Transcript 슬라이드 1 - Intelligent Manufacturing Systems
Manufacturing Technology Platform(MTP) Meeting Zurich, Switzerland
SaaS-Based MES/MOM using Wireless Sensor Network
Monday, 27 April 2009 S. K. Cha, Cofounder & Strategic planning ACS Co., Ltd. [email protected]
MES: Manufacturing Execution System MOM: Manufacturing Operation Management
Agenda I. Who is ACS ?
II. Needs and issues for Mfg. IT III.Core Technologies and features IV. Summary
I. Who is ACS?
Established in August 30, 1988 (20
th
anniversary)
Located in Seoul, Korea – Manufacturing contry (45.2% of GDP in 2006) Concentrating manufacturing software solution – u-Manufacturing (
u
Mfg® & Dab
o
m®-Visualzier) Visulizer has successfully completed in HMC, POSCO including more than 520 project Announced iVisualizer & iTPM for SME in FY2002 and currently more than 120 references ACS solution at Romania, Poland, Slovakia, Singapore, Thailand, China & Japan
ACS Facts
Capital : USD 1.4 Million Annual revenue: USD 13M(2007), USD 15M(2008) No of employees : 62 R&D: 5.2% of Revenue in 2008
Main Business
Consulting services for Manufacturing IT Visualizer – MES/MOM for global manufacturing iVisualizer – MES/MOM for SMEs iTPM – EAM for SMEs iDCU – M2M solutions Solutions Series
Manufacturing Processes
Core Technology
u-Mfg® middleware (iVisualizer) - (NeT, NeP, World Class Product, ES-ISO12119 certification) Lean Mfg. - 4 Zero (Waiting time, Inventory, Defects & Down-time) approach - (Patent No: 10-0545737) IT: Internet, mobile, RFID/USN, SOA with Web Services application - (Patents No:10-0695533 & 10-0788009) 4M Auto-Configuration® - (Patents No:10-2008-0084699) 3
ACS solution in Auto & Steel industries
I. Who is ACS?
Hyundai Motor Co.
-
More than 150 project has been completed
-
Strong in MES for engine application
-
Good reference for ALC (Assembly Line Control) system POSCO
-
Real time communication & large scale system
-
Approach an emerging new technology (Open UNIX System replaced from Special designed process computer )
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II. Needs & issues for Mfg. IT
Changing the Mfg. & IT environment
- Rapidly expanding global logistics and production requirements - Hard to managing multiple plant in worldwide - Increasing needed central managing high capital intensive production equipment - Increasing ICT maintenanace load and development risks - Emerging Manufacturing 2.0 solution for global coodination Manufacturing SOA: Operations process management, User-centric interface, Mobile and wireless sensor Source: u-Mfg Lab at POSTech 5 Source: AMR Research
II. Needs & issues for Mfg. IT
4M Integration in real time
- Mfg. Enterprises needed integration of 4M (Man, Machine, Material & Method) in real time for 4 Zero (Zero Waiting time, Inventory, Defect, Down time) approach as lean manufacturing - You cannot manage what you cannot measure – RTE (Real Time Enterprise)
change
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II. Needs & issues for Mfg. IT
Major issues for develoment of u-Manufactuirng
- Fusion of multiple technologies are key for successfully implementation and generation of new business opportunity
Automated Machines Technology Real-time interface Data base SOA, Web service Network (e-Biz , Web2.0) Ubiquitous Technology RFID/USN Manufacturing 2.0
u-Manufacturing solutions
Machine Center (CNC) Material logistic system Robot Machine Vision FMS Stack crane Information Technology Lean Manufacturing 6 Sigma, TQM 5S, TPM, OEE JIT, TPS SCM, APS Consulting Technology
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Production Technology
The wireless technogy
▶ “
CBM Is the Next Killer App For Wireless” – Dr. Jay Lee, Fortune Magazine, July 2002
- The Economist, 2008: A 14-page special report on the coming wirless revolution - Intech magazine, 2009: Wireless is most adopt over the next five years.
- Design Integration: expanding broad application area focused on low cost
II. Needs & issues for Mfg. IT
Real time device integration Design Interation External Devices Board Level • M2M (Machine to Machine) Devices Embedded Level Chip Level 8
II. Needs & issues for Mfg. IT
SaaS model Software as a Service
(
SaaS
, typically pronounced 'sass') is a model of software deployment whereby a provider licenses an application to customers for use as a service on demand. SaaS software vendors may host the application on their own web-servers or download the application to the consumer device, disabling it after use or after the on-demand contract expires. The on-demand function may be handled internally to share licenses within a firm or by a third-party application service provider (ASP) sharing licenses between firms.
