future manufacturing and fa integrated solution...
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COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
Dr. Kazuhiro Kusunoki General Manager, e-F@ctory Strategic Planning Project
Nagoya Works
Future Manufacturing and FA Integrated Solution “e-F@ctory”
Apr. 15th, 2015
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Mitsubishi Group Overview
Mitsubishi Heavy Industries, Ltd.
Mitsubishi Electric Corporation
Totally 217 companies belong to Mitsubishi Group.
Electric & Electronics Ships, Aircraft, Turbines Automobiles
Trading Banking
Cameras, Optical, Equipment
Casualty, Insurance
Nikon Corporation
Mitsubishi Corporation
The Bank of Tokyo-Mitsubishi
UFJ,Ltd.
Tokyo Marine & Nichido Fire
Insurance Co., Ltd. Nippon Yusen Kirin Holdings
Co.,Ltd.
Mitsubishi group of companies
Mitsubishi Motors Corporation
Global logistics
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Mitsubishi Electoric Overview
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FA System Group Overview
PLCs
HMI (Human Machine Interface)
Three phase motors
AC Servos Drive Products
Power distribution control products
Mechatronics Products
Inverters
No Fuse Breaker, Earth Leakage Breaker
Electromagnetic Switch
Electrical-Discharge Machines Laser Processing Machines
NC (Numerical Control)
Robots
Controller products
Transformer
→work like human brain and face
→work like human arms and legs
→machine tools /robots (work instead of
workers)
→control power distribution
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Overseas offices FA System Group Overview
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1. Future Vision of Monozukuri (Manufacturing)
2. FA Integrated Solution e-F@ctory
Solution for advanced factories of the future
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Data collection technology
Data analysis technology
Data communication technology
Sensing Artificial intelligence
Simulation
High-speed communication
Device-to-device communication Efficient collection
The following shows evolutions of the ICT and information infrastructure.
"Monozukuri(Manufacturing)" according to Environmental Changes
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"Monozukuri(Manufacturing) " using Digital Space
Product development
/Design
Trial /Evaluation
Production /Test
Packing /Shipment
Process in factory
Analysis
Market info.
Besides the above: [Marketing info.] Demand prediction from market/environmental info. → Production instruction [Sales info.] Optimal procurement [Logistics] Optimal transport, carrier arrangement [Maintenance] Life prediction, trend management, preventive plan for maintenance
・3D printer ・Evaluation data accumulation ・Failure analysis /feedback
・3D design ・Virtual reality ・Reliability prediction ・Simulation evaluation ・Machinability evaluation
・Automation ・Monitoring ・Quality analysis/feedback ・Equipment preventive maintenance ・Consumption energy management
・Automatic packing/shipment ・Delivery planning ・Individual identification ・Traceability
Using Digital spaces, each process work efficiency and shorten term.
・Market info. collection ・Trend prediction
Digital space
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Digital space shortens distance to the ideal but cannot give perfect solution.
Only "humans" can fill gaps between reality and virtual space. Only "humans" can improve higher quality. Only "humans" can find improvements.
Only "humans" can "realize" design data simulated on digital space. "Humans" suitably use things optimized in digital space to optimize "Monozukuri(Manufacturing)".
Digital space Real
Next-generation "Monozukuri(Manufacturing)“ that "Humans" realized with Machines
Realize design data and adjust/improve
Supplies the optimal data created in digital space to robot systems/humans.
Feeds back unpredictable "awareness/experience/know-how".
(On-site knowledge)
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1. Future Vision of Monozukuri (Manufacturing)
2. FA Integrated Solution e-F@ctory
A solution for advanced factories of the future
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The major concept is “TCO*" across development/ manufacturing/maintenance. This solution optimizes factories using advanced technologies/information to support the future of Monozukuri(Manufacturing).
• Collecting production-site data in real time • Seamlessly link the collected data in FA with the ICT system • Analysis results according to the ICT system are feed back to production sites
- FA integrated solution -
Basic concept
<Production site optimized by >
Mitsubishi's Efforts
*TCO:Total Cost of Ownership
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FA Integrated Solution This solution improves "productivity", "quality", "safety", and "environment" through visualization at production sites and assists companies to reduce TCO and improve the company values.
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Controller products
Drive products
Energy -saving products
Mechatronics products
ERP
CAD
SCM
SCADA CAM
Simulator
Production site
FA-ICT interface
ICT system
This solution organically connects all systems via network related to the production, quality, and safety in the factory to visualize what is happening and where it is happening. The data captured through this visualization allows optimal management.
Analysis
Collecting real-time info. on manufacturing sites
Feedback FA-ICT info. interface products
FA-ICT linkage
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Necessary Elements for
Need methods for figuring out what is happening at
production sites promptly, correctly, and efficiently
Need methods for linking various PLM tools
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EZSocket
CSP+
Problems and Solutions at Production Site Various engineering tools (development environment, monitor tool, etc.) are prepared according to the characteristics of equipment/devices at production sites, and connected via various FA networks.
The integrated software (iQ Works) and seamless linkage protocol (SLMP) offer to realize an integrated environment.
CAD Simulator Engineering tool CAM
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, high-speed/large-capacity communication
Packing process
Control info. (network shared memory)
Production instruction, manufacturing/quality
info. (massage communication)
= Message communication
(transient communication) = Access to shared memory
Even a large amount of quality/manufacturing info., it will not affect transmission of
control info.
A large amount of control/quality/manufacturing information at production sites can be processed at high-speed/large-capacity of 1 Gbps in real time.
FA Network Connecting Lines, Equipment, and Devices
Control/production/quality info. at production sites can be "visualized", and analysis will be easy.
