Innovators takes risks to learn how to avoid them. followers face issues without knowing they were risks. Wärtsilä INTERNAL

Transcription

1 Innovators takes risks to learn how to avoid them. followers face issues without knowing they were risks Wärtsilä INTERNAL

2 WHAT IS THIS? Just a clue it is from South Korea A. Most common, classical approach: check at the library / 3 days / B. Looking for an expert : find and ask / 1 day / C. Thinking digital: Take a photo, upload on Google search by images / 5 / FREE NOTE: The technology is just an ingredient, usually open, which allows to speed up the process and the creation of new products/services and business 2 Wärtsilä INTERNAL

3 INDUSTRY 4.0: ITALIAN GOVERNMENT FUNDING PLAN OVERVIEW The plan is aimed at pushing Italian Factories to invest in digitazing the core and generating new business oppportuinities. Assets, Instruments and hardware connected with factory system enabling to have operation controlled by computers and/or managed through appropriate sensors and drives (such as machines for production, packaging, processing, machine tools, robots, co-bots, iot devices etc.); Advanced logistics and tracking of goods (integration of factories through the whole value chain) Quality assurance systems and energy sustainability (e.g. sensor systems, systems for traceability, smart energy systems, rfid, etc.); Human machine interaction devices (wearables, AR systems, image recognition) Smart SW (3D design and simulation, data mining, data anlystics, machine lerning, etc..) Improved ergonomics and worker safety in 4.0 logic (such as security systems to prevent injuries, reduce errors and increase efficiency). 3 Wärtsilä INTERNAL 24 Febbraio 2017

4 Assets, Instruments and hardware connected with factory system Quality assurance & Traceability systems CONNECTED FLEXIBLE MACHINING SYSTEM: WHERE EVERYTHING HAS STARTED H14000 CRUP/ CRLP Casting loading/ unloading station H10000 Cylinder Heads Robotized coordinatemeasuring machine New Flexible manufacturing System and state of the art machines integrated with CAD/CAM Fully automated and connected to ERP Deburring Robotic cell Automatic Loading/ unloading station Automatic Quality measurement integrated in the manufacturing process Wärtsilä INTERNAL

5 SMART DIGITAL FACTORY DCT SMART DIGITAL FACTORY NEW PARADIGM AND HORIZONS FOR THE FUTURE Vision Secure seamless communication based on automatic data acquisition for real time information sharing, Smart SW performance mgmt and predictive analytics to constantly Human improve machine quality. interaction devices Assets, Instruments and hardware connected with factory system Connected intelligent systems that communicate information and key relevant data with users/stakeholders (e.g. machining data, quality measurement, assembly performance, field feedbacks) (2017) Smart Human to Machine interfaces in assembly line that tell operator how to process parts. (2017) Real-time performance management for Efficiency Increase and data gathering from machining centers Quality and assurance logistics. & (2017) Traceability systems Big Data Analytics, Collaboration Self Learning System and Predictive Maintenance approach (2018 ) Co-bots supporting and interacting with the human beings (2018 ) Advanced logistics and tracking of goods Assets, Instruments and hardware connected with factory system 5 Wärtsilä INTERNAL [Presentation name / Author]

6 PROJECT CONSTRAINTS FIVE BASIC IDEAS AS PILLARS OF BEING SMART Enable a fast SMART Digital transformation of our manufacturing digital to serve simple process and operational excellence as embedded approach. PEOPLE is the key: Use internal competences and available solutions (strengthen synergies if any ) to build a fully scalable system Don t look for complicate solutions outside as first. Necessity is the mother of invention: does not exists ready made solutions for your problem but let s look around to get inspiration for own ingenious solutions. Once the concept is set then let s use available commercial & open source technologies with limited budget. Not big projects but BIG THINKING in small scale start up approach with less planning, more doing. Wärtsilä INTERNAL

7 SMART FACTORY - DIGI SYSTEM LOGICS & INTEGRATION LEVEL Big Data Analytics, Collaboration Sync With Azure Cloud (replica of data to shared) WDCT DATA WAREHOUSE CONFIGURATOR SQL DB SMART DIGITAL CORE: WISE* NO-SQL DB INTEGRATION LAYER & ODS MQTT HTTP EVENT INTERFACE CONNECTIVITY AND DATA MODEL Wärtsilä INTERNAL *Wartsila Integrated Smart Environment

8 SMART DIGITAL CORE: «2-WISE» SW The Brain" to manage all device and sensor connectivity in production API routines, protocols and tools for interacting with WISE system Real Time Value Stream Mapping Capability to manage configurable events and statuses for every workbench. Fully scalable and configurable (e.g.: advanced communication with PLCs/NCs); Plant modelling and configuration that can be applied for simulations and advanced optimization with direct interface to industry leaders (Google); User Friendly VISUAL 8 Wärtsilä INTERNAL [Presentation name / Author]

9 SMART FACTORY SMART DIGITAL LAB: THE START UP Laboratory where all ideas and concept are tested with a start up approach and developed by a small team in house Remote real time monitoring of Test Run FAT and Running In (in collaboration with Services) Idea Board where on a weekly base suggestion for «digital improvement» are collected and later assessed and discussed with the ones promoting them 9 Wärtsilä INTERNAL Project DCT Smart & Green

