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MDA Technologies 2/2016

MDA Technologies 2/2016

Putting people in the

Putting people in the spotlight of Industry 4.0 CONTROL AND MEASUREMENT Dr. Steffen Haack, member of Executive Board for the Business Unit – Industrial Applications and Coordination Sales of the Bosch Rexroth AG With networked automation solutions and digital assistance systems, leading German exhibitors at Hannover Messe 2016 present their solutions for intelligent integration of assembly stations in the versatile production facility. Dr. Steffen Haack, a member of the Executive Board responsible for the Business Unit Industrial Applications and Coordination Sales of the Bosch Rexroth AG is convinced that “Acceptance by associates is a significant factor in the success of Industry 4.0. We have already accumulated comprehensive experience in our respective production facilities in a large number of projects, and have used this knowledge as the basis for developing new system solutions which support both the process and the associates in the integrated factory.”

About Bosch Rexroth Bosch Rexroth is a worldwide leading supplier of hydraulics, electric drives and controls, gear technology, linear motion and assembly technology. With locations in over 80 countries and more than 33,700 associates, the company generated sales revenue of approximately 5.6 billion Euros in 2014. The company has a global expertise in the market segments of Mobile Applications, Machinery Applications and Engineering, and Factory Automation to develop innovative components as well as tailored system solutions and services. High quality process and quality management in assembly and joining processes The software process quality manager – a joint solution by Bosch Rexroth and Bosch Software Innovations – offers support in quality control. Electrical screwing systems, for instance, can be integrated using the system, and the data on individual screwing processes can be detected, analysed, and visualized in real time. This has decisive advantages, especially in the automotive industry. There, thousands of tightening operations that are critical for proper functioning and relevant to safety are completed everyday, not all of which can be personally inspected. Centralized monitoring allows quality assurance specialists to maintain an overview of all screwing processes, and to recognize failures and trends in the production process as early as possible. This lets them act quickly, and reduce reworking and downtimes through proactive measures. Besides monitoring screwing processes, the process quality manager can also be used in other joining processes and can integrate tools from various manufacturers, depending on customer requirements. Digital assistance The modular and the flexible assembly system ‘ActiveAssist’ from Rexroth simplify the assembly of multiple versions. It links realworld assembly working stations with the virtual world of information technology, and leads the associate through the assembly steps using freely configurable sensors and assistants. The assistance system uses RFID to identify the work piece and loads the respective work plan via a connection with the overarching MES or ERP system. Digital assistance systems such as projectors that project work instructions and mark material crates or pick-to-light modules provide the associate with the right information for his job at all times. The language and working depth for these instructions can be adjusted easily on an individual basis, and the workstation can be rearranged according to new specifications in only a short time. This leads to high process reliability while also contributing to a reduced workload. Haack describes the measurable advantages of this as follows: “Systems that can be integrated on a modular basis, such as 3D cameras and ultrasonic sensors, review the work steps and help the worker to take corrective action right away.” This ensures high quality and productivity for the assembly of multiple versions. Active Cockpit: higher productivity through better information This software solution also integrates seamlessly into the Active Cockpit, a new production information system. This interactive web based communications platform detects all relevant data of the production line, updates it in a dynamic manner, and visualizes it clearly in real time, directly on the line. “This link between production and company IT already facilitates integrated assembly under Industry 4.0 conditions. The more transparency this helps us achieve is an important prerequisite for higher productivity in production,” Haack emphasizes. Associates can recognize deviations in production immediately and initiate optimization measures. The availability of all relevant data forms the basis for making appropriate decisions. The Active Cockpit is being used in about 20 plants in the Bosch Group. Modular production lines for the integrated factory The Active Cockpit is integrated into a modular production line at the Hannover Messe. Bosch Rexroth is using five intelligent, integrated stations to show an example of how autonomous production lines can be connected to manual assembly stations. The stations also present how functions of the production network and company IT interact, and how existing machines can be easily connected. Photographs: Bosch Rexroth AG www.boschrexroth.com MDA Technologies 2/2016

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