Ad-hoc/Custom (ASP Model) Configurable (Single intant, option) IT Trend Source: Salesforce.com
Configurable Multi-tenant (metadata, security, authorization) Configurable Multi-tenant scalable (N:M connection) SaaS Level Source: Gartner Group 9
u-Manufacturing Model for SaaS model
• Multiple manufacturing IT layers goes simple layers • Separate IT layer between real time and batch process • Needs central managing for distributed multiple plant in real time (RTE: Real Time Enterprise)
III. Core technolgies & features
Prospect of Manufacturing Application
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Configuration of u-Manufacturing system
III. Core technolgies & features
Paradigm shift of development background
▶ Distributed Architecture for Reconifigurable Manufacturing System & Single instance application at central IDC - MES/MOM are real time infrastrature IT layer of manufacturng enterprises - Open embedded system of low power comsuption in everywhere for green IT - single instance application of central management for Green IDC 11
III. Core technolgies & features
4M Integration in real time for SaaS model
• • • • •
Direct communication to device controllers via OPC, TCP/IP, MIMOSA Indirect communication to Process or sensor I/O by M2M device Wireless sensor communciation for tag management Manual data handling by touch screen, bar code reder & mobile devices SOA ESB provides common framework for interoperability to other enterprise application
MESA-11 ISA S95 ISO TC184 SC5 Open O&M OAGIS MIMOSA OMAC IEEE802.11.x
IEEE 802.15.4
6LowPan ISO/IEC JTC1 IEEE1451 Standard sensor Interface International Standard 12
4M Integration in real time by M2M devices
•
Wired M2M device
- Open embedded Linux based low power consumption intelligent device •
Wireless M2M device
- Low power and small size of IP based wireless sensor network
III. Core technolgies & features
Wireless M2M node generates XML data for sever 13
III. Core technolgies & features
4 M Digitalization – manual data handling (Touch Screen & Mobile)
•
Touch screen WBT (Windows Based Terminal)
-
IT rosource in servers, no IT resouce in terminal as just plug & play Low power comsumption, good for harsh environment No issue of hacking and IT security Easy to manual data entry by workers – display big characters & touch
•
Managing for moving and multiple equipment
-
Work order & report by mobile for production and maintenance
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III. Core technolgies & features
Comparation with other technology
Items PLC/DCS DAS
System configuration Private PLC CPU and network (An Example : AB, Siemens & Mitsubishi PLC) Indepent serial communication port with PC (An Example: RIC, MOXA)
PC based Control
Embedded DAS with PC (An Example: Field bus)
M2M Device
Support Wired/wireless + internet + existing interface Manual data handling Operation environment International standard Cost Application area Must needs PC for management N/A – De Fecto Standard by vendors Middle Sequencer control Must needs PC for management Recommended Standard (An Example: RS-232C, RS-422A, etc.) Low Compete with PLC & DCS Challenge to real time coverage, stablility & realibility PC based OS – Windows NT OMAC High CNC and PLC replacement Open emedded Linux Focus on new ICT standard (MIMOSA, OPC, ISO, IEEE, OMGi, XML/HTML, WSDL, SOAP…) Low All area (Zigbee, PLC, IP-USN, WiFi, WCDMA, Wibro and etc.) 15
Middleware Configuration for SaaS L3 L1
Auto-Configuration
L0
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III. Core technolgies & features
L2
III. Core technolgies & features
Auto-Configuration
•
Auto configuration for 4M resources - Definiton funciton - Editing function - Tag mapping fuction - Dynamic mapping function Before
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After
Major middleware functions
III. Core technolgies & features
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Predictable Maintenance
X = 48.4219 – 1.9485
Y = 159.2867 – 4.6858
T x
Z = 175.4714 – 7.4281
T T x x
+ 0.9847
T y
+ 7.7245
T y
– 5.4342
T y
+ 0.0857
T z
– 8.6694
T z
+ 8.7649
T z
– 1.0687
T
+ 0.5468
– 0.9827
T T
Changing predictable model by predictable parameters Real time conpensation based on measuring temperature & Speed
III. Core technolgies & features
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III. Core technolgies & features
Features of middleware for wireless sensor network
• Wireless becomes the default choice in production area • Interoperability with legacy system for protects investment in past • Reconfigurable 4M of auto-configuration provides rapidly chance of buisness and production environment
Prospect of wireless
20
Configuration of gateway for SaaS
8 Main Features for SaaS
III. Core technolgies & features
1 Multi-Tenant, Shared Systems 5 Various Integration Flexibility 2 Trusted Reliability & Performance 6 Mash-Ups 3 Democratization of Enterprise Apps 7 Application Exchanges 4 Easy to Customize : Metadata-Driven Customization 8 Multi-Device Delivery
Source: Salesforce.com
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Manufacturing Application – Needs transformation SOA
• SOA for MES application fits distributed all type of manufacturing enterprises - It provides single intant MES application service
III. Core technolgies & features
ISA-95 & MESA-11 MES model & ISO TC184 SC5 standard model
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Transformation SOA for MES application
III. Core technolgies & features
Customization for industry characteristics
Aero space Ship building Medical & Industry Equipmement
Industry Custom Application
Industry template
Industry Common Template
Auto Part & Electric Electronics Industry template
L1 Middleware for Saas
Auto-Configuration Steel & Chedmial Simiconductor Industry template
L2 Single instant Standard Application (ISA S-95 MESA-11) L0
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Operation of SaaS model
III. Core technolgies & features
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IV. Summary
Benefits of SaaS based MES/MOM using wirless sensor network
ㅁ View point of middleware - No Needs cable by Reconfigurable 4M – Auto Configurator & Point Manager - Easy to disparate application – DB Wizard Manager - Unfied 4M data model – Real time data manager - Easy to generate UI – Application Template Manager ㅁ View point of TCO (Total Cost Owenership) < TCO > 30 Development cost 15 Middleware for development 55 Middleware for maintenance road 70 Maintenance cost 15 Develop cost 15 < Benefit with Middleware> ㅁ View point of user - No more pay for hardware, software,maintanance, and upgrade… just pay for use as plug and play - No risks and pay to implementation, provide best practices application - No risks and pay to consulting services - No risks and pay to software maintenance and upgade for comapy groth up and business environment change 25