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FI Best Practice Conference 2017-에너지 관리 최적화 시스템 및 산업자동화 솔루션의 활용
WAGO KOREA김동훈 과장
THE INDIVIDUAL CUSTOMER NEEDS
INCREASE
19722017
Industrial Revolution
Industrial Revolution
Industrial Revolution
Industrial Revolution
Global activities of IIoT / Industry 4.0 / Made in China 2025
Industry 4.0 / IIoT / Made in China 2025
= Digitalization = Smart Factory
Requirements of a Smart Factory
The future success of manufacturing and commercial
ventures will be dependent of:
▪ efficient adaptability
▪ a high degree of cross-linking, from raw material
to production resources and the product itself up
to the end customer
▪ Lot size 1 without a significant increase of the
production costs
▪ a networked and modular production
▪ A transparent value chain, starting with the raw
material and ending by the end customer
Attributes of Digitalization in a Smart Factory
Sensors/
actors in all
levels down
to the
product and
into the
product
Horizontal
Connection
Higher
flexibility
through
a modular
production
with modular
automation
Vertical
ConnectionMaximum IT
Security
WAGO inside the Smart Factory
Sensor-
integration
Horizontal
Connection
Higher
flexibility
through
a modular
production
with modular
automation
Vertical
ConnectionMaximum IT
Security
DIMA(Software
methodology for
the effective
adaptation of
production
modules)
Cloud
Solution (MQTT Connection
to MS Azure, IBM,
AWS)
>400 750 I/O
Modules (Log data, collect,
summarize)
Software-supported,
horizontally networked
rail production
according to customer
requirements
IT Security by
Design (secure data transfer via
build-in security. LINUX, VPN,
HTTPS)
Requirements of a Smart Factory
Higher
flexibility
through
a modular
production
with modular
automation
Sensors/
actors in all
levels down
to the
product and
into the
product
Horizontal
Connection
Vertical
ConnectionMaximum IT
Security
Sensor Integration with
efficient, scalable and
modular I/O System
WAGO 750
The ideal Signal Integration: WAGO 750 I/O System
Maximum Return on Investment
Open, fieldbus-independent design optimizes
investments
Minimal Life-Cycle Costs
Simple operation minimizes planning,
commissioning and maintenance costs
Streamlined design significantly reduces handling
errors
Easy-to-install components eliminate unnecessary
(and often costly) accessories and manufacturer-
specific configuration tools
Best Price/Performance Ratio
Fine-granular I/O modules enable customization of
nodes
Space-saving design permits high packing density
and direct connection
Maximum Reliability
Industry-leading quality and reliability for a wide
variety of applications – all WAGO components
adhere to the highest standards for environmental
exposure (e.g., climate, vibration and shock loading,
EMC and emitted interference).
The ideal Fieldbus System
Universal, Compact and Economical – The Ideal Fieldbus Node
Fieldbus-
Independent
Automatic
Connection
Pluggable
Connections
Scalable
Control Solutions
Compact Size Maximum
Flexibility
Clear
IdentificationSecure and Reliable
Connections
Simple Handling
Fieldbus-
Independent
Universal, Compact and Economical – The Ideal Fieldbus Node
Automatic
Connection
Pluggable
Connections
Scalable
Control Solutions
Compact Size Maximum
Flexibility
Clear
IdentificationSecure and Reliable
Connections
Simple Handling
The system’s modularity is
reflected in its support of
numerous fieldbus systems
IEC 60870-5
IEC 61850
IEC 61400-25
I/O modules offer built-in
power contacts for potential
distribution and data contacts
for internal data transmission –
no chassis or jumpers
required.
Universal, Compact and Economical – The Ideal Fieldbus Node
Fieldbus-
Independent
Automatic
Connection
Pluggable
Connections
Scalable
Control Solutions
Compact Size Maximum
Flexibility
Clear
IdentificationSecure and Reliable
Connections
Simple Handling
Universal, Compact and Economical – The Ideal Fieldbus Node
Automatic
Connection
Pluggable
Connections
Scalable
Control Solutions
Compact Size Maximum
Flexibility
Clear
IdentificationSecure and Reliable
Connections
Module functionality is
identified via integrated and
pluggable marker carriers.
Connector assignment
and technical data are
located on the side of the
module.
