collaborative manufacturing network for competitive advantage · 2014. 9. 2. · version v 1.0 work...

284928

Collaborative Manufacturing Network

for Competitive Advantage

D6.5 – Final Report on Best Practices Plant Engineering and Commissioning

(public)

D6.5 –Final Report on Best Practices

WP6 –Plant Engineering and Commissioning

© ComVantage Consortium – 2014 2

Grant Agreement No. 284928

Project acronym ComVantage

Project title Collaborative Manufacturing Network for Competitive Advantage

Deliverable number D6.5

Deliverable name Final report on best practices

Version V 1.0

Work package WP6 – Plant Engineering and Commissioning

Lead beneficiary COMAU

Authors Fulvio Rusinà (COMAU), Pietro Cultrona (COMAU), Davide Grosso (COMAU)

Reviewers Julianna Katona (K&A), Walid Tfaili (Evidian)

Nature R – Report

Dissemination level PU- Public

Delivery date 31/08/2014 (M36)




Executive Summary The main objective of the ComVantage project is to create an interorganisational collaboration space turning today’s organisation-centric manufacturing approach into a product-centric one. In the automotive environment benefit derives from a flexible, efficient platform that helps operating as one virtual factory. The various elements of the project are summarised as follows:

To describe the background and the tasks of the project To describe the methods used for developing the inventories To describe the consensus building process for the final results of the project To outline problems and perspectives for the implementation of the proposed minimum quality

standards at European level A summary of project results

The basic concepts of ComVantage and its architectural results are out of scope of this deliverable. For more details, please refer to Deliverable D2.2.2 (ComVantage Architecture Specification) and D2.3 (ComVantage architecture best-practices).




Table of Contents

1 OVERVIEW .......................................................................................................................................... 6

1.1 INTRODUCTION ............................................................................................................................... 6

1.2 SCOPE OF THIS DOCUMENT ............................................................................................................... 6

1.3 RELATED DOCUMENTS...................................................................................................................... 6

2 GENERAL CONCEPTS OF PLANT ENGINEERING AND COMMISSIONING ............................................... 7

2.1 OVERVIEW ..................................................................................................................................... 7

2.2 INTEGRATION OF A NEW ICT TOOL FOR REMOTE ENGINEERING AND COMMISSIONING ..................................10

2.3 MAIN FOCUS OF IMPLEMENTING THE FINAL PROTOTYPE OF PLANT ENGINEERING AND COMMISSIONING...........10

3 INTEGRATION OF PLANT ENGINEERING AND COMMISSIONING INTO THE COMVANTAGE ARCHITECTURE ...........................................................................................................................................12

3.1 OVERVIEW OF THE COMVANTAGE ARCHITECTURE .................................................................................12

3.2 DETAILED ASPECTS OF INTEGRATION OF PLANT ENGINEERING AND COMMISSIONING INTO THE COMVANTAGE

ARCHITECTURE ...........................................................................................................................................13

3.2.1 Use of DAS .........................................................................................................................13

3.2.2 Use of Security Concepts ...................................................................................................14

3.2.3 Use of Triple Stores ............................................................................................................14

3.2.4 Use of IAF ..........................................................................................................................15

3.2.5 Use of OMI/ADOLog Modelling Tools .................................................................................16

4 CONCLUSION AND OUTLOOK.............................................................................................................18




List of Figures

Figure 1: Process general overview .............................................................................................................. 7

Figure 2: Line building and Set Up ................................................................................................................ 8

Figure 3: Complete ComVantage Architecture ............................................................................................13

Figure 4: Architecture of Final Prototype with focus on machine data integration (provided by the DHM adapter) .............................................................................................................................................14

Figure 5: Design time component (from D5.3.3) ..........................................................................................15

Figure 6: PlantSelection ..............................................................................................................................16

Figure 7: LineSelection ................................................................................................................................16

Figure 8: WP6 workflow Cycle Time Validation............................................................................................17




1 OVERVIEW

1.1 Introduction

With this deliverable COMAU S.p.A. is collecting the best practices achieved in the work package 6 “Plant Engineering and Commissioning” presenting the applicability of ComVantage results in the automotive environment.

1.2 Scope of this Document

This deliverable summarises best practices from the previous tasks of work package WP6.

