Industrie 4.0 Readiness-Konzept

INDUSTRIE 4.0-READINESS IN THE UPPER-RHINE REGION A n g e l a J ä g e r | D r. C h r i s t i a n L e r c h | F r a u n h o f e r I S I , Karlsruhe U.R. 4.0 - Action 1.1: Workshop

© Fraunhofer ISI

Readiness I4.0 in the Upper Rhine region Background and aims Study „Readiness I4.0 in Upper-Rhine region“: § description of the state of development towards Industry 4.0 of the Upper-Rhine region

§ tri-national comparison of the « readiness » of firms to the 4.0 technologies in the 3 regions covered by the Upper-Rhine regions (Alsace, Bade, and Basel area)

§ as well as of the distribution of nearly I4.0 technologies among manufacturing firms Analyses based on three data sources § regional extract of the European Manufacturing Survey Switzerland 2018

§ regional extract of the European Manufacturing Survey Germany 2018 § regional survey conducted by CCI Alsace Eurometropole (CCIAE) and BETA (Université of Strasbourg) addressing manufacturing firms in the French Upper-Rhine region 2018 with the following main characteristics:

§ (representative) sub-samples of manufacturing firms with at least 20 employees § covering production characteristics as well as use of technologies © Fraunhofer ISI Seite 2

Data from three parts of one region U p p e r- R h i n e r e g i o n Joint data set § n = 339

German part 4 municipalities and 10 “rural” districts additionally two neighbor districts included (n = 37)

§ representative for each regions § however, not adjusting for the different density of firms, but rather

§ equally representing all three areas Manufacturing firms Swiss part (n = 136)

Germany German part (n = 79)

French part (n = 124)

© Fraunhofer ISI Seite 3

France

Switzerland

French part 2 departments: Bas-Rhin and Haut-Rhine Swiss part 4 cantons: Basel 2x, Aargau, Jura, Solothurn

Three parts of one region Similar industry structure in data Firm size structure very similar § 70% of firms with less than 100 employees

§ 88% of SMEs French part

German part

Swiss part 54% 53% 49%

up to 49 employess

250 to 499 employees

7% 8% 7%

500 or more employees

4% 9% 1% 0%

share of firms

German part

Machinery and transport equipment Metal industry

60%

Data sources: Survey 2018 – extracts of Switzerland, Germany. ©European Fraunhofer Manufacturing ISI Digitization Survey 2018 Upper Rhine area of France.

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Swiss part

6% 3% 6% 11% 14% 14% 17% 11% 10% 19% 19% 14% 16%

Chemical industry (incl. pharma)

Food, beverage and tobacco industry

20% 13% 20%

100 to 249 employees

French part

Electronic and electrical industry

15% 18% 22%

50 to 99 employees

Comparable industrial structure § with some country specific sectoral highlights

23%

Wood, paper, printing industry

5%

33%

10%

15% 11% 9% 10% 9% 6% 9%

Rubber and plastics, nonmetal products Other industrial sectors 0%

Share of firms

40%

Data sources – three parts of one region R e g i o n a l d i ff e r e n c e s i n p r o d u c t i o n Simple products

Medium complexity

French part 10% German part

48%

20%

Swiss part

45%

24%

0%

Made-to-order

42%

§ Mainly small batches / single parts

34%

67%

13%

60%

14%

share of firms

100%

Assembly-to-order 69%

To stock 6%

25%

German part

74%

11%

15%

Swiss part

72%

15%

14%

0%

§ Significant regional differences Batch size

27%

French part

100%

Small or medium batch/lot

20%

Swiss part

25%

share of firms

Single unit production

German part

35%

59%

0%

Product complexity § 1/3 of firms produces complex products, even more in the French part

42%

16%

French part

Complex products

share of firms

100%

Data sources: Survey 2018 – extracts of Switzerland, Germany. ©European Fraunhofer Manufacturing ISI Digitization Survey 2018 Upper Rhine area of France.

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prod. § however, in the French part 1/3 of firms produces in larges batches Mode of production

§ Nearly three quarter of firms produce after customer's order

§ in the French part, production on stock much more prominent

Industry 4.0 in a holistic approach Product / offer perspective

Innovative products

Innovative services

resp.

Smart Products

resp.

Data-driven Services Critical competences

Process / user perspective

Innovative process technology resp.

Smart Factory

Physical

Innovative process organisation resp.