10 Quality assurance & Traceability systems Smart SW Human machine interaction devices Connected Assets, Instruments 10

11 INTEGRATED SMART ENERGY RECOVERY SYSTEM Quality & Energy Sustainability DISTRICT HEATING (2019 +) BOILER FOR OFFICE HEATING Wartsila HY Wärtsilä INTERNAL

12 RFID PILOT IMPLEMENTATION NOV 2017 Advanced logistics and tracking of goods Quality assurance & Traceability systems Smart SW I. RFID token is positioned on engine block before entering assembly line and programmed with engine serial (UII) TCP/IP comunication MANUF DB SMART DIGITAL CORE II. III. IV. Each assembly station has own RFID antenna to read token and send data to Smart Digital Core SW The system know serial UII of engine block present in station allowing automatic tracking Same system is used for bulk materials and Kanban boxes (collaboration with Würth) 12 Wärtsilä INTERNAL

13 SMART DIGITAL CTT CONTROLLABLE TRACEABLE TIGHTENING Quality assurance & Traceability systems Smart SW MANUF DB Automatic control of tightening quality data for critical components. The Integrated system (Hardware + Software + Data Management system) allows to interface the tightening tools with a remote mgmt and control. For every serial number the production system communicate to the tools the correct tightening procedures for that specific component. Correct Tightening Procedure Torque And Elongation Automatic Measurement Engine Book Monitor in real time if correct tightening is being executed, by giving the operator message if procedure is OK or NOT OK No risk of wrong tightening All tightening and automatic elongation measurement are linked to the component serial number and stored in data mgmt system as part of engine book. 13 Wärtsilä INTERNAL Project DCT Smart & Green

14 PARAMETER MOINITORING: HELLER CDS+ PREDICTIVE MAINTENANCE Assets, Instruments and hardware connected Step 1: Complete System overview Early Warning in case any deviation occurs cross-comparing to optimal machining process as designed and as originally measured during commissioning Step 2: (2018+) Predictive maintenance Trend analysis and historical data series Machine learning applied to acquired data (in collaboration with Heller, Uni UD, Manuifactrutring Engineering experts) Axis-Overview Speed-control deviation Torque Stiffness Spindle vibration Collision: Standstill monitoring à indirect collision alarm (in case an axis does movement without authorization) Contour monitoring indirect collision alarm IPM collision alarm à detection by monitoring axle electrical absorption External collision alarms check if caused by automation (FASTEMS e.g.) Maintenance-request: Continuous monitoring for levels of hydraulic-oil, Lube oil, Coolant pre warning and refill notification Filters status pre warning and replacement 14 Wärtsilä INTERNAL Project DCT Smart & Green

15 REAL TIME LESSONS LEARNT AND COLLABORATIVE RCA Smart SW Step 1 (Sept. 2017) Start populating tool with Past Root causes and use semantic search queries to find common issues or relation between previous problem solving data. For each recurrences will be provided a score in order to set level of filtering. Step 2 (Dec 2017) test goggle semantic research via google api. Step 3 (2018+) use machine learning logics to overcome limitation of simple semantic search. 15 Wärtsilä INTERNAL Project DCT Smart & Green

16 IOT CONFIG Human machine interaction devices Smart SW The IoT Config allow to configure any box on start up download the configuration from the system. New devices are automatically identified and recorded in the system to be configured. Configuration is made using graphical interface. Definition of new sensors is made using the web interface IoT Config is cross hardware since it s based on JAVA. e.g. Siemens IOT2000 or raspberrypi hardware is ready to be used. 16 Wärtsilä INTERNAL Project DCT Smart & Green

17 REALTIME VALUE STREAM MAP Smart SW REAL TIME Value Stream Map Capture the Value Stream Mapping Process from line process data DRILL DOWN DETAIL with touch interface possibility to drill down detail for each part of process PERIOD possible selection of time period to analyse data 17 Wärtsilä INTERNAL Project DCT Smart & Green

18 CO-BOTS AND INTEGRATED HUMAN-TO-MACHINE COBOTS Quality assurance & Traceability systems Human machine interaction devices Connected Assets, Instruments NO LONGER Machine/Robots replacing man, but in this new approach operator becomes crucial in coordinating, monitoring, managing and optimizing in real time machine performances Rethink the use of Robots for repetitive high risk operation critical for quality automatic Phase Array Ultrasonic System..but centrality of operator in interpreting results and in assessing quality Using Co-bots in assembly operation, total efficiency can be improved of 15% due to faster and easier handling of components (estimated). The Co-bot will enable full flexibility and being moveable can be used for many different operation and application. 18 Wärtsilä INTERNAL Project DCT Smart & Green

19 AUGMENTED REALITY Human machine interaction devices AR for augmented instruction on difficult assembly sequences AR for maintenance operations AR for training or services support Remote survey of Engine Tests 19 Wärtsilä INTERNAL Project DCT Smart & Green

20 Our Values a) If you can think it and have knowledge to realize it then let s do it!!! b) Before dropping an idea let s check if anyone in our company has competences to support you in making a Proof of Concept done. c) Think big in small scale. d) Act as you were a start up. e) Look for competences inside your organization and team with peers. f) Don t be scared to make mistakes but secure they are in a small scale. g) Be a big team not a big solo giant and break every silos h) Share knowledge and ideas with other companies the best innovation comes from different perspective and open knowledge. 20 Wärtsilä INTERNAL Project DCT Smart Digital Factory