슬라이드 1 - Intelligent Manufacturing Systems

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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

anniversary)

 Located in Seoul, Korea – Manufacturing contry (45.2% of GDP in 2006)  Concentrating manufacturing software solution – u-Manufacturing (

Mfg® & Dab

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 )

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

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

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

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

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

III. Core technolgies & features



Auto-Configuration

•

Auto configuration for 4M resources - Definiton funciton - Editing function - Tag mapping fuction - Dynamic mapping function Before

After



Major middleware functions

III. Core technolgies & features



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

+ 0.5468

– 0.9827

T T

Changing predictable model by predictable parameters Real time conpensation based on measuring temperature & Speed

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

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



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

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



Operation of SaaS model

III. Core technolgies & features

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