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PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
www.piovan.com
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Industry 4.0
GIORGIO SANTELLA – PIOVAN GROUP
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Piovan is the world leader in supplying ancillary equipment andservices for the plastics industry
Understanding our customers’ needs
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
940 employees
7 production sites
24 subsidiaries
50 countries with direct presence
70 countries followed by distributors
Understanding our customers’ needs
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Industry 4.0: Process control & production output optimization
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
• «Industrie 4.0» was devised in Germany
• It is a strategic initiative of the German government, that wasadopted as part of the High – Tech Strategy 2020 Action Plan.
• It was launched in January 2011 by the CommunicationPromoters Group of the Industry- Science Research Alliance.
• Its initial implementation recommendations were formulated by the Industrie 4.0 Working Group in October 2012.
INTRODUCTION
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
THE 4° INDUSTRIAL REVOLUTION
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
• Cyber Phisical Systems (CPS): businesses will establishglobal networks to incorporate machinery, warehousingsystems and production facilities (Smart Factories)
• Horizontal Integration through value networks
• End to end digital integration of engineering across the entire value chain
• Vertical Integration and networked manufacturing systems
THE 4 PILLARS OF INDUSTRY 4.0
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Cyber Physical Systems
CPS – INDUSTRY 4.0 AS PART OF A SMART, NETWORKED WORLD
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
CPS – INDUSTRY 4.0 AS PART OF A SMART, NETWORKED WORLD
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Industry 4.0 will lead the
development of new business
and partnership models that are
more geared towards meeting
individual/last minute customer
requirments
HORIZONTAL INTEGRATION THROUGHVALUE NETWORKS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
NIKEiD is a service provided by Nike allowing customers to personalize and design their own Nike merchandise.
USA, United Kingdom, Italy, France, Spain, Germany, China and Australia.
END TO END DIGITAL INTEGRATION
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
END TO END DIGITAL INTEGRATION
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
- Additive Manufacturing
- HMI – augmented reality
- Sensors for IoT
- Connectivity
- Big Data
- Advanced analitycs
- Cloud
IMPORTANT TECHNOLOGIES AND TRENDS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
- Additive Manufacturing
- HMI – augmented reality
- Sensors for IoT
- Connectivity
- Big Data
- Advanced analitycs
- Cloud
IMPORTANT TECHNOLOGIES AND TRENDS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
- cooperating with machinery suppliers to utilize the new protocol
OPC – UA (Open Platform Communications – Unified
Architecture)
- introducing Winfactory 4.0
- launching the evolution program of Winfactory 4.0
to have mobile access through Smart Devices
- developing a complete system for Energy metering and energy
efficiency (generation of Key Performance Indicators)
TODAY’S ACTIVITIES AT PIOVAN
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Winfactory 4.0
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
0
20
40
60
80
100
120
2008 2009 2010 2011 2012 2013 2014 2015
LIC
ENC
E
YEAR
Winfactory License by year and type
5E 10E 20E 35E 50E 65E 80E
WINFACTORY – 8 YEARS IN NUMBERS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Chiller2%
drying30%
energy1%
feeding46%
dosing13%
others8%
Winfactory family share
WINFACTORY – 8 YEARS IN NUMBERS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
LICENSE TABLE
BASE
+
configuration
+
TAGS
+
On-demandfunctions
+
On-demandservices
WF4.0 StandardPET – pref & bottMED – medicalFILM – extrusionSVS – customENERGY….