It comprises:

A short summary of the results

Best practices for applying generic concepts in the Plant Engineering and Commissioning application area.

o e.g. data modelling, business process modelling, app development and orchestration

o Description of learnings/findings during the prototype development

1.3 Related Documents

The related documents of this deliverable are the following:

Deliverable D6.1.2 Scenario specification and refinement Basis for the Enhanced Prototype and Final Prototype

Deliverable D4.2.3 Middleware adapter set The basis for sensor integration.

Deliverable D4.3.3 Business and engineering software adapter The basis for integrating existing data into Linked Data.

Deliverable D4.4.3 Linked Data support toolset The basis for keeping information used in different application settings available in the semantic web

The concepts and writings in this document are well aligned with the contents of the following documents:

Deliverable D2.3: ComVantage architecture best practices Deliverable D3.5.2: Guidelines for the secure collaboration model Deliverable D4.5: Linked Data best practices Deliverable D5.4.2: UI guidelines for mobile collaboration Deliverable D11.4: Final report on prototypical implementation of ComVantage




2 GENERAL CONCEPTS OF PLANT ENGINEERING AND COMMISSIONING

2.1 Overview

The Plant Engineering and Commissioning application area takes into consideration the engineering phase and the subsequent commissioning of automotive manufacturing plants.

The usual workflow for the system integrators is represented in figure 1: once an order from the customer has been acquired, the initial engineering phase starts in order to provide all the required documentation that will be used to buy materials, identify resources, build machines, plug devices, elaborate software. Then the hardware construction takes place with the mechanical and electrical subsystems. The next step sees the progressive assembling of the embedded systems in the customer plant. What is important to highlight are those overlaps between different processes: they are managed by different actors, such as designers (Dsg) for engineering (P4 and P9 in Figure 1) and automation engineers (A-Eng) for manufacturing and site management (P7 and P8) and the scenario requires a simple but efficient way to find information both from documentation and machine status, and an agile system able to share the acquired data.

Figure 1: Process general overview

The commissioning of automotive manufacturing plants requires a long time to be completed. During its execution several problems related to the product and to the process may be detected. The iterative process developed in the ComVantage project recursively searches data useful to solve these encountered problems assuring the proper quality, functionality, performance and safety of the overall production plant.




Figure 2: Line building and Set Up

The diagram in figure 2 shows the sequence of activities to build a production line. All these actions may be affected by faults created during the engineering phase, but encountered in the commissioning and set up phase, because no other activity can highlight these problems. Describing in details we can find:

Mechanical Installation: requires three months with several personnel involved - problems: procurement of materials

Pipe & Wire: it takes one and a half month involving electricians and fluidic technicians - problems: wrong analysis in engineering development and acquisition

Power On: it is a milestone that indicates the power distribution to the devices that compose the line




Robot Set Up: lasts for a half month involving robot engineers. The job developed offline (office programming from specific Dsg) has to be integrated in the production line

- problems: offline program not completed, mounting mistakes, robot interferences, low quality in the car metal sheets from dies (the process that provides metal sheets ready for body welding)

I/O Test (analysis of input and output): requires half a month with several software engineers and few electricians

- problems: electrical designs and project development contain unknown errors, wrong installation of devices, wrong wiring, early failure and breakdown of devices and components

Orchestration (Robot, PLC, HMI): needs one and a half month and many actors with different skills (specific A-Eng) electrician, mechanic, robot engineer and software engineer

- problems: harmonisation between different department and their own projects or documentations (mechanical, electrical, software, …), lack of elements for tests, delays induced (inefficiency chain)

Process Verify: is another milestone that indicates the line is ready for Process Verify; this means each station can provide all the operations and welding processes to a car element, even if in a manual way

- Quality and geometry are the main goal

Fine Tuning: is the core step before closing the whole commissioning. One month of work involving software engineer, robot engineer, welding specialist and mechanical quality specialist

- problems: Cycle time refinements, monitoring, error stack, historical alarm, status line diagnostic

Production: time production and shifts are depending on customer requirements. - problems: welding point not efficient, low quality elements, gluing instable, insufficient

coupling and joining of elements

When the series production must be started, the line requires higher performance in order to respect customer specification and contract submission. This means that the following critical issues must be addressed as soon as possible to reach the right production condition in time:

Robcad: this is the software tool to plan the offline robot program, but it cannot manage interlocks between several robots

Mechanical quality process: refinements from customer cyclically change steps and procedures related to the element

PLC: it is the manager of all the I/Os. In a line configuration there are more than 10.000 signals and PLC needs to be updated with thousands of modifications. It is subject to human mistakes during the programming phase.