The WAGO WSB marker
system also allows for module-
and channel-related
identification.
Simple Handling
Fieldbus-
Independent
Universal, Compact and Economical – The Ideal Fieldbus Node
Automatic
Connection
Pluggable
Connections
Clear
Identification
Scalable
Control Solutions
Compact Size Maximum
Flexibility
Secure and Reliable
Connections
Simple Handling
For convenient, in-the-field
wiring, the 753 Series
pluggable connectors are
100% compatible with 750
Series modules. Pre-harness
I/O connections permit plug-
and-play
wiring. This virtually eliminates
handling errors and saves time
– if needed, this can be
executed via place holder
modules.
Fieldbus-
Independent
Simple Handling
Universal, Compact and Economical – The Ideal Fieldbus Node
Automatic
Connection
Secure and Reliable
Connections
Pluggable
Connections
Clear
Identification
Scalable
Control Solutions
Compact Size Maximum
Flexibility
WAGO Spring Pressure
Connection Technology
guarantees continuous
operation, even under extreme
environmental conditions, such
as
thermal cycling, shock,
vibration, and electrostatic
discharge (ESD).
Fieldbus-
Independent
Universal, Compact and Economical – The Ideal Fieldbus Node
Automatic
Connection
Secure and Reliable
Connections
Pluggable
Connections
Clear
Identification
Scalable
Control Solutions
Compact Size Maximum
Flexibility
Simple Handling
The modular, DIN-rail mount
design allows for easy
installation, expansion, and
modification of the I/O node.
Other mechanical features
prevent potential distribution to
the wrong module and allow
tool-free removal of a single
module from the I/O node. In
addition, proven CAGE-
CLAMP® technology offers
fast, vibration-proof and
maintenance-free connections
that are
independent of operator skill.
Depending on the I/O module’s
granularity, the field
peripherals can be wired
directly using 1-, 2-, 3- or 4-
wire technology.
Fieldbus-
Independent
Universal, Compact and Economical – The Ideal Fieldbus Node
Automatic
Connection
Secure and Reliable
Connections
Pluggable
Connections
Clear
Identification
Scalable
Control Solutions
Compact Size Maximum
Flexibility
Simple Handling
Each node in the WAGO-I/O-
SYSTEM can be configured to
meet each channel’s
requirements, and various
potentials and
signal forms are available
(granularity of 1 to 8
channels). Digital and analog
I/O modules, as well as
specialty modules can be
freely mixed in the same node.
Supply modules allow different
voltages (e.g., 24V, 120 V, 230
V) in the same I/O node.
Fieldbus-
Independent
Universal, Compact and Economical – The Ideal Fieldbus Node
Automatic
Connection
Secure and Reliable
Connections
Pluggable
Connections
Clear
Identification
Scalable
Control Solutions
Compact Size Maximum
Flexibility
Simple Handling
Our patented mechanical
design allows for extremely
compact I/O nodes.
I/O modules can
accommodate up to 16
channels in a 12 mm (1/2”)
wide housing.
Fieldbus-
Independent
Universal, Compact and Economical – The Ideal Fieldbus Node
Fieldbus-
Independent
Automatic
Connection
Secure and Reliable
Connections
Pluggable
Connections
Clear
Identification
Scalable
Control Solutions
Compact Size Maximum
Flexibility
Simple Handling
Interfaces for any size and type of automation task –
from distributed I/O nodes or stand-alone control to global networks.
