MANUFACTURING PROCESS MANAGEMENT. Manufacturing Process Management Domain presentation

Transcription

1 MANUFACTURING PROCESS MANAGEMENT Manufacturing Process Management Domain presentation

2 OUTLINE State of the Art Virtual Control Room FASTory FH Rolls Royce Manufacturing Process Management Domain presentation 2

3 MANUFACTURING PROCESS MANAGEMENT DOMAIN Manufacturing can be defined as the use of machines, tools and labor produce goods, either for use or consumption. These machines and tools have to be designed, built, and used in harmony in an automated manner to accomplish the creation of products. There are many types of manufacturing and they all have different methods, some rely heavily on automated systems, while other rely on human labor or both, humans and machines. In the context of the ASTUTE project, there will be a focus in 2 types of manufacturing: Manual assembly of hydraulic systems Automated manufacturing cells with minimum necessary human support Manufacturing Process Management Domain presentation

4 MONITORING Manufacturing systems, depending on their size, can have anything from hundreds to thousands of I/O points. All these indicate the state of the system, and their behaviour must be monitored in order to maintain the system in operating condition. Monitoring systems in manufacturing are more often than not, customized solutions that employ many different technologies at different levels (e.g. Fieldbuses, SCADA systems, MES and ERP). As such, most of the focus in the implementation of current monitoring systems is given to the integration of information necessary to be able to monitor the system at different levels. Manufacturing Process Management Domain presentation 4

5 LOW LEVEL MONITORING When this information integration is accomplished the monitoring solutions implemented depend highly on the current system installations They are usually legacy and proprietary solutions that use specific communication protocols and software to be developed. At operation level there exist static screens, that use touch interface or buttons to interact with the user, simply referred to as HMI s; these are often static, don t change or adapt to the user and require a lot of hardcoded logic. The modification or upgrading of these systems requires especially qualified engineers that are both familiar with automation and basic functional UI design. Usability is rarely a concern in these systems. Manufacturing Process Management Domain presentation 5

6 HIGH LEVEL MONITORING At a higher level, the most common monitoring systems employed are Supervisory Control and Data Acquisition systems, or SCADA s. In contrast to low level HMI s which usually employ the same protocols that industrial controllers use, SCADA systems sometimes require intermediate levels that move the required information to databases before having access to the required information. Modern SCADA systems, and some legacy systems also support many protocols that allow interfacing directly with field devices In terms of usability, SCADA systems usually offer more flexibility than HMI systems, but they are still limited by the fact that SCADA systems are proprietary solutions with specific, and mostly very inflexible software. Modern SCADA solutions are usually web based, centralized systems that can be deployed anywhere regardless of the OS, and sometimes offer development kits that allow for the customization and enhancement of the system. Manufacturing Process Management Domain presentation 6

7 REPORTING Reporting systems in manufacturing are usually completely customized and are different in most every case. They require a more typical IT engineer, in contrast to the automation engineers required at other levels. They usually access same databases where the other systems save relevant information. This information is aggregated at the highest possible level, and usually in a hardcoded manner. Manufacturing Process Management Domain presentation 7

8 ASTUTE IN THE MANUFACTURING DOMAIN ASTUTE can bring many new concepts, ideas and improvement to the existing monitoring systems used in manufacturing. While it is now common and normal to carry smart devices everywhere, and there are mobile devices used in the manufacturing industry. The everyday use of this type of devices in manufacturing is still far off. Current systems have hardcoded intelligence to them, and require proprietary software that is programmed by specially qualified people. ASTUTE will provide a standard platform that provides inherent and easily modifiable intelligence that takes context, user and system into account. ASTUTE offers a new focus on the usability of the system and less focus on the integration of the information Normally, every level of a manufacturing system has its own unique interface with the user. ASTUTE will provide the same interface everywhere and to all the users. Manufacturing Process Management Domain presentation 8

9 VIRTUAL CONTROL ROOM Virtual Control Room.- Introduces mobility to the traditional fixed location monitoring paradigm. Allowing the user to bring and carry the necessary interfaces anywhere at any time. Manufacturing Process Management Domain presentation

10 FASTORY Re-furbished to simulate the production of 600+ different products Allows for any kind of customization and tests Composed of 11 modular manufacturing cells Allows Free reign in implementing, testing and evaluating new technologies Manufacturing Process Management Domain presentation

11 FASTORY SCENARIOS PARTNERS: NAMAHN+TUT+PDT Operator notices an error, and he can t fix it. Supervisor is notified of the fault, he checks the system and finds out the problem, he notifies maintenance. Maintenance interacts with the system in a previously not possible manner, receiving proactive suggestions and an easy user friendly interaction. Manufacturing Process Management Domain presentation 11

12 FASTORY USE CASE EXAMPLES PARTNERS: TUT+PDT E-UC-06 Pro-active suggestions E-UC-08 Controller Access Actions Suggestions Steps Information Location B E-UC-05 Location based information display Information Location A Manufacturing Process Management Domain presentation 12

13 VIRTUAL CONTROL ROOM 1st period review meeting, Brussels, 20th April 2012

14 FH ROLLS ROYCE PARTNERS: PDT+FH Hydraulic power unit used in ships and boats More than 300 different variants Requires custom hand assembly Currently has no support system and everything is paper based Manufacturing Process Management Domain presentation 14

15 FH ROLLS ROYCE SCENARIOS PARTNERS: PDT+FH+NAMAHN Supervisor has easy access and use production information Operators, builders and welders have interactive intelligent instruction guidance via ASTUTE Manufacturing Process Management Domain presentation 15