Drive: it is the controller of motor rotation and its tuning can be made by 1500 parameters. The implementation goes through specific ramps and profiles.

Welding point matrix: it is the scheme of the whole welding points that must be provided in the line. Distribution of these points may vary in order to get the proper cycle time in each station or according to quality tests or even in case of crash tests which indicates new welding and mechanical process.

Mechanical interferences: these are situations not quoted during the project engineering phase and can cause machine damages and modifications and deviations from the original project.




Component failure: mechanical and electrical devices are subject to early breakdown or unknown problems; our suppliers commercialise new products and the critical working conditions of the Body Shop (EMC Electromagnetic Compatibility, noise, vibrations, hardworking frequency, dust, oil, scraps welding and so on) are responsible for failures.

Commissioning errors: implementation of a detailed diagnostic is fundamental to quickly detect wrong functionalities in the system or bad settings of the process, but this is difficult because the programmer has to analyse an enormous quantity of possible faults and a lot of events that can determine anomalies.

Certification: machine has to be checked from many points of view; safety working condition, ergonomics, Methods Time Measurements, fieldbus certifications, grounding, trials, … What is out of standards must be improved and reset.

2.2 Integration of a New ICT Tool for Remote Engineering and Commissioning

In this chapter we want to summarise the concepts identified to help actors in facing the difficult situation presented in chapter 2.1.

Goal of the scenario is to implement a tool able to reduce distances and time reaction between stakeholders. The tool has in charge the possibility to analyse and test the embedded systems (that compose a production line) providing to actors the data and the information regarding the station under inspection.

The Automation Engineers that are operating in the customer plant need to collect data from the production line. They query the PLC that is currently managing the process, waiting for some specific results in order to complete their job or, eventually, to forward information to the Designer in order to receive help and maybe suggest feedback to a project mistake.

In particular, the completion of job means that the Automation Engineer can face previous issues verifying the sequences of mechanical tool, like robots and clamps. Another help derives from the possibility of measuring the time that a drive requires to pilot its motor: lower time reflects the necessity to further regulations. Also the analysis of welding time per robot to provide welding dots is useful to suggest welding dot distribution: such activity is often used to calibrate the robot workload and to reach the designed cycle time.

Power consumption or air leakage analysis are the first signal to easily detect component failure and to compile check list and certification of the machine.

2.3 Main Focus of Implementing the Final Prototype of Plant Engineering and Commissioning

COMAU has identified some machines that represent the core business in the body in white automotive environment.

These are:

1. Fixtures (tools, grippers) 2. Line feeding (Pallet conveyors) 3. Robot

These embedded systems are just examples of a wide variety of complex devices that compose production lines in body welding, but their value is representative of the environment because they cover a great percentage of the applied systems.




The other interesting argument is that all the devices are connected to a common fieldbus (ProfiNet) and the manager of the net is a Programmable Logic Controller (PLC) that collects, supervises, assigns and sequences all the data and signals. This means that a direct connection to the PLC allows users to get information of any machine connected to the same fieldbus with a unique interface.

Differences belong specifically to the hardware construction, piping and wiring assembly, data analysis and set up activities, but the App developed in ComVantage can independently manage all the devices information, performing specific tests, or data analysis and, consequently, feedbacks, sharing of information, open chat for discussions, involving Designer, Automation Engineer, machine experts, customers, everyone according his own skill and expertise.

1. Fixtures

With this term we are used to talk about systems able to fix the car element that will be worked in the station. They could be fixed tool, when the system is implemented on a fixed table, or gripper, when the system is mounted on board of a robot, turn table, when the system is installed on a rotating table.

2. Line feeding

This group of devices collects those products developed with the final goal of providing the car element to the production line. Main examples are pallet conveyors, extraction boxes and so on.

3. Robot

As stated by the Robot Institute of America, is "A reprogrammable, multifunctional manipulator designed to move material, parts, tools, or specialised devices through various programmed motions for the performance of a variety of tasks". The main task of the robots is to help people in the works that would be difficult, unsafe, or boring for a human to do. The main applications in the manufacturing plants, as shown in the picture below, are assembling, handling, welding, sealing, painting and inspecting.