Fieldbus couplers
Standard for high I/O counts
and economy for highly distributed applications
Programmable fieldbus controllers
For stand-alone, distributed, or master control
PFC200 Controllers
High processing speed
multiple communication interfaces, scalable power
WAGO-I/O-PRO Software
Configuration, programming and visualization
IEC 61131-3-compliant (CODESYS) software package
500+ individual function modules are available
in 1-, 2-, 4-, 8- and 16-channel configurations
Digital Inputs
• 1, 2, 4, 8, 16
channels
• 5VDC to 230VAC
• Pulse extension
• Intruder detection
• Diagnostics
• NAMUR
• PROFIsafe
• Ex i
Digital Outputs
• 1, 2, 4, 8, 16
channels
• 5VDC to 230VAC
• Max. 16A
• Optocouplers, SSR,
Relays
• Diagnostics
• PROFIsafe
• Ex i
Analog Inputs
• 1, 2, 4, channels
• 12-16-bit resolution
• Diagnostics
• Current, voltage,
resistance,
thermocouples,
• strain gauge
• 3-phase power
measurement
• HART
• Ex i
Analog Outputs
• 2, 4 channels
• Current, voltage
• Ex i
Specialty Functions• Counter
• SSI transmitter interface
• Incremental encoder interface
• Serial interface
• RTC
• Radio modules (Bluetooth® ,
EnOcean)
• Subsystems (KNX, DALI, MP-
Bus, LON® ,
• CAN, AS-Interface, IO-Link, M-
Bus, SMI)
• Vibration monitoring
• Motion control
• PROFIsafe
• Ex i
• 0-250V AC/DC supply
Requirements of a Smart Factory
Higher
flexibility
through
a modular
production
with modular
automation
Sensors/
actors in all
levels down
to the
product and
into the
product
Horicontal
Connection
Vertical
ConnectionMaximum IT
Security
Higher flexibility due to
modular production
facilities
DIMA
A flexible production
needs modularity and a
high degree of cross-
linking up to the final
product
The product communicates with
the production island
The production island exchanges
information about the production
status
The production island informs
the MES, the MES informs the
distributor
Flexible Production needs Modularity
1 2 3 4 5
Service - orientated architecture
Production Control
Vorlage Reaktor Filter Abfüller
DIMA Technology
Basic principle of the DIMA
Versatile production plants
… are constructed modulary, …
… the automation not.
Basic principle of the DIMA
Versatile production plants should consist of modules with seperate,
decentralised automation. This is essential for an efficient and fast changing
production plant.
Basic principle of DIMA
Versatile production plants need
modular Engineering
• One module fullfills one production function
• The production process is formed through the
combination of different pre-assembled modules (in
series or parallel)
• The modules are couple to a Backbone.
Challenge
➢ The dynamic coupling- and decoupling of the
production modules has to be to mapped identically
into the production process and into mechatronic,
process engineering as well as into the automation.
➢ The engineering of the automation has to enable
the modules‘ coupling- and decoupling without
programming.Template Reactor Filter Bottler
Backbone
NCO2
Production control
Vorlage Reaktor Filter Abfüller
Basic principle of DIMA
The production control has to
discover the moduls function/s
The skill description has to:
• describe the services of the module to make them
retrievable,
• include the information to the module‘s visual
representation,
• enable the communication between the module and
the process control,
• provide the documentation of the module,
• contain equipment information to the
parameterization of important field devices
skill
description
Reactor
Production control
Basic principle of the DIMA
The MTP – Module Type Package –
contains the the description of the
capabilities of the module.
Content of MTP:
• The description of the offered service and their
parameters
• Description of the visual image of the module in the
process management
• Information to start communication immediately
between the process management and to the
module
➢ The module becomes a service provider
➢ The orchestration of the various module services
takes place in the software-tool of the process
management
➢ The execution of the service is driven by the logic of
the module Reactor
Production control
MTPskill
description
Basic principle of the DIMA
Modul 3
Modul 2
DIMA Workflow
Automatically
generated
MTP
MTPMTP
1. step:
module-engineering
Compile &
Load
2. step:
integration-engineering
integration of the
module into the
backbone
Backbone
NCO2
ModuleModule 1 Module 3Module 2
MTP
Automatically
generated
AbrufenMTP
PFEBasic principle of DIMA
DIMA is based on OPC UA
Factory
floor
PLC
SCADA
HMI
MES
ERPCloud• OPC UA will be the
upcoming standard for
factory and process
automation
• Based on TCP/IP
• Controller independent
• Consistent
communication between
different levels like
Control, HMI, MES,
Cloud, etc.
