efficient presence detection in, for example, the construction and real estate sector. The solution is a small, inexpensive, battery-powered and IoT-caged sensor that will also be able to be connected very quickly with the help of the upcoming 5G networks. Anders Jansson, CTO at the Swedish IR sensor company JonDeTech, explains how. A rapid technological development within what is sensors that can send data to just one gateway, known as the Internet of Things (IoT) means that which in turn controls the lamp exactly the way more and more things in our everyday life will be you want. connected. The connection is made with the help of a gateway or a hub, which can collect data from Today’s pyro electric sensors provide limited a large number of sensors, which it then sends to presence detection the cloud via, for example, 5G. IoT and sensors will be each other’s preconditions in a variety of Most of today’s sensors for presence detection technical solution areas in this connected world. are built with pyro electric sensors. But its One such area is smart homes and buildings. properties are limited and can only sense changes Here, the development is very fast – from older in temperature, making them less suitable for sensors that control a relay that turns on and off a areas where the user is expected to remain, for lightning system – to a whole new generation of example in a room or in front of a computer. The new sensor, on the other hand, has the ability to 30 An insight into Industry 4.0 May/June 2019

detect human presence by detecting the heat libraries, for example, to see if a place is vacant radiation. In this way, it is much better at detecting or not. By using the sensor to wake a device immobile people in a room, office space or in only when someone is present, you can reduce front of a unit, like a computer or a tablet. the energy consumption and extend the battery life. The new type of sensors can potentially also Improved thermopile sensor an important be used to activate biometric authentication component for smarter presence detection systems, such as fingerprint scanning or facial and iris recognition, which consume a lot of So how is this sensor constructed? The new energy when active. generation of presence detection is equipped with a so-called thermopile, which is manufactured Nanotechnology makes the sensor extremely using nanotechnology. Thermopile is a series thin, flexible and cost-effective of connected thermocouples that can convert thermal energy (heat energy) into electrical The sensor itself is based on nanotechnology, energy. They can be used to measure absolute which results in a lot of advantages. It measures or relative temperature and heat flow. This can in only 0.17 millimetres in thickness and is almost turn be used to detect, for example, movement or entirely made of plastic. The plastic piece is presence. Moreover, they are passive and do not very robust and can be used without the metal consume any energy when not measuring. housing, or protective cover, which is often used on conventional sensors. In addition to being thin Several new applications within construction and robust, the sensor is also very flexible, but and property save energy and increase safety also cost-effective to produce in large volumes. It makes it suitable for all types of applications that Common areas of use include smoke and gas require small sensors where temperature or heat detection, movement, absolute temperature flow should be measured. measurements, heat measurement and control of heat-sensitive parts and plumbing. Other areas of www.jondetech.se use include smart offices or public spaces such as i40today.com 31

What is Optimised Buildings providing that others in the market aren’t with their ‘Bureau’ services? By Chris Atkin, Energy Optimiser, Optimised Buildings Before we address this question, let’s first of all look at what the ‘majority’ of service providers deliver in the way of a bureau service to their customers today. The primary function for most bureau services delivered by BMS systems integrators is that of reacting to ‘HVAC and Building Services Alarms’ via the BMS. This is the underlying core functionality, on top of this some may offer an engineering function that will drill down into the BMS and attempt to resolve issues remotely where possible. Before we address this question, let’s first of all to the offering than this. Below are some of the look at what the ‘majority’ of service providers value add’s that are provided which differentiate deliver in the way of a bureau service to their not only the service they provide, but also the customers today. The primary function for most financial benefits that the client takes away from bureau services delivered by BMS systems the service: integrators is that of reacting to ‘HVAC and Building Services Alarms’ via the BMS. This is Optimised Analytics the underlying core functionality, on top of this some may offer an engineering function that will OB have partnered with the leading BMS analytics drill down into the BMS and attempt to resolve company globally, to deliver a service that is issues remotely where possible. The next level of retail focused. In doing so they have now built a functionality is then (although on many occasions specific set of analytical business rules which are delivered by another part of the business) energy designed to drive down operating costs for retail monitoring. Although the dots are rarely joined clients when acted upon. They can instigate new up between BMS Alarms, Engineering and rules to meet clients needs, but typically drive this Energy. This can then lead to managing remotely strategy for their clients. This enables the client deployed engineers to the site if problems and to stay focused on the business outcomes which issues cannot be resolved remotely, as part of are being delivered to drive their business goals, reactive call out service. rather than focusing on the technology. The focus will be on turning these insights into business Optimised Buildings (OB) was set-up 5½ years outcomes that will result in (a) generating energy ago to deliver energy efficient buildings and savings through optimisation of BMS, HVAC and facilities without compromising the comfort Lighting (b) reduction in other operational costs levels of the occupants. The whole premise of e.g. maintenance and lifecycle of assets (c) an what the company does revolves around having improved environment for occupants. core infrastructure in place (typically BMS and Metering). Unfortunately, in most cases clients, Transforming data into operational information. FM’s and service providers do not maximise the The cloud based software tools identifies issues value from this infrastructure and struggle to and patterns, not just as a one off exercise - but exploit the maximum value from this investment. on a continuous basis, ensuring your buildings This is where Optimised Buildings is different. are being optimised 24/7. They combine technology and expertise through their Optimised Bureau service, to ensure that this business objective is met. Delivering energy savings, maintenance savings, carbon reduction, increased life of assets and an improved environment for staff and customers alike. Optimised Buildings certainly provide the core service identified above, in a similar way to others in their market however, they add more value 32 An insight into Industry 4.0 May/June 2019