Smart Operations

Virtual/ not-physical

Sources: S. et ŠKinkel, Fraunhofer ISIal. (2005): Innovation: Mehr als Forschung und Entwicklung. In: Industrie-Management 21/3, S. 54-58 Lichtblau, K. et al. (2015): Industrie 4.0-Readiness. Hg.: IW KÜln Consult GmbH und FIR e.V. an der RWTH Aachen Seite 6

Industry 4.0 technology fields Digital production Management

Digital Management Systems

Production system

Near Cyber-PhysicalProduction System (CPS) processes

Product-LifecycleManagement Systems

Digital data exchange with customers and/or suppliers

Software for production planning and scheduling

Automation and management of internal logistics Near real-time production control system

Š Fraunhofer ISI Seite 7

Human-machinecommunication

Wireless humanmachine cooperation Mobile devices for programming and/or operating systems and/or machines

Digital visualization

Defining an index of I4.0-Readiness

Top group

Level 5

CPS-related processes

Level 4

Basic readiness

Basic levels Lower

IT-related processes

No readiness Non(yet) users

Š Fraunhofer ISI Seite 8

Several CPSrelated processes in use

Level 3 Individual or several IT-related processes in use

Level 2 Level 1

Level 0

Traditional processes

Higher

I4.0 similar processes

I4.0 Readiness

No I4.0 enabling technologies in use

Levels of the I4.0-Readiness index

Non-users who do not (yet) display any readiness for I4.0: § Level 0: firms that do not use any of the I4.0 enabling technologies examined and still tend to rely on traditional production processes.

Basic levels, as a foundation for the path to I4.0, with a low degree of readiness:

§ Level 1 (beginners): firms that use IT-related processes in one of the three technology fields.

§ Level 2 (advanced beginners): firms that use IT-related processes in two of the three technology fields.

§ Level 3 (advanced users): firms that are active in all three technology fields and, thus, use both IT-related processes and CPS-related processes.

Top group, as pioneers on the road to I4.0, with slightly higher readiness:

§ Level 4: firms that are active in all three technology fields and use at least two CPSrelated technologies.

§ Level 5: firms that are active in all three technology fields and use at least three CPSrelated technologies.

© Fraunhofer ISI Seite 9

I4.0-readiness profile of manufacturing in Upper-Rhine Only 10 percent of firms do not use any of the analsyed I4.0 technologies

Status of readiness Level 0

9%

Level 1 bis 3

No use (yet) 22%

Level 4 und 5

36%

13%

20 percent with I4.0 readiness 0%

25%

Share50% of firms

75%

Data sources: Survey 2018 – extracts of Switzerland, Germany. ŠEuropean Fraunhofer Manufacturing ISI Digitization Survey 2018 Upper Rhine area of France.

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71 percent of IT near processes 9% 11% 100%

Every fifth firm is using technologies of all three fields and at least two CPS related applications Still a large share of over 50 percent of firms uses only technologies of one or two fields

I4.0-readiness profile of the Upper-Rhine regions - compared by firm size Large differences by firm size remain Level 1

Large firms (250 or more)

14%

Medium sized firms

Level 2

32%

15%

Small firms (< 50 empl.)

Level 4

14%

36%

28%

0%

Level 3

19%

14%

38%

25%

Level 5

50% Share of firms

Data sources: Survey 2018 – extracts of Switzerland, Germany. ©European Fraunhofer Manufacturing ISI Digitization Survey 2018 Upper Rhine area of France.

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13%

22%

17%

12% 5%

75%

Larger firms § all firms use digital technology § over a third are in the top group

5%

100%

Smaller firms § are mainly in using IT related technologies for management and human-machinecommunication

I4.0-readiness profile of manufacturing in Upper-Rhine – selected sectors Basic users Rubber and plastics, non-metal products

Top group 82%

Machinery and transport equipment

75%

Chemical and pharma industry

72%

Food and beverage industry

71%

Electronic and electrical products

70%

Metal industry

64%

Wood, paper, printing industry

57% 0%

12% 16% 28%

17%

Classic discrete part production with the highest share of basic users

Chemical as well as electronic and electrical industry with a large share of basic users and a high shore of top group

30% 24%

Process industry with a quite high share of CPS related process

27%

Share of firms

Data sources: Survey 2018 – extracts of Switzerland, Germany. ©European Fraunhofer Manufacturing ISI Digitization Survey 2018 Upper Rhine area of France.

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100%

Share of firms in Top group (level 4 and 5)

I4.0-readiness depending on production characteristics Product complexity

35% 30% 25% 20%

complex product are fully engaged in digitization

Large batch/lot

§ Producers of simple

Complex products

Medium complexity

products rarely use near CPS technologies

Small or medium batch/lot

15% 10%

§ Producers of

Batch size

Simple products

§ Firms with single unit

Single unit production

5% 0% 65%

68%

71%

74%

77%

Share of basic users (level 1 to 3) average for the region Data sources: Survey 2018 – extracts of Switzerland, Germany. ©European Fraunhofer Manufacturing ISI Digitization Survey 2018 Upper Rhine area of France.