152550100200400800
MTSADALRCPTSCHMSCHEMGRPOMGRVCLACLFEAOPC-UA
SUSUGRRSS
WINFACTORY 4.0 – NEW LICENSE SETUP
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
On-demand functions
MTS Material Tracking System ADA Advance Data AnalisysLRCP Line RecipeTSCH Time SchedulerMSCH Maintenance SchedulerEMGR Energy ManagerPOMGR Production Order ManagerMBT Batch trace for batch blenders and LybraVCL License for 1 Video ClientVCL5 Licence for 5 Video Clients ACL Alarm ClientOPC OPC-UA ServerAGE Advance Graphics editor (material line)
On-demand services
SUS Software Update Service (annual fee)RSS Remote Support ServiceUGR Upgrade from old software version
WINFACTORY 4.0 – NEW LICENSE ITEMS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
New feature
Language11 (Italian, English, German, French, Spanish, Portuguese, Russian, Czech, Polish, Swedish, Chinese
Graphics New interface with vector graphics (SVG)3D graphic Yes Layout Yes with support up to 4 displaysMaterial lines Layout Yes with new layout editorTouch display support Yes (native)
User accounts Yes, with new badge support
Bar code reader New support for material trackingAlarms/log New graphics report
Alarms display New display for alarms (32,42,50“)
e-mail Yes, account option for alarms notificationUpdate Client Update automatic (over the network)PDF reader Yes for machine/device (included by end user)
WINFACTORY 4.0 – NEW FEATURES
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
WINFACTORY 4.0 – PAGE ELEMENTS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
WINFACTORY 4.0 – PAGE ELEMENTS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
WINFACTORY 4.0 – PAGE ELEMENTS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
WINFACTORY 4.0 – PAGE ELEMENTS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
WINFACTORY 4.0 – PAGE ELEMENTS
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
OPC – UAOpen Platform Communications Unified Architecture
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
CONTROL
SUPERVISION
MANAGEMENT
ENTERPRISE
MACHINE
ERP
Enterprise resource planning
WINFACTORYTYPICAL FACTORY AUTOMATION LAYERS
MESManufacturing Execution System
Winfactory
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
WINFACTORY 4.0 – OPC-UANEW FACTORY AUTOMATION LAYER SETUP
CONTROL
SUPERVISION
MANAGEMENT
ENTERPRISE
MACHINE
ERP
Enterprise resource planning
MESManufacturing Execution System
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
OPC-UA – production cell set up
Ethernet
RS485 ModbusRTU
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
OPC Foundation and Euromap
- February 2017
platform independent interoperability standard - Euromap 77 – link to MES
- Euromap 79 – link to robot
- Euromap 82 – link to auxiliaries
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Winfactory 4.0 mobile
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Bus/field
control
Lan/Factory Lan
WF4.0 Server
Up to 2/4 display
Client (PC panel)
Alarms
DisplayAlarms Display
(stand alone)
Client WIFI
(windows)
FireWal
l
Client mobile
WINFACTORY 4.0 – MOBILE
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Winfactory 4.0 - Energy
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
MANUFACTURING OPERATIONS
Plastic material
Energy
Plastic product
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
PRODUCT COSTS
Plastic material represents60% to 90% of the cost
Energy < 15% of the costPlastic product
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
COST OPTIMIZATION
Continuous improvement
Poor optimization
Rejects ≤ 5%
Inefficiencies ≤ 50%
Plastic material
Energy
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
ENERGY BURDEN
Less than 10% of the manufacturers know how much energy each device
consumes
Less than 1% measures it
?
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
ENERGY MANAGEMENT
Split the machinery and equipment setup into predetermined categories
Injection / Moulding Cooling Material Handling
Measure the energy utilized by each category
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Energy efficiency is one of the pillars of the SMART
FACTORY
Today’s conventional applications are focused only on
energy supply measuring, without any relation with the
production output
The most common applications are factory based and not
enterprise-wide
WINFACTORY 4.0 – ENERGY
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Provide a fully integrated solution with Winfactory 4.0
for energy metering, for each typology (electricity,
natural gas, oil) able to calculate the KPI related to the
production output at enterprise level
WINFACTORY 4.0 – ENERGY
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Piovan Cloud
Internet
Smart
Devices
Factory 1
Factory 2
Factory 4
Factory 3
Factory 5
Overall production efficiency
WINFACTORY 4.0 – ENERGY (ENTERPRISE LEVEL)
PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS
Thank you GIORGIO SANTELLA