Optimised aM&T being launched on a daily basis, the one thing sense. However, it is not simply the technology that these solutions rely on is a common data or service, it always comes down to compelling OB’s enterprise energy monitoring software is set to ingest. OB have adopted Project Haystack business model that stacks up and where another global platform which they have been as the open source initiative to streamline possible all OB’s solutions come with a business delivering since the company was formed. They working with data from the Internet of Things. model to support them. don’t use this data in isolation, but in conjunction They standardise semantic data models and with the BMS systems data and analytics to build web services with the goal of making it easier Hosting in the cloud a picture of where problems are occurring and to unlock value from the vast quantity of data & disaster recovery monitor, manage and then maintain savings. The being generated by smart devices. platform has full IPMVP tracking so any store or OB have made considerable investment in program can be effectively tracked. OB take a Enterprise level KPI dashboards their Bureau services, such that everything is proactive approach to energy management and hosted in the cloud, with full back-up resilience. are continually optimising the worst performing OB clients typically have very little resource Should their building burn down, their engineers stores for their clients. to be able to manage their supply chain. As could be back up and running undertaking the a result, they try to address this through their services they provide within the hour, from their Delivering visibility of energy data. The powerful enterprise level dashboards, which wrap up home location. aM&T platform provides visibility of energy real-time KPI data on performance, from energy, data that is suited to many stakeholders alarms, calls, targets, work orders and anything Enterprise level control involved in monitoring or managing energy else that matters to them. OB try to avoid within a business. weekly and monthly reports and automate the Through the power of Niagara, enterprise KPI’s so they are always up to date through the level control is now viable for a group or Optimised DSM enterprise dashboards. all of the stores connected. Provide simple mechanisms to manage a DSM strategy, night Following optimisation of the core infrastructure, IoT setback change, trading hours’ time change or many of OB’s clients look for the next level BST time adjustment. of savings by avoiding peak time electricity OB are not limiting their Bureau services to BMS costs (Red Zone DUoS charges) and Triads data. The industry is moving at an incredible Ticketing / Case Management (TNUoS charges). Through strategies deployed in pace that will impact the commercial results of the BMS, they are able to minimise some of these businesses that operate real estate portfolios. OB have adopted Salesforce Service Application pass-through charges via enterprise level control Whatever the technology, OB want to be able for their internal ticketing solution. This is used strategies, with significant financial impact. to adopt sensors, AI, IoT and applications that when they have identified an issue, yet no will benefit their clients without them having WO or call has been received from the client. Our Demand Side Management (DSM) solution to adopt the operation of these technologies An example of this might be high energy minimises electricity supply pass through directly. OB have already partnered with some consumption in one particular building, so a charges such as TNUoS and DUoS, also more amazing sensing technology from Disruptive ticket will be generated to capture this to ensure commonly known as Triads and Red Zones. Technologies along with an IoT platform. this is looked into proactively. BMS Platforms / Alarm Management Wireless sensors lead to shorter payback Call Logging period. Utilising new and disruptive technologies Whilst every BMS has some form of supervisor to change the way buildings are monitored, All OB calls are logged and the KPI’s made visible head-end, OB have where possible, tried to controlled and optimised. to their clients through their enterprise portal. bring everything back to a Niagara based This provides data such as number of calls that platform (N4 or IQVision). This has enabled 24/7 Service day, week, month, etc, average number of rings them to develop specific applications to aid our before calls are answered, store with most calls. Bureau engineers in resolving problems quickly OB bureau service operates 24/7, with a team of and efficiently, for both OB and their clients highly educated engineers, which is not just a call Process benefit. Alarm management, when possible is centre and/or BMS alarm management service. done at this level, unless the BMS vendor does It is critical for OB that a defined process is not adopt open standards and OB are forced to Integration of CAFM with mapped out as to how the Bureau is to operate, use their proprietary supervisor. BMS Alarms they work with their clients to ensure that this is as full-proof as possible. A flow chart is defined Meta Tagging While some BMS Alarms may warrant remote for each of their clients to map the different investigation before an engineer is dispatched, scenarios and the action and response that has As we move into a world where software others are pass through alarms, that no matter to be adopted. applications, analytical tools, AI and IoT are what, an engineer is required to attend e.g. boiler lockout, pump trip, etc. These alarms can Account Management generate a Work Order directly if integrated with Verisae, saving time and enabling the work OB work with their clients to drive a successful order to be completed more efficiently. and efficient strategy across their portfolio. Many look to them as their trusted advisor for Integration / Expertise / Technical new savings, efficiencies and smarter ways of knowledge & the Business Case working. OB sit in on energy committees, attend weekly operational meetings or can simply act OB are continually challenged with how to run as a consultant, dependent upon their clients’ retail estates more effectively, and through the needs and wishes. expertise of their team and some very forward- thinking development engineers, OB help their All of the above wrapped up into clients think outside the box when it comes to a single managed service offering… solutions and technologies that make business We are confident that our ‘Optimised Bureau’ service will as a minimum pay for itself through additional energy savings and with the right client support we could multiply this saving 2-3 fold! www.optimisedbuildings.com i40today.com 33