All these machines were considered during their installation in the customer plant and have been analysed in order to detect time values, power consumptions and air leakages which are useful to check the working behavior of each embedded system. Data collected is compared with theoretical values: changes or deviations from the expected results determine:

a corrective intervention from the on-site personnel in case of wrong installation or

a project revision from office personnel in case of engineering mistake.




3 INTEGRATION OF PLANT ENGINEERING AND COMMISSIONING INTO THE COMVANTAGE ARCHITECTURE With interchanges between consortium partners, the critical point of handling the machine data coming from the PLC has been solved merging the knowledge available. Experts in Java programming, Android App development, Safety systems, mobile applications, network manager, server and data storing, have jointly worked to create the previous mentioned “ICT tool”. It bases its features on appropriate ontologies, on specific adapters, on Data Harmonisation Middleware, on communication channels that have been studied and adapted for the purpose of the application area. Collecting measured data and storing them into the defined data structures we have implemented the infrastructure to allow the app ensemble for accessing these data and to elaborate results. The following chapter describes the ComVantage architecture in detail for the application area of Plant Engineering and Commissioning (WP6).

3.1 Overview of the ComVantage Architecture

Within the complete ComVantage Architecture some layers were specifically implemented for WP6 Plant Engineering and Commissioning: these parts are the Adapted Apps, the use case specific ontologies, the DHM-Adapter and a XLWrap for mapping data previously stored in Excel files into the ComVantage data structures (see Figure 3).




Figure 3: Complete ComVantage Architecture

3.2 Detailed Aspects of Integration of Plant Engineering and Commissioning into the ComVantage Architecture

3.2.1 Use of DAS

For the specific deployment of the ComVantage components, the integration with the Domain Access Server has the advantage of an easy configuration with one access point for the connection from the tablet computer. Any subsequent changes in the backend will be hidden from the application on the tablet by the DAS.




The Domain Access Server has been enhanced to enable routing of requests to the DHM-Adapter (see Figure 4). This technique is especially useful for the WP6 use case which depends on the availability of PLC signals while history data and organisational data are stored in a Linked Data Store and retrieved via SPARQL and SPARUL requests.

Figure 4: Architecture of Final Prototype with focus on machine data integration (provided by the DHM adapter)

3.2.2 Use of Security Concepts

Role definition for access control is a general principle which has also been used by the ComVantage Approach. Due to the dynamic nature of the data collected by the DHM-Adapter for use in the Plant Engineering and Commissioning application area, the SPARQL- Rewriting technique with its out of band creation of views as described in deliverable D3.3.2c (Prototype of security mechanisms) needed to be enhanced with pre-configured views for data that is created during operation from the backend itself.

3.2.3 Use of Triple Stores

The application area Plant Engineering and Commissioning (PEC) (WP6) requires several well defined vocabularies in order to be able to express all relevant information for humans as well as machines.

For that reason the following ontologies have been developed.




Users Ontology (Users) It has the description of detailed properties for each account. It includes information such as names, family name, e-mail, username and password, etc.

Roles Ontology (Roles) The roles ontology is designed to describe the role of the user that is accessing the system. It is used by the security part of ComVantage platform to allow or deny the data access.

Plants Ontology (Plants) This ontology is in charge of describing the structure of a customer plant. It collects information from the production lines and outputs. The final goal is to receive real values from the field that have to be compared with theoretical ones. This offers the possibility to validate the cycle time of each station under analysis.

Machine Semantic Ontology (MSem) From the collaboration between Work Packages 6 and 8 a joint ontology has been developed: Machine Semantic (MSem), already described in detail in section 2.1.1 of D4.1.3. This ontology, valid for both scenarios, replaces and extends the old ProdLine (created with the objective to describe in a hierarchical structure the dependencies of the devices that provide the input and output of a system process).

3.2.4 Use of IAF

The objective of ComVantage was to create a set of common design time and run time components that implement a specific app orchestration process for industrial use in factories of the future. The IAF includes all tools for developing generic apps for orchestration and for deploying them to the target devices.

