1 saas-based mes/mom using wireless sensor network 1 s. k. cha, cofounder & strategic planning...

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SaaS-Based MES/MOM using SaaS-Based MES/MOM using Wireless Sensor NetworkWireless Sensor Network

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S. K. Cha, S. K. Cha, Cofounder & Strategic planningCofounder & Strategic planning

ACS Co., Ltd. ACS Co., Ltd. [email protected]@acs.co.kr

S. K. Cha, S. K. Cha, Cofounder & Strategic planningCofounder & Strategic planning

ACS Co., Ltd. ACS Co., Ltd. [email protected]@acs.co.kr

Manufacturing Technology Platform(MTP) MeetingZurich, Switzerland

Manufacturing Technology Platform(MTP) MeetingZurich, Switzerland

MES: Manufacturing Execution System MOM: Manufacturing Operation ManagementMES: Manufacturing Execution System MOM: Manufacturing Operation Management

Monday, 27 April 2009Monday, 27 April 2009

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AgendaAgenda I. Who is ACS ?II. Needs and issues for Mfg. ITIII.Core Technologies and features IV. Summary

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I. Who is ACS? I. Who is ACS?

Established in August 30, 1988 (20th anniversary) Located in Seoul, Korea – Manufacturing contry (45.2% of GDP in 2006) Concentrating manufacturing software solution – u-Manufacturing (uMfg® & Dabom®-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

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)

Manufacturing Processes

Solutions Series

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I. Who is ACS? I. Who is ACS?

Hyundai Motor Co.Hyundai Motor Co.Hyundai Motor Co.Hyundai Motor Co.

POSCOPOSCOPOSCOPOSCO

- More than 150 project has been completed- Strong in MES for engine application- Good reference for ALC (Assembly Line Control) system

- Real time communication & large scale system- Approach an emerging new technology (Open UNIX System replaced from Special designed process computer )

ACS solution in Auto & Steel industriesACS solution in Auto & Steel industries

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Changing the Mfg. & IT environmentChanging the Mfg. & IT environment

II. Needs & issues for Mfg. IT II. Needs & issues for Mfg. IT

- 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: AMR Research

Source: u-Mfg Lab at POSTech

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4M Integration in real time4M 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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Major issues for develoment of u-ManufactuirngMajor issues for develoment of u-Manufactuirng


u-Manufacturingsolutions

Automated Machines

Technology

InformationTechnology

ProductionTechnology

Machine Center (CNC)Material logistic system

RobotMachine Vision

FMSStack crane

Lean Manufacturing6 Sigma, TQM5S, TPM, OEE

JIT, TPSSCM, APS

Real-time interfaceData base

SOA, Web serviceNetwork (e-Biz , Web2.0)Ubiquitous Technology

RFID/USNManufacturing 2.0

ConsultingTechnology

- Fusion of multiple technologies are key for successfully implementation and generation of new business opportunity

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The wireless technogyThe 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

ExternalDevices

Board Level EmbeddedLevel

Chip Level

Design Interation

Real time device integration

• M2M (Machine to Machine) Devices

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SaaS modelSaaS 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)

Ad-hoc/Custom(ASP Model) Configurable

(Single intant, option)

Configurable(Single intant, option)

Configurable Multi-tenant(metadata, security, authorization)

Configurable Multi-tenant(metadata, security, authorization) Configurable Multi-tenant scalable

(N:M connection)

Configurable Multi-tenant scalable(N:M connection)

IT TrendIT Trend

SaaS LevelSaaS Level


Source: Salesforce.com Source: Gartner Group

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• 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)

u-Manufacturing Model for SaaS model

Configuration of u-Manufacturing systemProspect of Manufacturing Application

III. Core technolgies & features III. Core technolgies & features

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Paradigm shift of development backgroundParadigm 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

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4M Integration in real time for SaaS model 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

IEEE802.11.xIEEE 802.15.4

6LowPan

IEEE802.11.xIEEE 802.15.4

6LowPan

ISO/IEC JTC1IEEE1451

Standard sensorInterface

ISO/IEC JTC1IEEE1451

Standard sensorInterface

MESA-11ISA S95

ISO TC184 SC5

MESA-11ISA S95

ISO TC184 SC5

Open O&MOAGIS

MIMOSAOMAC

Open O&MOAGIS

MIMOSAOMAC

International Standard

International Standard

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4M Integration in real time by M2M devices 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