How Industrial IoT is revolutionizing manufacturing By Brady Bruce, VP Marketing, Tempo Automation The Industrial Internet of Things (IIoT) is catalyzing an unprecedented change in the manufacturing world. With hundreds of connected devices that work together to gather and share data, factories and machines have never been more sophisticated—and this rate of improvement is only expected to compound: IDC predicts that worldwide spending on IIoT will reach $745 billion in 2019 and $1 trillion by 2022. As more systems become connected, manufacturers are better able to optimize their operations, find new efficiencies, and, ultimately, enable greater innovations. At the heart of these industrial connected systems is the technology that comprises their infrastructure, networks and other key components. For manufacturers adapting their buildings into smart factories, the primary goal is to optimize data and networks for improved efficiencies; this often includes trends like the growing implementation of IT/OT to converge IT systems with operational (OT) systems. Many are also seeking to develop their smart factories using a software-based approach, where software can be used to control systems, provide data analytics, and learn from that data to continuously improve operations. This setup of IIoT devices is revolutionizing manufacturing processes by creating a single digital thread that runs from the customer to the factory and back again to improve communications and streamline operations. At its core, a network of connected devices fills the communication gap between engineer and manufacturer by automating the flow of information from the engineer’s design to the machines and the people on the connected factory floor in a continuous cycle of design, build, and test. Tempo Automation, for example, has created a printed circuit board assembly (PCBA) smart factory that connects customer engagement, order processing, parts sourcing, factory operations, and shipment of finished PCBAs into one continuous cycle. This enables Tempo to build and deliver high complexity printed circuit board assemblies in days instead of the weeks typical of other manufacturers. By leveraging software on both the user front-end for quoting and ordering, and on the back-end for factory operations, their smart factory is able to create an unbroken data flow from customer to manufacturer. In addition to connecting engineer to manufacturer, a rich IIoT network also enables transparent communication between the manufacturers on the factory floor and the 34 An insight into Industry 4.0 May/June 2019

machines that they’re working with. Altogether, managed by a software platform also streamlines this creates a circular network of connectivity operations. For example, a smart factory with that works to continuously improve itself for sensors connected throughout can monitor greater efficiencies. factors like temperature, humidity, equipment status, job progress, and reported defects. All of For example, imagine a group of robots and this connected data can give engineers insight people working together on the factory floor. In into how the factory is operating, which they can a traditional manufacturing process—particularly, then use to optimize the engineering process. in an industrial market--the process is slow, opaque, and low-quality. This is due in part to the While robotics and machines can have many fact that the machines and people are all analog self-functioning features, smart factories will and disconnected, making the factories islands still require a certain level of human expertise— of isolated technology. Without any kind of IIoT even in future manufacturing processes. A level or software-based systems, these factories are of human oversight will always be needed, unable to provide engineers with insight into the particularly in situations such as QA/QC that outcome of their designs prior to manufacture. require a secondary pair of eyes and assessment. This human oversight, too, can be improved A smart factory that integrates IIoT devices with the use of connected IIoT devices by giving throughout its operations, on the other hand, can manufacturers overview of the single digital automatically configure, operate, and monitor its thread that runs from the customer to the factory various control systems – from intake to assembly and back again. and dispatch. Tempos’ smart factory, specifically, uses IIoT to automatically connect every person To streamline communications and improve and machine on the factory floor to ensure quality, operations, more manufacturers are looking to delivery, speed, and accuracy. transition to smart factories with a rich network of IIoT devices. Specifically, to best leverage the IIoT devices also add value to the manufacturing value of an IIoT network, manufacturers should process by connecting personnel working on the base their new factories on a software-based factory floor up to senior-level management. approach, which enables them to manage their IIoT-generated data for optimal practices. Besides facilitating transparent communication from customer to smart factory and within the www.tempoautomation.com smart factory itself, a connected IIoT network i40today.com 35

