Industry 4.0 - On the way to a Smart Factory Dr. Andreas Wittmann Industry 4.0 @ Infineon n Infineon Technologies – Company Overview and Market n Industry 4.0 – On the way to a Smart Factory n Challenges on the way to Industry 4.0 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 2 Industry 4.0 @ Infineon n Infineon Technologies – Company Overview and Market n Industry 4.0 – On the way to a Smart Factory n Challenges on the way to Industry 4.0 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 3 Infineon at a Glance The Company n Infineon provides semiconductor and system solutions, focusing on three central needs of our modern society: Energy Efficiency, Mobility and Security n Revenue in FY 2013: € 3.843 billion n Around 29.000 employees worldwide (as of June 2014) n Strong technology portfolio with more than 18,650 patents and patent applications (as of September 2013) n 21 R&D locations; 12 manufacturing locations n Germany's largest and Europe's second largest semiconductor company 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 4 We Focus on Three Central Needs of Modern Society Energy Efficiency Mobility Security Automotive Industrial Power Control Power Management & Multimarket Chip Card & Security 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 5 Infineon Holds Top Positions in All Major Product Categories Automotive semiconductors Power semiconductors total market in 2013: $25.1bn total market in 2012: $15.0bn Renesas 13.3% Infineon STMicro Freescale NXP 9.6% 7.9% Infineon Toshiba Smart card ICs total market in 2013: $2.48bn 11.8% NXP 7.0% Infineon Mitsubishi 6.5% 21.7% 6.9% STMicro 7.4% 32.3% STMicro 5.6% Fairchild 5.6% Samsung 17.9% 16.5% Automotive semiconductors incl. semiconductor sensors. Discrete power semiconductors and power modules. Microcontroller-based smart card ICs. Source: Strategy Analytics, April 2014. Source: IHS, December 2013. Source: IHS, July 2014. 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 6 Our CO2 Balance: Emission Reduction Enabled by Our Products and Solutions More than 15.8 million tons 1.2 million tons CO2 burden1) Ratio 1:13 CO2 savings2) Net ecological benefit : more than 14.6 million tons of CO2 emission reduction 1) including manufacturing, transport, material, chemistry, emissions, water, waste and waste water, energy consumption; values are based on internal figures as well as official data for one year. 2) considering only automotive products, lighting, PC power supply, regenerative energy production (photovoltaic, wind) and drives, calculation based on average lifetime and Infineon market-share. July 30, 2014 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 7 Industry 4.0 @ Infineon n Infineon Technologies – Company Overview and Market n Industry 4.0 – On the way to a Smart Factory n Challenges on the way to Industry 4.0 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 8 Microelectronics are enablers for Industry 4.0 Brain = Microprocessor Eyes, Ears = Sensors, MEMS Mouth = Communication Components Muscles = Power Semiconductor Immune System = Hardware–based Safety & Security concept Source: Dr. Ploss 2014 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 9 „Smart Factory“ - The Central Element of Industry 4.0 In the Smart Factory people, machines and resources communicate naturally as in a social network. n In a Smart Factory intelligent products are clearly identifiable and locatable at any time. n The Smart Factory links value chain networks in real time. n The Smart Factory manages complexity of intelligent systems, increases efficiency of production and and is also robust against disturbances. 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 10 Industry 4.0 contributes to achieve the following Operational Targets of Manufacturing react quickly to changes because of transparent procedures competitive strength, as efficiency can be increased through integration of production, data and people Enhance Flexibilty innovative business models are developed Shorten Time to Market 2014-09-17 Industry 4.0 Increase Efficiency Copyright © Infineon Technologies AG 2014. All rights reserved. Page 11 One of the most complex production system is a Semiconductor Frontend Fab. Furnace IMPLANT Defect Densitiy ETCH Wet Etching Metrology Lithography PVD / MCVD (Physical Vapor Deposition) Start CMP (Chemical Mechanical Polishing) 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. CVD (Chemical Vapor Deposition) Page 12 Essential Fields of Action to deploy Industry 4.0 into Manufacturing Source: WZL/Frauenhofer IPT Logistics Automation Ergonomics IT Technical Infra HR System Info & IT Security Energy Efficiency Production Planning & Control Quality Management Engineering Maintenance !!no claim to completeness!! 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 13 Verticale Integration Industry 4.0 State of the Art FrontEnd factories realized elements of a „Smart Factory“. Manufacturing Information The most complex production system is a semiconductor FrontEnd in Real fabrication. time Paperless Manufacturing Clearly identified and located Collaborative Human-Maschine Interaction 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 14 The potential of Industry 4.0 is immense – e.g. Energy Efficiency Transformation Ability / Mutability § From Mass Production to Lot size 1 § Fast Product Ramp Up § Time to Market Resilient Factory Robustness § Stable production § Fast adaptation in case of disturbances § Strong defense against hackers Energy Efficiency Resource Efficiency Example from Aachener Werkzeugmaschinenkolloquium 2014 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 15 Potentials with Industry 4.0 for an energy efficient production n A semiconductor manufacturing consumes Production Infineon 100 GWh and more per year 1). n More than 60% of the energy consumption is related to process tools, chillers and supply air fans n This potential can only be developed by having robust and demand oriented steering mechanisms! De-Ionized Water 5% Support 3% Process Tools 35% Supply Air Fans 19% „Subfab“ – Medium supply Exhaust Air Fans 7% Sources: Example from Aachener Werkzeugmaschinenkolloquium 2014 2014-09-17 Liquid Nitrogen Plant 7% Process Cooling Water 4% Chiller 20% 1) EPA. 1997. Proceedings of the Semiconductor Energy Efficiency Opportunities Workshop. San Jose, CA, November 13-14. Washington, DC: U.S. Environmental Protection Agency Copyright © Infineon Technologies AG 2014. All rights reserved. Page 16 Energy Efficiency Potentials through Industry 4.0 Today Industry 4.0 n Robust media supply for challenging process tools and manufacturing processes n Robust and demand oriented media supply for the challenging process tools and manufacturing processes n Limited transparency of energy and media consumption of the single equipment, e.g. pumps are running with constant speed n Only a few machines share the same supply aggregates n Real-time Information of energy consumption for supply aggregates (e.g. chiller) n Retrofitting of existing e.g. chillers with the ad-hoc connectivity capability and demand oriented steering mechanisms n new Services could develop „pay per use“ e.g. cooling 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 17 Industry 4.0 @ Infineon n Infineon Technologies – Company Overview and Market n Industry 4.0 – On the way to a Smart Factory n Challenges on the way to Industry 4.0 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 18 Industry 4.0 offers immense potentials for us, for us as semiconductor supplier and for our factories! However: Several challenges need to be solved to move towards Industry 4.0 Smart Factories need to be stable and beneficial. Know-how needs to be secured successfully. Company 1 Company 2 Tool 1 Security Tool 2 Tool 3 Tool 4 Manufacturing tools are linked together internally and externally. Therefore they need to be protected from manipulation. The Smart Factory needs to be able to control complexity and to be robust against dysfunctions. Deployment of Industry 4.0 will only be successful within collaboration networks: e.g. Politics, Institutions, Research, SMEs 2014-09-17 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 19