Wireless M2M node generates XML data for severWireless M2M node generates XML data for sever

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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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Comparation with other technology

Items PLC/DCS DAS PC based Control M2M

DeviceSystem configuration Private PLC CPU and

network

(An Example : AB, Siemens & Mitsubishi PLC)

Indepent serial communication port with PC (An Example: RIC, MOXA)

Embedded DAS with PC

(An Example: Field bus)

Support Wired/wireless + internet + existing interface

Manual data handling

Operation environment

Must needs PC for management

Must needs PC for management

PC based OS – Windows NT

Open emedded Linux

International standard N/A – De Fecto Standard by vendors

Recommended Standard

(An Example: RS-232C, RS-422A, etc.)

OMAC Focus on new ICT standard

(MIMOSA, OPC, ISO, IEEE, OMGi, XML/HTML, WSDL, SOAP…)

Cost Middle Low High Low

Application area Sequencer control Compete with PLC & DCS Challenge to real time coverage, stablility & realibility

CNC and PLC replacement

All area

(Zigbee, PLC, IP-USN, WiFi, WCDMA, Wibro and etc.)


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Middleware Configuration for SaaS


Auto-Configuration

L0

L1 L2

L3

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Auto-Configuration

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

Before After

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Major middleware functions

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Predictable Maintenance

X = 48.4219 – 1.9485Tx + 0.9847Ty + 0.0857Tz – 1.0687TY = 159.2867 – 4.6858Tx + 7.7245Ty – 8.6694Tz + 0.5468TZ = 175.4714 – 7.4281Tx – 5.4342Ty + 8.7649Tz – 0.9827T

X = 48.4219 – 1.9485Tx + 0.9847Ty + 0.0857Tz – 1.0687TY = 159.2867 – 4.6858Tx + 7.7245Ty – 8.6694Tz + 0.5468TZ = 175.4714 – 7.4281Tx – 5.4342Ty + 8.7649Tz – 0.9827T

Changing predictable model by predictable parametersChanging predictable model by predictable parameters

Real time conpensation based on measuring temperature & Speed

Real time conpensation based on measuring temperature & Speed

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• 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

Configuration of gateway for SaaS Prospect of wireless


Features of middleware for wireless sensor network

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8 Main Features for SaaS


Democratization of Enterprise Apps

Mash-Ups

Trusted Reliability & Performance

Multi-Tenant, Shared Systems

Various Integration Flexibility

Easy to Customize : Metadata-Driven Customization

Application Exchanges

Multi-Device Delivery

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33

22

44

55

66

77

88

Source: Salesforce.com

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ISA-95 & MESA-11 MES model & ISO TC184 SC5standard model

Transformation SOA for MES application

• SOA for MES application fits distributed all type of manufacturing enterprises - It provides single intant MES application service

Manufacturing Application – Needs transformation SOA


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IndustryCommonTemplate

IndustryCustom

Application

Industry template

Aero spaceShip building

Medical & Industry Equipmement

Auto Part &Electric

Electronics

Steel &Chedmial

Simiconductor

Industry template Industry template

Middlewarefor Saas

Single instantStandard Application

(ISA S-95MESA-11)

Customization for industry characteristics


L0

L1L2

Auto-Configuration

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Operation of SaaS model

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< TCO >

Maintenance costDevelop cost

< Benefit with Middleware>

ㅁ View point of TCO (Total Cost Owenership)

ㅁ View point of user

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70

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Maintenance cost

Development cost

Middleware for maintenance road

Middleware for development

절감효과

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15Benefit

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- 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

- 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 middleware

IV. SummaryIV. Summary

- 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

- 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

Benefits of SaaS based MES/MOM using wirless sensor network

1 saas-based mes/mom using wireless sensor network 1 s. k. cha, cofounder & strategic planning...

Documents

waiting time

korea manufacturing

time approach patent

references acs solution

rte real time enterprisechange

develoment of u

major issues

umfg lab