digital transformation of traditional factory using iot

Charles Wu

AIM Center, TECO E&M Co., LTD

Digital Transformation of Traditional Factory Using IoT Technologies

1

智動化暨生產技術中心

MESMHM

ERP

Factory

Automation

History of TECO’s Intelligent Manufacturing

in Chun-Li, Taiwan

Production 4.0Production 3.0Production 2.0Production 1.0

2015200119911979 2017

1979Chun-Li Factory

Established

- CNC implement- Line Automation- Efficiency/Quality - Mass production

ERP/MESIntegration fromSoftware Deploy

Mass Production Mass Customization

智動化暨生產技術中心

Structure of TECO’s Intelligent factory

ConsumerService

Provider

Manufacturing

Collaboration

E-Commerce

Machine CloudSupplier

Quality

Operator

5

2

4

EMS

MHM

IntelligenceManufacturing

Machine CloudQuality & Maintenance

integration

B2B e-commerceCustomer pull process

ERP & MESVertical integration SOP,

Manufacturing Management

M2MCommunication

M. CollaborationOpen information

Resource prediction

3

1

1

3

SCADA

MES

ERP

Machines

智動化暨生產技術中心

SAP ERP

SAP MES

Reports Management

SHOP FLOOR CONTROL SYSTEM

Coding control

(Logistic)

Quality control

(Big data)

Real time

BulletinMCS SYSTEM

IN-LINE CONTROL SYSTEMMuti-AGV

CONTROL System

Gateway

Conveyor VisionRobot

Main Machines Auxiliaries Safety CTL.

AGV Rout

Exchange port

Intermediate

Stocks

Robot cell ports

Copper wire

Intelligent Manufacturing of Stator Shop Floor

(Demo site) Intense use of sensors、RFID

& 1D/2D/3D vision、

Robot/AGV& fiber network for

factory automation。

Direct Link among

machines to ERP/MES

- Auto work assignment、

working time report

- Real time recipe check

- Tool check & process

data collection

- Quality and process

trace back ability

- No paper environment

- IoT & Big data ready

Sh

op

floo

r lev

el

Facto

ry le

ve

l

智動化暨生產技術中心

Existing Equipment

TECO MHM Solution

LPWAN_LoRa Solution

NewEquipment

Winding Center as a

Demo Line

Spread to other

processes

Solutions of existing Equipment/Old Machines

ConsumerService

Provider

SCADA

MES

ERP

Manufacturing

Collaboration

E-Commerce

PasS

(Edge computing)

Manufacturer

Quality

Operator

4

3

5

2

3

Machines

45

5

Supplier1

MHM

LoRa

智動化暨生產技術中心

Basic Scheme of TECO’s solution

6

Ref. Advantech IoT structure.

TECO LoRa Module

(Machine Status)

TECO MhM Module

(Maintenance)

智動化暨生產技術中心

LPWAN_LoRa

7

Tiny Server

智動化暨生產技術中心

Data collection using LPWAN (LoRa)

8

1.Status

Start、Uptime、idle

2.Process

Count、Speed

3.Environment

Temp、Humid、pressure

4.Maintenance

Downtime、Abnormal

Utilization rate

Capacity, availability

Environment, parameter

MTBF, Prediction

MhM: Application Structure Diagram

9 All remote operations are managed by Private Cloud, to protect operation privacy.

WiFi / 3G / 4G

Internet

Motor

Switchgear

IoT

Gateway

Sensors

異

常

:

Smart Phone with App

Existing SCADA

Machine Health management System

(MHm)

Broadband

Router

RS485

(Industry

Standard)

1

0

Sensors Product Series : Temperature

Analog

Magnet

USB

Stick-on

11

Sensors Product Series : Vibration

Wired

RS485

Screw-down type Magnetic Suck-on type Magnetic Suck-on type

Wired

RS485

USB

RS485

All with integrated transducer

12

4 x USB recepicles

for USB inputs

Built-in WiFi for

WiFi input/output

IoT (Internet of Things) Gateway : AG-300U

Current

Voltage

KW (Consumption)

Vibration

Temperature

RPM

Torque

13

What to manage

Machine Health Vitals

Protection Relay (OV, OC, UV,

GF…..)

Thermal Image

Air Analysis

All Sensors/detectors ever used in

SGR industry

Smart Phone APP Display

14

MHm Software Display (server-based)

15

MHm Software Display (server-based)

16

17

Vibration Temperature

MHm Software Display (server-based)

18

Just plug the gauges and the mobile power pack to the Gateway and play.

All-Smart Portable

智動化暨生產技術中心

Application of IoT technology to high-

efficiency factories

19

Prediction and symptom managementPrinciple：No downtime、No defect

Method：Big data、AI technology

Target：Minimize accidental, continuous defect

Focus Management

Principle ：分析與分層後的信息於當地實物確認

Method：Process automation, Data visualization

Target：Compression the load of daily work stream

Source Improvement

Principle：Real time confirm the operation and

improvement of the factory

Method：Big data、CPS

Target：Speed up of value concretization

Co-Creation Improvement

Principle：Cross business and national boundaries

Method：Big data、CPS

Target：Speed-up of improvement and innovation

Key Machines

Real time monitoring

Manufacturing

management

KPI

IoT

Platform

Thank You For Your Listening!

Charles Wu

AIM Center, TECO E&M Co., LTD