• Communication
standard for Industry 4.0
DIMA in the context of Industry 4.0
• encapsulation in Layer-Model
• Linking of manufacturer and user in
one value chain
• Observing different life cycles of a
production network
• Focussing on Functional aspects of
a production system
• IEC 61512
• OPC-UA
• AutomationML
DIMA: An essantial brick as a solution of the requirements of INDUSTRY 4.0
Industry 4.0
DIMA
Manifest
Resource-Manager
• MTP-declaration contains the data and the
information of the virtual and technical
representation of its physícal device
• Through the modeling of the MTP on the actual
module-control, the „Ressource-Manager“ can be
realized
• Modeling the MTP in the information model of the
OPC-UA-Server of the module control
➢ MTPs are the foundation of Industry 4.0-
administrative shell - hereby the module becomes
an Industry 4.0 component
➢ CP-classification = 44
(Entity, totally able to communicate)
The MTP as a
Management bowl
reactor
PFE
MTPMTP
DIMA in the context of
Industry 4.0
▪ The DIMA methodology enables the integration of the production module into the production
management within a significant short time frame
▪ I/O signals do not have to be programmed in the master computer of the production for each
signal
▪ The communication happens through the unified service invocation from the command level
▪ The services will be communicated to the master computer through the MTP (Module Type
Package)
▪ The visualization of a module will be generated by the master computer of the production
through the information provided by the MTP
▪ The simple selection function within e!COCKPIT enables the activation and the deactivation of
functions(services) of the programmed module
▪ The creation of the MTP happens at the push of a button and will be exporteded out of
e!COCKPIT
Benefits of DIMA
DCS-Manufacturer Sensor / Actuator UserDecentralised
AutomationUniversities
ABB
Emerson
HIMA Safety
Honeywell
Rockwell Automation
Schneider Electric
Siemens
Yokogawa
Endress + Hauser
Festo
Krohne
Samson
BASF
Bayer
Bilfinger
Boehringer Ingelheim
Clariant
Evonik
Invite
Merck
Novartis
Sanofi
Spiratec
Helmut-Schmidt-
University Hamburg
RWTH Aachen
Technical University
Dresden
Pepperl + Fuchs
Phoenix Contact
Stahl
Wago
DIMA – Involved Companies
Requirements of a Smart Factory
Higher
flexibility
through
a modular
production
with modular
automation
Sensors/
actors in all
levels down
to the
product and
into the
product
Horicontal
Connection
Vertical
ConnectionMaximum IT
Security
Efficient Energy
Management for the Cost
Saving
EDMS
Energy (Data) Management
Within the framework of an energy review, all energy sources, energy consumption and
influencing factors must be analyzed on the basis of measurements and other data.DIN EN ISO 50001, Sect. 4.4.3, Energy Review
REQUIREMENTS FOR ENERGY DATA MANAGEMENT
Energy (Data) Management
At least 90 % of total energy consumption
can be attributed to the company's systems and equipment.See also, bulletin for energy audits according to legal provisions set forth in Section 8 ff. EDL-G /Bafa
REQUIREMENTS FOR ENERGY DATA MANAGEMENT
Energy (Data) Management
DIFFERENT APPLICATIONS
VARIOUS INTERFACES
For sensors of different signal types
FOR DIFFERENT FORMS OF ENERGY
water / electricity / gas / heat
Energy (Data) Management
DIFFERENT APPLICATIONS
-BUILDING
Energy (Data) Management
DIFFERENT APPLICATIONS
-INDUSTRY
WAGO – Energy Data Management
Solution Concept
THE MOST VARYING INTERFACES
Sensors with the most varying types of signals
DIFFERENT FORMS OF ENERGY
Water/Electricity/Gas/Heat
Energy (Data) Management
EFFICIENCY
ENERGY
REQUIREMENT
PRODUCTION DATA/
INFLUENCING FACTORS
Data – Basis for efficiency
MODULAR DATA ACQUISITION
WAGO – Energy Data Management
Your benefits at a glance
Flexible data acquisition, without any experience required
Easy commissioning without any programming
Linking and parameterization of different input signals: Pulse signalsAnalog signals 3-phase power measurementM-bus / EnOcean
Variable connection of M-bus counters for different media: Electrical energyWater Heat
15 min. load curve analysis in synch with energy provider
Modular expansion possible at any time
Data logging on an SD card in csv format
Data provision via FTP-S or MODBUS
Energy (Data) Management
E-Power GAS WATERHEAT
S0-Interface
Tra
nspare
ncy
WAGO – Energy Data Management
• Our Answer to the Challenge of the Target Customer
➢ Modular data acquisition for the visualization of energy and
process data in an easy way
• The WAGO Solution in Detail
Record different signals and data via the WAGO-I/O-SYSTEM
Automatic detection of the connected I/O modules
Commissioning without any programming
Easy to use configuration user interfaces
Easy checking of data availability during commissioning using the
data plotter
Various options for collecting and forwarding data
How can WAGO help you to tackle these challenges?