ffaucnts Would Brits embrace working with a robot? By OnBuy.com • Overall, more than half of men and women feel uncomfortable at the thought of working with a robot, both as a colleague or manager. • 17% of British men can imagine forming a friendship with a robot in the future • (3% ‘Definitely will’ & 14% ‘Probably will’). • Unsurprisingly, 77% of women stated they cannot imagine being friends with a robot in the near future (30% ‘Probably won’t’ & 47% ‘Definitely won’t’). The concept of robots living among humans has Understandably, a large majority saw often been explored within the genre of sci-fi. And whilst the idea seems far-fetched, the idea this as a step too far into the future, that robots could become part of everyday life has become a topic of conversation. With the with a staggering 82% of men and influence of TV shows such as Westworld and 93% of women responding ‘No’ to Humans, and movies such as Blade Runner and forming a romantic relationship Her, robot-human relationships has become a with a robot. If you look at the figures concept many have begun to form an opinion on. broken down an overwhelming As A.I continues to advance, the possibility of 66% of men and 83% of women building relationships with robots grows. With stipulated, they ‘Definitely would smart speakers such as Alexa already a central not’; demonstrating their stern component in the homes of many, are robot opinion towards the subject. companions really that hard to imagine? 83% Predictably, overall 68% of men and 77% of women As A.I continues to stated ‘No’ when asked “Can you imagine forming advance, the possibility of women a friendship with a robot in the future?”. When of building relationships broken down, 31% of men and 30% of women stipulated they ‘Definitely claim they ‘Probably won’t’, and 37% of men and with robots grows. would not’ form a romantic 47% of women stating they ‘Definitely won’t’. With smart speakers such as Alexa already relationship with a robot. More interestingly, 17% of men (3% ‘Definitely a central component in will’ & 14% ‘Probably will’) and 10% of women (1% the homes of many, are 33% ‘Definitely will’ & 9% ‘Probably will’) overall said robot companions really of men ‘Yes’, when asked the same question. that hard to imagine? claim they would be Unsurprisingly, OnBuy can reveal that comfortable with overall only 9% of men (2% ‘Definitely a robot colleague. would’ & 7% ‘Probably would’) and 3% of women (1% ‘Definitely would’ & 2% ‘Probably would’) stated ‘Yes’ when asked “Can you imagine forming a romantic relationship with a robot in the future?”. 36 An insight into Industry 4.0 May/June 2019

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And as robots in the workplace become seemingly When asked “How would you feel working with more apparent and growing in popularity, OnBuy a manager that was a robot?”, 20% of men (5% found from their analysis of the results that 33% ‘Very comfortable’& 15% ‘Fairly comfortable’) and of men (7% ‘Very comfortable’& 26% ‘Fairly 12% of women (3% ‘Very comfortable’& 9% ‘Fairly comfortable’) and 22% of women (3% ‘Very comfortable’) felt ‘Comfortable’. comfortable’& 19% ‘Fairly comfortable’) claiming they would be comfortable with a colleague that Predictably, 66% of men and 75% of women felt was a robot. ‘Uncomfortable’ at the thought of a manager that would be a robot rather than a human. However, it seems that the idea of a robotic colleague is still all too much at present, as *The survey was conducted based on a sample more than half of both men and women feel of 2,041 British adults aged 18-55+. The data was uncomfortable at the prospect of working with published 13-14th August 2018. a robot - 54% of men (22% ‘Fairly uncomfortable’ & 32% ‘Very uncomfortable’) and 65% of https://onbuy.com women (23% ‘Fairly uncomfortable’& 42% ‘Very uncomfortable’). Would Brits embrace robots? Male Female Can you imagine forming a friendship with a robot in the future? Yes 17% 10% No 68% 77% Don’t know 15% 13% Can you imagine forming a romantic relationship with a robot in the future? Yes 9% 3% No 82% 93% Don’t know 8% 4% Prefer not to say 1% 1% How would you feel working with a colleague that was a robot? Comfortable 33% 22% Uncomfortable 54% 65% Don’t know 13% 13% How would you feel working with a manager that was a robot? Comfortable 20% 12% Uncomfortable 66% 75% Don’t know 14% 13% 38 An insight into Industry 4.0 May/June 2019

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