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80%

production are (still) less using near CPS technologies § Large batch production is most engaged in near CPS technology

D i ff e r e n c e s i n u s e o f t e c h n o l o g i e s Management and Human-Machine-Commun. used

Product-LifecycleManagement Systems

French part

Digital production planning and scheduling

18%

German part Swiss part

planned

25%

5%

15% 10%

German part

72%

French part

Mobile devices for French part programming and/or German part operating systems and/or machines

32%

French part

27%

German part

45%

Swiss part

44% 0%

in all three region for standard application Human-machinecommunication § lower shares of users in the French part of the region

17%

31%

§ similar share of users

100%

planned

21%

Swiss part

8%

share of firms

used

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6%

74% 0%

Data sources: data. ISI ©Joint Fraunhofer

7%

80%

Swiss part

Digital visualization

Digital management § LifecycleManagement more often used in the German part

3%

12% 15% 23% 18% 14% share of firms

100%

D i ff e r e n c e s i n u s e o f t e c h n o l o g i e s Near CPS processes used

Digital data exchange with customers and/or suppliers Near real-time production control system

Automation and management of internal logistics

French part

54%

German part

11%

41%

9%

Swiss part

50%

12%

French part

50%

10%

German part

28%

Swiss part

30%

French part

40%

German part

28%

Swiss part

29% 0%

Technologies of near CPS processes § higher shares of users in the French part (partially in the Swiss part) of the region

planned

13% 18%

11% 16% 18% share of firms

Data sources: Survey 2018 – extracts of Switzerland, Germany. ©European Fraunhofer Manufacturing ISI Digitization Survey 2018 Upper Rhine area of France.

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100%

I4.0-readiness profile of the Upper-Rhine r e g i o n s – d i ff e r e n t i a t e d b y r e g i o n s Readiness status of firms in the Upper-Rhine region Level 1 French part

Level 2

Level 3

21%

German part

44%

25%

Swiss part

28% 25%

Level 5 4% 10%

36%

20% 0%

Level 4

17%

19% 50% Share of firms

10% 75%

§ A quarter of French firms is using technologies of all three fields and at least two CPS related applications

15%

7% 7%

11% 100%

Ø regional differences are rather related to differences in production structure than localisation

Data sources: Survey 2018 – extracts of Switzerland, Germany. ©European Fraunhofer Manufacturing ISI Digitization Survey 2018 Upper Rhine area of France.

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§ In the Swiss and French part with a lower share of nonusers

§ Single use of CPS related technologies much more prominent in German and Swiss part of the Upper-Rhine region.

Share of firms in Top group (level 4 and 5)

I4.0-readiness profile of the Upper-Rhine regions – compared to other German regions Upper-Rhine region

35% 30% 25%

§ In comparison to other regions, ..

Upper-Rhine region with higher shares of § top group AND § basic users

German states

French part NRW

20% 15%

Swiss part

BadenWurttemberg

German part Bavaria

10%

§ the Swiss part includes a higher share of non-users

5% 0% 65%

§ In German part of the region, a quite low share of top group

68%

71%

74%

77%

Share of basic users (level 1 to 3)

Data sources: Survey 2018 – extracts of Switzerland, Germany. ©European Fraunhofer Manufacturing ISI Digitization Survey 2018 Upper Rhine area of France.

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80%

Summary § Readiness level of firms strongly depends on firm and production characteristics (especially on firm size, product complexity, batch size)

§ Use of multiple CPS related technologies mainly by larger firms § Digitization is still mainly used to increase automisation (large batches) § Firms of the Upper-Rhine region are using to a higher share digital technologies in production

§ the German part has the highest share of basic users § in the French part, the highest share of top group was detected § Specific for firms from the French part is: § CPS related technologies are used to a higher share § They are less active in simpler application to increase human-machine-communication

© Fraunhofer ISI Seite 18

Kontakt

Thank you for your attention!

Angela Jäger Koordination European Manufacturing Survey (EMS) E-Mail: angela.jaeger@isi.fraunhofer.de Dr. Christian Lerch Leiter Geschäftsfeld Industrielle Innovationsstrategien E-Mail: christian.lerch@isi.fraunhofer.de Tel: +49 721 6809-322 Fraunhofer Institut für System- und Innovationsforschung ISI Breslauer Straße 48 76139 Karlsruhe, Germany www.isi.fraunhofer.de © Fraunhofer ISI Seite 19