Energy (Data) Management
Controller: 750-8202/000-022 (PFC200)
AI: 1x 750-452 2 channel analog input; 0-20 mA; differential input
2x 750-496 8 channel analog input; 0-20 mA; 4-20 mA
2x 750-497 8 channel analog input; 0-10 V; +- 10 V
2x 750-451 8 channel analog input; resistance measurement
DI: 4x 750-638 2 Up/ Down Counter DC 24 V / 500 Hz
1x 750-402 4 channel digital input
3-PPM: 750-495 3-phase power measurement; 1 A
18x 750-495 /- 001 3-phase power measurement; 5 A
750-495 /- 002 3-phase power measurement; Rogowski coils
Serial: 2x 750-652 serial interface; RS 232 / 485 for M-Bus / EnOcean
WAGO – Energy Data Management
Solution Concept
Software
WAGO Energy Data Management
Select the I/O hardware
and sensors
Download the software
from www.wago.com
to the application controller
Install the hardware
WAGO – Energy Data Management
Solution Concept
Link to an
analysis tool
If required:
Other I/O modules can be added
Commissioning
Parameterizing the inputs
Energy (Data) Management
Measuring
Converting
Evaluating
VisualizingParametrization
CLOUD
Always and everywhere - all relevant data available!
Cloud
CLOUD
IBM BLUEMIX
MQTT MQTT
Microsoft Azure
CLOUD - Security
Internet Demilitarized zone Intranet
Router 1
Firewall 1
Router 2
Firewall 2
Controller with
internet access
Establish a demilitarized zone (DMZ)
Cloud
TLS 1.2
TLS 1.2 encrypted communication
MQTT
CLOUD - Security
Encrypted communication
Energy and process management for cardboard´s
End User: Klingele Papierfabrik, Werne , Germany
Industry Sector: Paper manufacturer industry
Task
• Continuously record all relevant building and
production data
• Evaluation of the recorded measurement data and
• meaningful visualization
• Reducing energy costs and increase product quality
WAGO Products in Use
• WAGO Ethernet Controller PFC 200
• WAGO 3-Phase Power Measurement 750-495
• WAGO in-/ output modules for digital und
analog signals series 750
• WAGO Industrial-Managed-Switch Series 852
Solution
• Modular data acquisition system I/O 750
• Integration of various signal types of process
and energy data
• Easy software connection via flexible fieldbus
structure
• Measurement of the electrical machine
consumption by the I / O system
Requirements of a Smart Factory
Higher
flexibility
through
a modular
production
with modular
automation
Sensors/
actors in all
levels down
to the
product and
into the
product
Horicontal
Connection
Vertical
ConnectionMaximum IT
Security
Vertical communication
with open fieldbus
controller
WAGO 750
Vertical communication to control the production floor
Task:
• Feeding SAP productive
system with energy data from
all parts of the factory
Solution:
• WAGO PFC
• 3ph energy measurement
• Ethernet connection
Products in use:
• 750-8100
• 750-494 / 495
• e!Cockpit
Linking Energy Data to SAP
Company details:
- Adr.Nr.: 7320422
- City: Ulm
- Responsible Sales: L. Karl
- Systemengineer: F. Mueller
- Why WAGO? Good experience from
private home application ;-)
Linking Energy Data to SAP
Application / further information / system details:
1st step: PFC was linked with Modbus TCP
2nd step: SAP driver for OPC UA in pilot phase
Customer Röhm packing: 50 to 100 nodes planned
Ethernet
Vertical communication to control the production floor
Central Energy Consumption Control
of FORD production facilities worldwide
Task:
• Security with SSL/TLS
• User Administatration
• Use of Ford LDAP Servers
Solution:
• Use of OpenLDAP Package
Products in use:
• PFC 200
Central Energy Consumption Control
of FORD production facilities worldwide
Requirements of a Smart Factory
Higher
flexibility
through
a modular
production
with modular
automation
Sensors/
actors in all
levels down
to the
product and
into the
product
Horicontal
Connection
Vertical
ConnectionMaximum IT
Security
Horizontal Connection
in the production line
WAGO 750
Porsche SE
Task:
• Contact to conveyer
• Reading production code
• Advice to camera
Solution:
• WAGO I/O-System
• WagoLibDB.lib
• WagoLibMSSQL_03.lib
Products in use:
• 750-881
• 750-400
• 750-501
• 787-1122
• 788-354
Requirements of a Smart Factory
Higher
flexibility
through
a modular
production
with modular
automation
Sensors/
actors in all
levels down
to the
product and
into the
product
Horicontal
Connection
Vertical
ConnectionMaximum IT
Security
Security by Design
IT Security and Safety
Functional Safety
„Protect Human against Maschine“
IT Security
The goals are different!