Bottling process
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Device level CC-Link AnyWire ASLINK CC-Link Safety
I/O control Safety control Motion control
SSCNET
Controller distributed control
CC-Link IE Field
Info. communication
CC-Link IE Control
Ethernet Computer level
Controller level
Seamless info. linkage
SLMP SLMP (SeamLess Message Protocol): Common protocol that provides seamless device communication regardless of network types/hierarchies
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Database, ORACLE, SQL Server, etc.
ICT Linkage Technology
Various applications can be operated in the ICT system, such as ERP, MES, schedulers, and simulators.
ERP CAD SCM SCADA CAM Simulator
ERP
CAD
SCM
SCADA
CAM
Simulator
Adoption of this architecture is postponed because of the expandability and versatility.
MES
MES
Direct connection Network fault processing : Buffer memory : Automatic refresh Automatic setting of
collection time info.
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Information Interface Products
PLCs are connected directly to the MES without the use of gateway PCs or communication programs.
Greater compatibility with diverse platforms and databases ensures direct connections between the shop floor and information systems.
The GOT2000/1000 HMI collects and sends data from connected FA products to the MES.
Production and inspection information of production sites can be collected in real time.
Designed specifically for MELSEC-Q Series PLCs, the new data logging module can be easily installed in the PLC CPU and set up to provide efficient data logging solutions.
To the system that has already operated and is operating, this module can be additionally installed, allowing data collection of the system.
MELSEC-Q PLC MES Interface MES Interface IT for MELSEC-Q PLCs GOT2000/1000 HMI MES Interface
BOX data logger High-speed Data Logger Module for MELSEC-Q PLCs Data collection analyzer MELQIC MES Interface
Information interface products eliminate PCs/programs from processes of on-site information collection (FA → ICT) and processes of information spread from information systems (ICT → FA).
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Partners having abundant experience/technologies in various fields
e-F@ctory Alliance Mitsubishi Partners to be familiar with problems offer the best solutions.
Offer software required for collection/analysis/management.
Offer devices required for measurement/control.
Total Support for the construction/operation on production-site
SI partners Software partners
Device partners
No. of participants: 282 companies (including both inside/outside Japan) (as of Feb.2014)
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Design phase
Maintenance phase Production phase
Utilize CAD for machine simulation : Interference check : Operation verification
Utilize schedule system for production planning : Best approach for production planning
Utilize data logging : Implementation of traceability : Troubleshooting quickly
e-F@ctory : Production efficiency by using digital space in the phase of design, production and maintenance
Digital space
“Digital space” will be used more and more for Monozukuri (Manufacturing)
Solution by utilizing ICT
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①EPLAN supports Mitsubishi FA products information Easy to check : Line connection, interference Easy to calculation : Line length
EPLAN(Software Partners) EPLAN Data Portal Electrical CAD drawing
②Support of label exchange between EPLAN and iQ Works (Development:2015-2016) Advance : Design efficiency, Quality
EPLAN iQ Works (GX Works3)
Signal name can be exchanged between EPLAN and iQ Works
Electrical CAD
drawing iQ Works
system configuration
③Auto generation of system configuration (I/O assignment, Network Parameter) in iQ Works Advance : Design efficiency for utilize of Electrical CAD drawing
Mitsubishi FA
Products macro
Import macro data
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e-F@ctory concept release 2003
2000
2003
2005 MES Interface module
2006 GOT-MES
C Controller 2007
2008 MES Interface IT
2006
2008
2011 2014
Model plant
[2005] Nagoya [2010] Fukuyama [2012] Kani [2013] Gunma [2013] Changshu, China
History of
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Application Examples of
Over 5,000 e-F@ctory systems are operating in over 100 companies worldwide.
(spreading globalization/overseas factories)
e-F@ctory is supported by customers in various fields, such as automobile, solar battery, secondary battery,
precision equipment, semiconductor, food, metal processing.
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Integrated analysis/ optimal management/ Remote diagnosis
IoT/Big Data Compatibility, Architecture of
Adopting approaches to Big Data advocated by ICT companies is difficult for manufacturing sites
Various data is generated at production sites.
(Data is generated in many facilities at different cycles.) On-site knowledge is
required to understand the data and correlations.
The best data-processing architecture is the e-F@ctory, in which primary data processing is conducted at production sites.
The keyword is ...
Local analysis/optimal production Quality management
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A preventive maintenance system for production equipment using the IoT technology has been developed.
Press release together with Intel Corporation (on Sep. 29) (http://www.mitsubishielectric.co.jp/news/2014/0929.pdf) The system was introduced to Intel's semiconductor production line (Malaysia) in 2013 on trial
and improved the yield, reducing the annual cost by about 9 hundred million yen.
MES Data analysis software (Revolution Analytics product)
Process data measurement/monitoring (CIMSNIPER produced by NIPPON DENNO) Primary data processing
Instruction
Instruction
Various sensor data
Instruction + Sensor data
Application Example (Preventive Maintenance System for Production Equipment)
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Necessary information can be Accessible from Anywhere Anytime
Allow remote monitoring about operating status of equipment and instructions to the maintenance workers.
Smartphone Tablet PC
Future Prospects
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Proactive Predictive
Reactive
Equipment Data Collection/Analysis on the Real-time
Production efficiency(JIT) will be realized through real-time collection/analysis on production/energy data.
Future Prospects
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Company and production activities link seamlessly to respond to market/situation changes.
Improve the company value by improving productivity/quality/product value and conducting social contribution through energy saving.
Shift from Production Phases to Entire Industry
Future Prospects
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We will widen the scope of e-F@ctory and enhance the functions with our partners.
for Promoting "Monozukuri(Manufacturing)"
We evolve e-F@ctory with accumulated know-how for the "Monozukuri(Manufacturing)" future.
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