when we think about the future we
typically think it will be designed by
people like this I believe the next big
thing will be crafted by people like
that engineers and not just because I am
one of them let me show you what I
believe engineering is going to be the
next big thing and these guys could even
be the new hipsters so machines have
always been great and done amazing thing
for us but we're in the middle of a
revolution machines are becoming
intelligent I'd like to think of
machinery automation a little bit like
our human body we see with our eyes that
sensing we move with our hands and arms
that's actuation and we process with our
brains I mean most of the time that's
process control machines have
classically Blinn only like the
actuation over the past thirty years we
added a lot of sensors and sense into
the machines but still machines are
missing the key thing and that is
intelligence and now the fourth
Industrial ushion will bring that into
life why do we call it fourth first one
was the steam machine second one was
linear assembly systems people think
about Henry Ford's model-t well actually
they were first implemented in the
slaughterhouses of Chicago sorry for no
better news their third is the robots
that entered our factories and forth is
now the combination of physical products
and the intelligence and data all those
elements like autonomous robots additive
manufacturing technologies and big data
analytics they already exist today so
it's starting to happen they are not
full-blown yet and they are not
connected to each other once they are
it'll allow for new ways to produce to
design for companies to operate and it
will also change the way how we work in
the world of labor you might say well
how does this all help us think about
the helicopter stuck somewhere in a
remote place in Africa it's needed in a
food delivery mission the next mechanic
is some 17 flight hours away we want to
have the chopper back in the air within
two hours it's as possible with industry
4.0
we freaked out in seven minutes let's
first look at production and let's look
at the product we all like food and
beverage that's a six hundred billion
dollar industry constantly innovating in
order to catch our attention now I grew
up in the Black Forest so I love natural
food and I spent most most days outside
and on top of the three meals provided
in our home I needed some extra calories
so I used to have those yogurts 500
milliliter a glass they came in four
flavors on a very good day I would have
all four of them today the very same
product from the very same company comes
in 96 variants now that's even for me a
challenge if you look at the machinery
that's behind that that's some
fascinating piece of equipment that is
able to fill some twenty four thousands
of those yogurts per hour but in essence
it is done it will do exactly how it was
set up so if we want to fill hazelnut
yogurt and we have a chocolate packaging
and chocolate label around that the
machine will do exactly that and you
will have hazelnut yogurt that looks
from the outside like chocolate or
24,000 of them per hour now in the best
case and this area is detected before
the product leaves the factory it will
create a quality cost something that
that industry very nicely called product
loss it makes up to 8% of the value in
food production or some 15 billion
dollars annually in the worst case and
this error is not detected it may send a
not allergic consumer straight from
supermarket to emergency room well why
does this happen
the machine is fast and it can sense but
there is no real connection between the
two and this would be different in the
area of 4.0 each physical product
whether it's the yogurt the container or
the label will have what we call the
digital twin that's their surrogate in
the software world here it is where the
machine will detect that nut and
chocolate is a mismatch and will stop
that process automatically now yogurt is
just one example in food and beverage is
just one industry and this machine to
machine a machine two-part communication
is just one application
the multitude of such application
throughout all industries and normally
in engineering we fight very hard to
improve an annual improvement of one to
two percentage points here we have the
opportunity to make production 30%
faster and 25% cheaper that's a true
leapfrog so great for production or
fascinates me even more is the fact that
you can basically reinvade companies
this is a harbor crane it's hand its
actuation is a motor that's a beautiful
piece of equipment that lifts a
container as easily as you lift a pencil
a company I work with let's call them
motors and more manufacturers these
brilliant equipment sells them to harbor
operators for something like five
thousand euros apiece now with a new
technology we added sensors to those
motors and we built a software model so
basically the idea is the motor can
sense and it can sense the real weight
in real time of the container as we lift
it as opposed to the weight that it's in
the paperwork and that might be just a
little bit different so basically while
lifting the container it sends that data
to a software model which then builds a
3d model of the ship again that's the
digital twin of that ship and it will
tell the motor exactly where to place
the next container in order to optimize
the weight balancing of the ship and
with an optimized weight balancing that
ship can save up to $1,000 a day on fuel
that is some five to eight percent gain
and fuel efficiency adjust by optimizing
the shuffling of the container I think
that's quite a big impact just for a
reshuffling of it while bringing that
technology to into the market we had an
idea what if instead of selling that
motor as an equipment which charged a
couple of send for each weighing and
trimming movement that we did so the
harbor would only pay if the crane is on
duty and four motors and more it would
mean that by charging a couple of cents
but a lot of them per year they could
make up as much at one thousand euros
per year definitely a much more
profitable business model than the one
we saw before so for companies that know
how to adjust to this digital world
that's great news but you might say
great reproduction great for companies
what about us what about human Labor's
are we just sitting there and watching
as we lose our job to those smart
machines and the simple answer to that
is yes there's certain mechanical work
that will not be needed anymore think
about moving stuff in a factory checking
I'll be filling hazelnut in a chocolate
container that is not needed anymore
machines will do that automatically if
you look at an economy like Germany over
the next ten years that means some
600,000 jobs will be gone but there's
more to that with new technology new
business models and newer tasks emerge
think about motors and more they will
need a lot of software programmers data
analysts and 3d models that will result
in a gain of about 1 million new jobs in
an economy like Germany so net we have a
gain of 400,000 jobs so you might say
wait a second that might be interesting
for the economy but what if I didn't go
to school and learn the right things the
software modeling the likes will I be
out of a job again I have a different
view on that today
your employer looks a lot at your
education and your years of experience
but we can change that with technology
think back about that helicopter stuck
in Africa and remote place and think
about what if you had an argumentative
glass on your head connected to a
central computer that would know
everything and every detail about that
machine you could basically perform the
repair action that necessary because it
would tell you again as an overlay of
the real world that's again the digital
twin where to place your tools which
parts to repair and you could suddenly
fix a helicopter as easy as a picture
book I sometimes think of it as if my
grandma used to be a farmer could
suddenly fix a helicopter even if the
first time she touches one so overall
I'm really excited about this new
opportunity in this new world of
connected machinery and industry 4.0
machines will not be able to do the work
on their own interaction with humans
will remain a critical success factor
some of the low-skilled jobs that might
disappear they will be replaced by new
skilled jobs yet there is no firm answer
yet on how this transition will to be is
to be managed however when I look back
at the engineering friends we saw at the
beginning I am sure that their curiosity
and decorative 'ti would lead us to new
and better ways to master our business
and personal lives
thank you