• Goals
• Risks
• Systemically
• Technologies
• By Design
• Example
IT Security: GoalsWhat goals does IT Security have?
The CIAA
Data Confidentiality
Data Authentication
Data Integrity
Data Availability
Denial of action to reduce the availability of resources e.g. networks to communicate
Unauthorized Modification or Theft of Information
Denial of Service (DoS) or Prevention of Authorized
Access
Unauthorized Access to Information
IT Security: Goals
What goals does IT Security have?
The CIAA
Data Confidentiality
Data Authentication
Data Integrity
Data Availability
➢ Information is transmitted over channels. Therefore, measures are taken to protect these channels.
➢Other sensible assets are the automation system and the operator stations. They have to be protected likewise against misuse.
IT Security: higher Relevance
• Access to automation network
from the office network for
analysis and logistic control
• Lower availability leads to
profit losses
• Maintenance and service
complicated for on board
staff remote support
• Implementation of
preventive maintenance
schemes
• Remote service and diagnosis
of wide-spread installations
decrease personnel costs
• Legal requirements for
documentation of emissions,
consumptions
Systematically IT-Security
Identify assets Analyze threats
Analyze and
evaluate risks
Select protective
measures
Process auditIdentify relevant
safety targets
Demonstrate measures and
evaluate effectiveness
Implement
protective measures
Process
documentation
Start(analysis)
Source: [VDI2182A]
IT-Security: Solving strategies
Layer Effect
Permissions Knowledge only when needed
Employee Raise awareness and define rules of
conduct (USB-Stick)
NetworkImplement a network segmentation
with access controls and protocols
Network
boundaries
Use of restrictive firewalls and rule-
based defense systems (white
listening,…)
Tech
no
log
ies a
nd
Se
rvic
es
Ma
na
ge
me
nt
It-Security: Technologies and ServicesT
ec
hn
olo
gie
s a
nd
Se
rvic
es
Ma
na
ge
me
nt
Corporate Security Policy and Management
Security Policy
and Standards
Certificate and Key
Management
During Attack Coping
and Post-Attack
Recovery
Security checks, Monitoring,
Change Control and Updating
Security Risk Assessment of
Assets
Security Compliance
Reporting
Security and Vulnerability
ReportingSecurity Attack Litigation
Go
al
Th
reats
Unauthorized Access to
Information
Denial of Service (DoS) or
Prevention of Authorized Access
Non-Authorized Modification or
Theft of InformationDenial of Action that took place or Claim of
action that did not take place, Accountability
Confidentiality Data Authentication Integrity Data Availability
Symmetric und Asymmetric Encryption (AES)
Backup and RecoveryNetwork & System
Management
Firewall with Access Control Lists (ACL)
Antivirus / Antispy
Logging Intrusion Detection Sys
Virtual Private Network (VPN)
Transport Level Security (TLS)
WPA2 for wirelessAGA12-1 „bump-in-the-
wire“Digital Signatures CRC
Identity Management
Public Key
Infrastructure (PKI)
IEC 62351 for DNP, IEC 61850
Password Certificates Bandwidth Control
Credential
Management
Authentication of Role-Based Access Control (RBAC)
IT Security WAGO
Security-Services
• Password authentication and User
management
• SSL/TLS 1.2 Encryption
• SSH – Secure Shell-Access
• VPN (OpenVPN, IPSec)
• Firewall
• MAC-Whitelist
Integrated Linux-Services
• Syslog
• SD-Card reader
• FTPs, SFTP, SCP
• optional: Rsync
• optional: Virenscanner
• optional: Fail2BanPaying attention to Security Mechanism by designing the FW-software regarding also the value chain?
>Security By Design<
Industry 4.0 – Smart Factory