Figure 5: Design time component (from D5.3.3)

The success of such envisioned system is represented by the reusability and flexibility of the various implemented Apps collected in a specific App Pool: partners have developed their application program and




then a process of selecting, adapting and managing a set of instances of generic apps has implemented more complex workflows. The App Pool stores all available Apps which may include highly adaptive Generic Apps, normal apps that have been optimised for orchestration and regular apps without modification.

An exhaustive example of reusing apps in different contexts is been represented by the App “PlantNavigation”: the program for browsing the elements in a hierarchical structure is the same when we are selecting the plant that we want to take in consideration or when we are choosing the subsequent production line that is under analysis. The following figures 6 and 7 display this reusability of an App once that an orchestration has provided the connection.

Figure 6: PlantSelection

Figure 7: LineSelection

3.2.5 Use of OMI/ADOLog Modelling Tools

In a complex environment like the automotive one, it is fundamental to graphically describe a specific workflow. The tool developed for this purpose is the OMI modelling tool that simplifies the elaboration of different use cases, describing the actors involved, interconnecting them and supporting the description of Tasks and Apps that compose each specific use case. As you can see in figure 8, the two main roles involved




in the WP6 Cycle Time Validation are shown in an easy diagram description that helps the organisation of Apps, leading the orchestration of Generic Apps which can be associated according to the relevant task that has to be performed. As previously described, the picture simply shows how the Automation Engineer is able to access machine data and how the Designer is able to receive feedback. The users can exchange information and quickly face the problem they encountered.

Figure 8: WP6 workflow Cycle Time Validation




4 CONCLUSION AND OUTLOOK Within a production process the most important aspects on the customer’s side is the close attention to deadlines, production volumes and cycle time. Delays that do not meet the specified deadline result into severe economic losses. Today system integrators have the possibility to check and verify the final productive status of the production systems with the help of monitoring applications; stack errors and PLC fault register that highlight a wrong workflow during the normal operation. Such tools are not available to control the ramp up phases, providing feedback and data useful both for engineers (working on the design of the production line) and technicians (implementing the production lines on the basis of projects from engineering departments). The ComVantage project has allowed the development of innovative concepts and prototypes to overcome problems previously detected. Focusing the overall ComVantage architecture we can identify some macro areas that collect the main software and technical aspects.

ComVantage Shopfloor adapter: thanks to the activities performed in the integrations of the shopfloor devices, COMAU has acquired a deep knowledge of specific communication protocols, such as OPC-UA and OPC-DA standard. These will be adopted in further programs in which COMAU Body Welding will be involved.

GUI mobile devices: working with the other ComVantage Partners COMAU has started the development of new user interface applications based on Android, Java and the high level object-oriented programming. These applications represent a real breakthrough in the definition of new HMI with power of high flexibility and modularity that are an important feature in an environment like the automotive one (App Orchestration). An additional benefit is the introduction of portability thanks to Wireless communication that allows the use of mobile terminals instead of traditional legacy fixed terminals.

Security management: thanks to the implementation of the overall ComVantage architecture several experiences have been gained by COMAU. In particular topics such as secure access, internal policies and data sharing have been analysed and implemented assuring the high security level required by a large enterprise that needs to protect data from external access.

The strengths of ComVantage are the possibility:

to measure the work in progress to easily detect differences between planned workflow and real one to access the machines performance remotely to quickly communicate information, data and documents between stakeholders

The benefits are represented by a fast reaction to process modifications arisen during execution, avoiding the requests of travelling in most of the occasions. Accurate information between the actors with the use of mobile devices, that perform advanced communications, turns a skill-based manufacturing into a knowledge-based manufacturing: immediate data access automates trouble shooting and recovery actions (historical databases).




DISCLAIMER

The information in this document is provided "as is", and no guarantee or warranty is given that the information is fit for any particular purpose. The above referenced consortium members shall have no liability for damages of any kind including without limitation direct, special, indirect, or consequential damages that may result from the use of these materials subject to any liability which is mandatory due to applicable law.

Copyright 2014 by SAP SE, Asociación de Empresas Tecnológicas Innovalia, Ben-Gurion University of the Negev, BOC Business Objectives Consulting S.L.U, Comau S.p.A., Technische Universität Dresden, Dresscode 21 GmbH, Evidian S.A., ISN Innovation Service Network d.o.o., Kölsch & Altmann GmbH, Nextel S.A., RST Industrie Automation GmbH, University of Vienna.